HIGH-PERFORMANCE HOT ROLLING MILLS Electrics and … · CONTENTS X-Pact® Electrics and Automation 4 Modern hardware solutions 6 Energy distribution and drive systems 8 Automation

HIGH-PERFORMANCE HOT ROLLING MILLSHIGH-PERFORMANCE HOT ROLLING MILLS Electrics and Automation

Hot Rolling Mills

SMS SIEMAG

ELECTRICS and AUTOMATION

CONTENTS

X-Pact® Electrics and Automation 4

Modern hardware solutions 6

Energy distribution anddrive systems 8

Automation systems 10

Process automation for hot strip rolling mills 14

Level 3-productionplanning systems 18

Safety strategy 20

Plug & Work test 22

Modernization strategies 24

Services 26

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Electrics and AutomationSMS SIEMAG

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ELECTRICS AND AUTOMATIONELECTRICS AND AUTOMATION for hot rolling mills

HOLISTIC SYSTEM EXPERTISE

Now, more than ever, the market for metallurgicalplant automation demands high plant availability andquality of the end products. To meet these require-ments, SMS Siemag many years ago launched itspolicy of supplying not only engineering, technologi-cal controls and process models, but also the entireelectrics, automation, drive technology as well asenergy distribution for its plants. We are therefore anall-inclusive supplier for all aspects of engineering,construction, and commissioning. Acutely aware ofour responsibility to you, we ensure all system com-ponents mesh perfectly. Short paths, direct commu-nication, and the common interests of everybodyinvolved add up to the best conditions for just that.

EXTENSIVE

MODERNIZATION STRATEGIES

As an operator of metallurgical plants, you know howcrucial it is to constantly add to and renew your pro-duction equipment so you retain your market stand-ing with excellent product quality. This kind ofgrowth comes not only from the latest engineeringsolutions, but also requires integrated automation toactually improve your end products. SMS Siemagoffers you seamless revamps so you benefit fromtechnological improvement of your production acrossthe board.

PROFESSIONAL PARTNER

FOR HOT ROLLING MILLS

SMS Siemag supplies hot rolling mills for almost allproducts and capacities. Included here are:

Classic high-performance hot strip mills with sever-al roughing stands and if necessary one sizing press Compact hot wide strip mills with a roughingstand and, if necessary, a coilboxCSP plants Steckel mills

Our experts in electrical, automation, technological,and mechanical systems work together to ensure theplants you get are perfectly coordinated in all aspects.That’s how you can rely on intelligent, market-drivensolutions with high productivity for top-quality hot strip.


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X-PACT®X-PACT®

Electrics and Automation

The entire spectrum of automation technology fromSMS Siemag is available to you under the X-Pact®

brand name. That applies to all plant types:from steelworks to casters from hot rolling mills to strip processing lines

Central to X-Pact® for hot rolling mills are high cost-efficiency and transparency of our control technology.X-Pact® encompasses all levels of automation fromLevel 0 to Level 3.

X-PACT® FOR HOT ROLLING MILLS

X-Pact® for hot rolling mills pools our special processknow-how in a system oriented toward the distinctprocess technology required here. Additionally,because X-Pact® focuses on the hot rolling processand customer requirements, we were able to imple-ment tailor-made application software. That enabledus to fine-tune the application software at a loweroutlay. Your advantage is that our solution comes witha leaner system structure, making it much morestraightforward to use.

Plan of the variousmodule levels.

MULTI-STEP STRATEGY

All the systems are based on uniform platforms with-in a modular structure. We apply the latest hardwareand software developments here. Everything is bro-ken down into separate levels (system modules,technological modules, plant-specific modules), soelements only have to be customized where neces-sary. If the IT environment changes, for instance dueto new hardware, only the system modules need tobe modified. Similarly, when new technologies comeinto play, only the technology modules are affected.The plant-specific modules contain project-specificfunctions and routines. You benefit from this struc-ture because it improves both the effectiveness andlifetime of the technology modules. What you canalso count on is the stability of the plant-specificmodules, even if you replace your IT infrastructure orchange certain equipment.

HOMOGENEOUS

SYSTEM ENVIRONMENT

So, in X-pact® for hot rolling mills, all regulation andcontrol functions are implemented on our uniformsystem platform (X-Pact® ProBAS), and are pro-grammed and parameterized in a common develop-

ment environment. That ensures maximum availabili-ty of all system variables. Interfaces between differ-ent system platforms are no longer necessarybecause the reflective memory (RFM) architecturesupplies all process data to all the sub-systems –immediately and simultaneously. This is also how aPDA system can be integrated into the overall arrayusing RFM. It’s one of our principles to react flexiblyto customer standards or special requirements,especially for revamps. That’s why our solutions eas-ily integrate your existing control systems. Further-more, other system platforms such as programma-ble logic control (PLC) can also be included in theX-Pact® system landscape.

SIMPLE SYSTEM MANAGEMENT

The open architecture of X-Pact® ProBAS makes itindependent of proprietary solutions. That means theautomation systems are entirely implemented underlogi.CAD on the basis of international standardIEC61131-3. This is important for international pro-jects and ensures our systems can be updated, main-tained, and further developed also by our customers(or: and ensures that either we or you [yourself] canupdate, maintain, and further develop / improve oursystems?). Using logi.CAD is the easiest thing in the

world for system engineers and programmers familiarwith PLC programming. The FBD (Function Block Dia-gram) technology in logi.CAD features the samestructure and procedures as the CFC technology(Continuous Flow Chart) used in a PLC programmingenvironment.

FBD function block diagram.

Production planning system

Process models, production data capture and reporting

Controls, sequence controls, drive controls

Drive technologyEnergy distribution


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MODERN HARDWARE SOLUTIONSMODERN HARDWARE SOLUTIONS

HARDWARE AND SOFTWARE

PLATFORM

We use state-of-the-art computer technologies forour Level 1 process regulation in real-time. Equallyadvanced, ProBAS software takes care of graphicprogramming and diagnosis. A typical configurationconsists of:One or more engineering stations (MS Windows)An X-Pact® ProBAS development serverOne or more X-Pact® embedded automation PCs

X-PACT®

EMBEDDED AUTOMATION PC

X-Pact® Embedded is the SMS Siemag hardware plat-form for modern, sophisticated control and techno-logical regulation systems in hot rolling. X-Pact®

Embedded is based on modern Core™ 2-Duo tech-nology from Intel® and provides maximum computingpower to all applications.

It’s an added advantage that X-Pact® Embedded hard-ware saves space in the control cabinet. A cover onthe front of the device protects the drive bays (DVD,HDD) as well as two Compact-Flash ports. Switchingbetween drives is made easy by the modular inser-tion feature. To make working with this hardwareeven more convenient, all ports and interfaces arelocated on the top of the housing. There are no pro-truding ports at the back which would demand extrainstallation depth. You can always add modules to thehardware, adjusting it to the complexity of your plant.Whatever the installation situation, you can rely on anarray that makes optimal use of the space inside thecontrol cabinet. That’s due to the different capacitiesof X-Pact® Embedded modules with one, two, or sev-eral card ports (for PCI/PCI express cards).

Typical X-Pact® embedded configurationfor a hot strip rolling mill.

ETHERNET-BASED

FIELDBUS SYSTEMS

X-Pact® automation from SMS Siemag supports thelatest technology in real-time-capable fieldbus sys-tems. Here are the advantages of an Ethernet-basedsystem over a classic fieldbus solution:

Much higher performanceReal-time-capability for fast control Extensive diagnosis options Wide-scale use with very good acceptanceInterfaces to classic bus systems

Furthermore, using this technology drastically cutshardware engineering requirements because for thefirst time signals for the highly dynamic actors/sen-sors can be picked up close to the mill by the non-central periphery devices. That eliminates masses ofcable as well as the associated adaptation of processsignals. The automation systems from SMS Siemaguse EtherCAT (from Beckhoff) as a real-time-capablefieldbus. All this goes to show that, with our newtechnology we harness a modern, powerful and real-time-capable communication medium for our automa-tion systems. Flexible tree structures ensure you canexpand the network as you want, when you want.

X-Pact® Embedded

E-room

CPU

Pro!

bus

Realtime EthernetPro!bus

Remote I/O Boxes

Valve Cylinder Sensor Drives & I/O

Field

ValveSensor

DE-CENTRALIZED SYSTEM

ARCHITECTURE:

Single CPU-systems (APC; Automation Programmable Controller)Only power supply and networkconnected to the field Real-time Ethernet as fast field-busReduced signal- and HW-engineering Highly reduced complexity

An increasing number of supplierssupport devices with fast Ethernet interface, e.g. new valve series fromMOOG, position transducers by Heidenhain


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ENERGY DISTRIBUTION and DRIVE SYSTEMSENERGY DISTRIBUTION and DRIVE SYSTEMS

Our Electrics and Automation Division also suppliesthe equipment for energy distribution and drive tech-nology in hot rolling mills.

SCOPE OF SUPPLY

FOR ENERGY DISTRIBUTION

Included in our supply range for energy distributionare high and medium-voltage switchgears, distribu-tor transformers, compensation and filter systems,emergency power generators, USV plants as well aslow-voltage main distributors and the associatedEmergency Off strategies.

ENERGY DISTRIBUTION

FROM ONE SOURCE

We use a single-line scheme to design your energydistribution system. You can also rely on our supportin choosing the best method of connection to theintegrated network. To determine the necessary filterand compensation plants, we analyze the network.This includes identifying the reactive power require-ment and the level of network harmonics. Our in-depth process know-how means we can exactlydetermine the diversity factors and evaluate passschedule data. As a result, we can optimally dimen-sion all components, from overhead line feeds tomechanical control elements.

SCOPE OF SUPPLY

FOR DRIVE SYSTEMS

Here, we supply all types of drive for hot rolling millsas well as roller table distribution systems. The bot-tom line for you? Low investment and operatingcosts due to reduced power dissipation, a smallerfootprint, and low maintenance are serious advan-tages of our energy distribution and drive systems.

Main drive of rougher.

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Main drives of a rolling mill.

RELIABLE DRIVE SYSTEMS

There are a large number of parameters that influencethe design of drives, especially in the Megawattpower range. Together with renowned suppliers, wedevised and optimized new foundations for thesemedium-voltage drives. We have also already installedthem in several reference plants. Intelligent switchingsystems are able to reduce the harmonic wave strainon the network side to such an extent that no filtersare necessary on this terminal server. These powertrains (medium voltage switch, converter transformer,voltage converter, motor) are dimensioned according

to the actual process requirements, which can beseen from the pass schedule calculations. Using anoptimized transmission of the drives, we ensure youget a plant with maximum flexibility in the design ofyour production processes.

Included in the X-Pact® electrics and automation pack-age are the technological drive functions. They keepthe interface to the drives lean and standardized.

Transformer rooms.

Low-voltageswitching plant.


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AUTOMATION SYSTEMSAUTOMATION SYSTEMS

Stability, easy maintenance, no-fuss adaptation to newenvironments, and top technological performance –that’s what you expect from modern automation sys-tems. This requires a simple yet powerful basis. AllX-Pact® automation systems for hot rolling mills arebased on our uniform X-Pact® ProBAS system plat-form. As a result, they readily adapt to differenttopologies in hot rolling.

What do our automation systems mean for you? Tobegin with, you can rely on excellent technology andfunctionality. Other stand-out features of the systemsinclude maximum availability plus a high degree ofprocess automation coupled with effective servicefunctions. There is close coordination between ourautomation experts and design department to developand thoroughly test software modules for eachmechanical unit.

Furthermore, we have systematically broken downthe concept of our automation systems for hot rollingmills into automation product units. Using this modu-lar system, we can put together overall automationsystem with tried-and-tested sub-units for differentsystem types. The picture on the right shows youthe product structure and configuration for the hotrolling mills.

We subdivide our automation systemsinto these functions:

Level 1 – Process controls Level 2 – Process automationIntegrated operator HMI system for Level 1and Level 2 as well as local operating stationsSafety controls

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Visualizationand operation

Level 2automation

Level 1automation

MCCFrequency converterLocal control stationsTerminal boxes


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PRODUCTION DATA CAPTURE

AND REPORTING

The production data capture is based on the processevents in the Level 1 system. To this end, all prod-ucts that are located in the system are monitoredwith their current status in the Level 2 system. Thisallows plausibility checks to be performed for the pro-duction sequence and product-specific values to bespecified for the rolling and production process. Therelevant production data and product data are savedin a database and can be made available for produc-tion evaluations and quality and product reports.

AUTOMATION SYSTEMSAUTOMATION SYSTEMS

LEVEL 1 –

PROCESS CONTROL

Included in Level 1-automation arerapid-action control loops for thehydraulic control elements, and super-ordinate process control loops. Theyare responsible for e.g. width andthickness control, wedge-free andcamber-free rolling in the roughingtrain, cropping optimization, and profileand flatness control. All this ensuresmooth operation in the differentareas of your rolling mill. You'll noticethat in many improvements, such asstable material flow and efficient func-tioning of the media systems.

The drive controls include all drive sys-tems that are involved in transporting,rolling and coiling the hot strip.

LEVEL 2 –

PROCESS AUTOMATION

Improving the product quality and increas-ing the productivity and flexibility in pro-duction are the main tasks of the X-Pact®

Level 2-systems, which are based onmathematical-physical process models.As part of quality assurance, these sys-tems must guarantee the product andproduction data acquisition of the plant inaddition to the process optimization func-tions. As in the other automation levels,the SMS Siemag Level 2-systems areindependent of the hardware structurethat is used. Communication with theexternal systems, such as a cross-plantproduction planning system or inspectionsystems, is implemented on a modularbasis in order to achieve high flexibilitywith regard to the different connections.

Modules of the Level 2 system.

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Pass schedule and set value calculation.

Tonnage report.

INTEGRATED OPERATOR

HMI SYSTEM

Our integrated operator HMI system links the plantand the operator. It maps the rolling process includ-ing everything to do with materials and technology.Armed with the information from the process obser-vation, the operator uses the latest graphical meth-ods to manually influence process control or opera-tion of the integrated machine groups such as mediaplants. In line with our operator-centered approach,our employees work closely with your operating per-sonnel. Involving your team in the Plug & Work testsis another effective way to prepare them for theirnew tasks.


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PROCESS AUTOMATION FOR HOTSTRIP ROLLING MILLSPROCESS AUTOMATION FOR HOTSTRIP ROLLING MILLS

"material data base". Also available to you is the set upcalculation for the entire roughing mill section. It givesyou not only a wealth of data, such as force, torque,speed, thickness, width and slab and transfer bar tem-perature calculations, but also considers the basicapproaches to describe the production condition. ThePSC® is adapted pass-by-pass in the roughing mill andfeeds width correction information to the pass sched-ule calculation of the finishing mill. Then the final mea-sured strip width is fed back to the roughing mill sec-tion. All this creates a plant-wide control system forhigh strip width accuracy.

ADVANCED COILBOX CONTROL

As the transfer bars are coiled in the mandrelless coil-box, a heat exchange takes place between the coilwindings. As a result, you can count on a more or lessconstant temperature over the transfer bar length. Ourfully automatic coilbox controls ensure optimum coil-box sequencing to maintain the transfer bar tempera-ture. That markedly improves rolling conditions in yourfinishing mill.

Yet there is even more than an automatic mode.Using our system, you can take over manually at anytime if the production situation requires your help.It’s also possible to switch back to automation modewhenever you wish.

AUTOMATIC WIDTH CONTROL

High accuracy in the strip width saves edge scrap aswell as stock and energy. That’s why the purpose ofthe width control is to obtain a constant strip widthover the entire length of the finished strip. Crucialhere is that it is as close to the target width as possi-ble. Yet there is no chance of influencing the width inthe finishing mill. So you have make sure that theactual width control takes place both in the slab siz-ing press and in the edger stands of the roughingmill section.

The width control system is a Level 1-function. It isparameterized from the Level 2 PSC® Pass ScheduleCalculation pass-by-pass and consists, for example,mainly of these functional modules:

Edger gap control to adjust the edger roll gap.Short stroke control for control for slab tail andslab head ends.Compensation of edger stretch.

The Pass Schedule Calculation for the sizing press androughing mill section ensures you achieve a high accu-racy when it comes to predicting the process parame-ters. This is due to physical modelling of the rollingprocess combined with adaptation to actual measuredvalues. The material model describes the flow stressbehaviour of the various grades based on an extensive

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THICKNESS AND MASS FLOW

CONTROL IN THE FINISHING MILL

We use our Automatic Gauge Control (AGC) in eachmill stand to keep the exit thickness constant. That’sbecause thickness deviations may occur as a result ofvariations in temperature, incoming thickness, materi-al hardness or width changes. The AGC uses a mod-ern observer control strategy. Using a high-accuracymill stand stretch model and the measured roll force,we apply the gaugemeter principle to calculate theactual thickness within each mill stand. Then we cor-rect the feed forward from the AGC to the main dri-ves and hydraulic looper to decouple the thicknessand tension control. This not only stabilizes the massflow, which is very important for thin strip rolling. Italso avoids thickness fluctuations as a result of rolleccentricities by using special adaptive filtering proce-dures. The monitor control feeds measured thicknessdeviations back to the thickness control to finelyadjust the final product thickness.

We have also developed a special control techniquefor Steckel mills. It is applied at the strip head and tailends to stabilize your products. Unique to this tech-nique is the Steckel looper that optimizes tensioncontrol. This increases both the rolling speed and theproductivity of your Steckel mill.

ROBUST PRODUCTION CONTROL

AND SEQUENCING

What modern hot strip mills need to succeed is notjust advanced control technology for prime-qualityproduction, but also the high availablility of electricaland automation systems. Equally crucial if you wantto boost your productivity is the fault-tolerant handlingof unplausible sensor readings.

That’s where our comprehensive monitoring and diag-nosis tools come in. They help our maintenancedepartment solve sensor problems like this duringongoing production.

CAMBER AND WEDGE-FREE

TRANSFER BAR ROLLING

Cambers may form due to thickness wedges in theslab cross-section or asymmetric heating of theslabs. To ensure improved production conditions forthe finishing mill, camber and wedge-free rollingplays a vital role in the roughing mill.

Essential for straight transfer bars is an effectiveinterplay between the heavy side guides in front ofand behind the roughing mill stand. Just as importanthere is our hydraulic roll gap adjusting system. Thecontrol system for camber and wedge-free rolling(CFR) consists of:

Roll Alignment Control (RAC) for automatic levelingof the hydraulic roll gap systemHydraulic roll Gap Control (HGC) Side Guide control Interactive control and micro-tracking

Width control.

Coilbox.

Camber andwedge-free rolling.

After pass 1 After pass 5


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PROCESS AUTOMATION FOR HOTSTRIP ROLLING MILLSPROCESS AUTOMATION FOR HOTSTRIP ROLLING MILLS

STRIP GUIDE CONTROL IN

THE FINISHING MILL

RAC Roll Alignment Control

As you know, symmetrical rolling in your finishing millcan be disrupted. That inevitably leads to instability ofthe rolling process – as a result of:

Temperature differences on the drive/operator sideOff-centered stripCamber shape of the transfer barWedge-shaped transfer bar

There is nothing to worry about because our RAC RollAlignment Control compensates such disturbances. Itstarts by taking the measured differential rolling forceas a basis for calculating the output. The position con-trol then uses this reference value to level the roll gaparound the mill center line. Even more: You can alsoadjust the mill stand leveling setting manually duringrolling – at any time.

DTL Differential Tension Looper

Another intelligent solution is our differential tensionlooper. It responds to the measured average andwedge portion of strip differential tension over thestrip width. Here’s how it works: The conventionallooper is equipped with load cells integrated in thelooper arms. They calculate the average strip tensionand the wedge portion (differential tension) fromboth force signals. These variables then go to theALC Automatic Leveling Control for roll gap leveling.

ALC Automatic Leveling Control

It’s very important during thin strip rolling that the fin-ishing mill stands level the strip effectively. That stabi-lizes the strip flow and, in turn, the whole rollingprocess. Strip flow problems are for example causedby an asymmetrical i.e. unilateral distribution of thestrip tension that may lead to unilateral edge waves.

There is only one way at present to avoid these prob-lems. As an operator, you can level your mill stands,i.e. set position corrections with inverse signs for theadjusting system on the drive and/or operator side.But you can only intervene when the strip flow prob-lems become visible, e.g. in the form of unilateraledge waves. The ALC Automatic Leveling Controlcontrols asymmetrical strip tension distribution mea-sured by the DTL Differential Tension Looper.

Tail-end monitoring

The tail-end monitoring function improves rolling sta-bility, especially close to the strip tail end. It gives yourecommendations that assist in the pre-leveling of themill stands – to optimize your strip flow and reducetail-end cobbles. Then, after the tail end passesthrough the previous mill stand, the system evaluatesthis recommendation and visualizes it at the operatorHMI for the next strip to be rolled.

PROFILE, CONTOUR AND

FLATNESS CONTROL

There has been a huge increase in demands on theprofile, thickness, flatness, and surface quality of hot-rolled strip. That's why we continuously develop ourprofile, contour, and flatness control technology andimprove our mechanical control elements. It features:

Automatic step control.

CVC-plus work roll grinding with a muchlarger control rangeCVC plus back-up roll grinding to reduce roll wearShape-optimized shifting strategies to reduce profile anomalies and extend rolling campaignsPass-schedule-free rolling strategies for flexiblestrip production according to orders in hand

You know how important it is to be able to count onhigh-performance mechanical control elements.Essential here is the implementation of sophisticatedmodels based on physical and mathematical equationsthat determine in real time the current strip profile,contour, and flatness according to the operating para-meters. What you get with our profile, contour, andflatness control are functions that control work rollshifting and bending for the next strip, as well as solu-tions that optimize strip profile and flatness along theentire strip length. Considering these advantages, it'sno wonder we have installed our PCFC® automationsystem more than 100 times to date.

RUN-OUT TABLE COOLING

SECTION CONTROL

What’s the function of our run-out table laminar stripcooling system? It’s designed to cool down the stripbetween the last stand of the finishing mill and thedown coiler – according to the mechanical strip prop-erties to be produced. Our cooling section technologyachieves a very high accuracy in the process control.It is also capable of all the cooling strategies for awide range of hot rolled products. Finally there is ourcontrol system that can be used with many differentmechanical designs. Included here is the control ofthe compact cooling. That’s exactly what you need for

adjusting cooling rates to produce e.g. pipe, DQ, high-strength as well as multiphase steel grades.

COILER CONTROL

Our process control system for down coilers or upcoilers ensures high coiling quality. It helps you forexample with new wraps as the first windings arecoiled. Right there, directly above the front edge ofthe strip, you may find that considerable forces occurin the stock and in the mechanical equipment. Theylead to severe loads on the mechanical equipmentand marks on the strip during initial coiling. Our stepcontrol ensures you avoid most of these disadvan-tages. Here’s how: It all starts before the front stripedge reaches the position of a wrapper roll. Now theroll is raised by slightly more than the strip thicknessand placed down again after the front edge haspassed through. The other rolls follow the same pro-cedure in sequence. This means that, while one ofthe rolls is being retracted, the other rolls hold thestrip as it is wrapped. This procedure is repeats itselfuntil strip tension has been built up and the rolls havebeen pivoted to their outer end position.

Profile control by means of CVC pluswork roll shifting.

Run-out tablestrip cooling.

Automatic leveling control usingDifferential Tension Looper.

Without leveling control:Drift to asymmetrical tension distribution

With leveling control:Symmetrical tension distribution during rolling


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LEVEL 3 – PRODUCTIONPLANNING SYSTEMLEVEL 3 – PRODUCTIONPLANNING SYSTEM

Today, there is a constantly growing product variety,while customers expect ever shorter delivery times fortop product quality. That demands meticulous planningof your production processes. What’s more, you needclose links to the production systems of suppliers andcustomers so you can react quickly to changes.

Development here focuses on “Real Time Enterprise”(RTE), a method that checks and responds to thesechanges in real time.

The restrictive factors are the technical and technolog-ical limits of the plants, which we have to take intoaccount during program planning. That, in turn, cre-ates a demand for comprehensive production planningsystems.

X-PACT® LEVEL 3

X-Pact® Level 3 provides plant operators with all thetools necessary for planning and control of the pro-duction process in metallurgical plants and rollingmills. An effective link between the commercial sideof the business and the technological processautomation systems, Level 3 production planningoffers you these advantages:

From customer order tomanufacturing order.

Maximization of overall production rate Planning and minimization of inventoriesfor interim productsUniform, multi-plant product trackingCumulative quality control up to finalquality approvalIncrease of delivery date compliance

MANUFACTURING ORDERS

You can rely on our systems to convert customerorders into technically executable manufacturing pro-jects. According to customer specifications, an exten-sive calculation model generates the manufacturingdata for the product ordered.

Definition of the necessary production steps andpossible plant alternativesDefinition of the dimensions and quality ofthe initial and intermediate productsPlanning of the output of every production stage todetermine the necessary quantities of input materialDefinition of sampling and test regulations

THE FACTORY MODEL

A uniform planning system covering all areas isbased on a factory model. The factory model isimplemented in the planning system as an electronicplanning table.

PRODUCTION PLANNING

It’s vital to determine the doable delivery dates for allmanufacturing orders in advance. That’s where ourcapacity and deadline planning comes in, examiningall the plants and plant alternatives available. As a

result, you get a sequence plan for the individualplants as well as a plan of the available input materi-als for each manufacturing order.

QUALITY TRACKING

There is a data exchange between the Level 2 sys-tems of the overall plant and the Level 3 system. Thatmeans Level 3 is informed at all times about everyproduction step and the product quality after eachstep. Inspection and lab data add to the accuracy ofthe result. This forms the basis for quality approval ofthe final products before delivery.

Material flow in a hotrolling mill.

Heating furnace

Edger

Roughing Mill

Finishing mill

Cold rolling mill

Dividingshear

Slittingshear

Plates

Customer

Cold strip

Customer

Hot strip

Customer

Slit coils

Customer


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SAFETY STRATEGYSAFETY STRATEGY

Improving machine and plant safety is becomingmore and more important – worldwide. Legislationand standards demand the protection of people andthe environment.

Essential for safe plant operation is a coordinatedapproach during planning and design. Together, theengineering and electronic systems form the mainelements in our safety strategy:

Layout of the danger zoneRisk assessmentThe electro-mechanical function „safety“Emergency Stop strategy

The danger zone layout divides the plant into variousdanger zones. It indicates all the plant-related safetyequipment as well as the plant limits.

The risk assessment identifies and evaluates all thepossible hazards inherent in a plant, and describesthe necessary precautions.

There is also an in-depth Emergency Stop plan drawnup for each plant.

Together with our customers, we worked out a prac-tical solution with the safety control functions operat-ing independently from the machine controls. Thisstrategy also complies with all safety laws and stan-dards. Better still, it reduces the time and cost oftesting, documentation, and commissioning. Thesafety control functions are extensively tested earlyon, during the Plug & Work process.

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Level 1 (unsafe partof controlsystem)

Extract from a dangerarea layout.

Separation of safety functionsand control functions.

Machine safety.

Monitoring adanger area.


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PLUG & WORK TESTPLUG & WORK TEST

Setting up a Plug & Work test in the test field.

Our long-established Plug & Work service is increas-ingly popular with our customers. Central to Plug &Work are production simulations that mimic realitydown to the smallest detail. Today, due to our long-standing experience in engineering and process tech-nology, we know exactly how processes behave andwhat regulators achieve which product qualities. Oursimulation system maps this complex interplay of vari-ables for exhaustive tests of your system.

MODULE AND INTEGRATION TEST

Plug & Work starts with module tests that put theindividual hardware and software componentsthrough isolated function checks. Next, integrationtests examine the fault-free interaction of the mod-ules. Unlike other suppliers who usually wrap up thepre-testing and resume only after the entire plant isfinished, we use this valuable time to the benefit ofour customers. Here’s how: We install the entireautomation system in one of our test fields and con-nect it up to a simulation system. Finally, all that’s leftto be done is to set up the customer-specific con-struction models of the plant including the kinematicand dynamic parameters of the plant behavior and thesensors. This is how we build a computer-aided simu-lation model to test the operating and process behav-ior of your plant.

The result: The operator feels he is working on theactual plant – all the operational procedures andprocesses are visualized in real-time. He can controlproduction virtually, but also learn maintenance rou-tines. Using this hands-on method, we fine-tune theautomation system in advance so you benefit fromsmooth running and perfect operability.

The solution palpably reduces commissioning times,as well as on-site corrections. Your operators appreci-ate the real-life training opportunity provided duringtesting because it’s an ideal way for them to preparefor their future work on the plant.

TRAINING

Intensive training of your personnel on your new,complex systems is a priority for us.

First comes the theory in the classroom, where ourexpert employees pass on their know-how to yourpersonnel. Also available for them is detailed trainingmaterial, so if necessary they can look things up later.

Test using the originalequipment.

We always organize an extra instruction session forthe manufacturer’s experts to explain the operationand maintenance of the measuring systems installedin our automation solutions. After this thoroughgrounding, we train your operators during the Plug &Work phase.

Only then do we follow up with on-site training at theconstruction location. It’s standard procedure for us toinclude your employees in plant commissioning, andas a result they get to know the systems andprocesses on the ground.

Each training module builds on the last so that by theend of commissioning your staff will be able to oper-ate the plant reliably and independently. If faultsoccur, they will know how to pinpoint the cause andwhat to do about it.

Operator training in thetest field.


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MODERNIZATIONSTRATEGIESMODERNIZATIONSTRATEGIES

SMS Siemag has developed a strategy that ensuresproduction continues throughout alteration or mod-ernization work. Compared with conventional meth-ods, it gives you a much higher protection againstfailure, shorter commissioning time, steeper run-upcurves, and therefore an early return on investment.

GOOD REASONS FOR REVAMPS

Improved product propertiesBetter production/productivityReduced production costsIncreased availabilityReplacement of old systems

SMS Siemag revamp strategies utilize all aspects ofmodern metallurgical automation systems:

Integration of new process technologiesReproducible process sequencesImproved ergonomics and safety technology Replacement of obsolete systemsProven quality of product properties using techno-logical values in the entire process

PROCEDURE

These are the main steps in a revamp project:Current state analysis, adaptation to plant operatingprocedures, conversion work planning, if necessary aswitch-over plan, plant test, re-commissioning, andoptimization.

CURRENT-STATE ANALYSIS

The first step to successful modernization is an in-depth assessment of the current state of theautomation system. Included here is an examinationof the sensory systems installed, to find out whetherthey can be re-used. This check simultaneouslydetermines how new sensory and measuring sys-

tems can be installed. Significant here is that the cur-rent state analysis examines all the relevant electricaland automation system components as well as thecomplete technological process sequence.

The second key stage is considering and selectinginterfaces to the automation systems and IT infra-structure that are to stay in place. Essentially, theknowledge gained here goes into a motor and com-ponent list, a technological process description, anda documentation of the interfaces for each conver-sion phase.

ADAPTATION TO THE

OPERATIONAL PROCEDURES

It’s quite normal that, over time, all plants developtheir own standard operational procedures. TheseSOP need to be carefully examined during the current-state analysis. They are identified and docu-mented on site in cooperation with the operating andmaintenance crew. Taking this as a basis, SMSSiemag and the people who work on the plant devel-op and agree on the new procedures.

PLANNING THE

CONVERSION PHASES

Together with you, we plan the phases for the majorconversion stages of mechanical, media, and electricalsystems. These plans are mapped out in detail prior tothe individual conversion steps.

Here again you benefit because maximization of opera-tions carried out in parallel before, during, and afterproduction standstills minimizes overall stoppagetimes. Then, according to pre-defined milestones, eachstandstill is tracked and if necessary re-planned byexpert construction managers working hand-in-hand.

SWITCH-OVER PLAN

Simply switching the signals at the interfaces is theeasiest way of changing plant operations over fromold to new automation systems. That’s what we doduring the modernization standstill – we shift the fieldsignals from the old to the new automation system.Invaluable here is that, in the course of maintenancestandstills before the conversion, individual functionscan be tested in advance. However, changeovers dur-ing standstills have a certain finality. It’s almostimpossible to change back to the old plant.

What we usually suggest, especially in the case ofcomplex interfaces and production-critical plant parts,is a switching plan. It allows testing of partial func-tions of the new automation system over severalplanned maintenance standstills prior to the conver-

sion standstill itself. Furthermore, the electronic ver-sion of the switch-over plan makes monitoring opera-tion possible. This is how the relevant data and sig-nals from the existing automation system areaggregated and evaluated by powerful monitoringsystems.

In highly critical cases, the switch-over technology isdesigned so that the entire plant can be switchedover from the old to the new automation systemwithout any major production interruption. This iswhere our tried-and-tested PIOS system is invaluable.

We cooperate closely with you to choose theswitchover plan, taking into account all the economicand technological aspects.

RE-COMMISSIONING

The steps described above reduce many of the risksinherent in conversions. You can rest assured that,due to our long-standing experience in commission-ing metallurgical plants, we can get your plant up andrunning again within a minimum timeframe. The highpoint of the whole project is the plant run-up afterthe revamp. Yet, before this happens, we team upwith you to carefully plan production of the materialquality and dimensions you require. The data record-ed during monitoring operation is applied to pre-opti-mize our process models, clearing the way for imme-diate production start with saleable product quality.

What’s more, you can rely on comprehensive sup-port, starting with continuous assistance during run-up, through to technology support from our develop-ment departments. Sometimes, both sides recognizethe potential for joint further development and sign acooperation agreement that might even lead to excit-ing innovations! Many successful projects confirmthe effectiveness of our revamp strategies.

Old

PPS/L3

Process models / L2

Process control / L1

Remote IO’s

Remote IO’sPIOS

Process models / L2

Process control / L1

New

Switch-over plan betweenold and new automation.

PIOS (ProcessIO Server) =“electronicterminal strip”


26 27

SERVICESSERVICES

COMMISSIONING

Right from the start of the Plug & Work tests, ourexperienced engineers are on the spot in the testfield. As the final stage of the Plug & Work test,when the scope of supply and functioning has beenconfirmed, they test the automation to make sure it’sperfectly ready for commissioning.

Essentially, commissioning on site consists of the fol-lowing stages:

Cold commissioning Hot commissioningSystem optimization during production Performance tests

Cold commissioning

Included in cold commissioning are all the activitiesnecessary for rolling the first strip. It concludes withthe first strip.

Hot commissioning

This starts with rolling the first strip. It’s the phasewhen all the mechanical and electrical functions aretested under load to check that the open and closed-loop controls are working properly.

Optimization of the systems

during production

This is when the parameters of all the systems areadjusted to ensure the new facility achieves therequired performance.

Performance tests

Finally, a test program we run through together withthe customer demonstrates that the plant meets thecontract specifications.

AFTER SALES SERVICE

Whenever you need us, we are always there to help– and it shows: in the form of our after sales service.This keeps you in touch with our expert know-how.

Specially developed for X-Pact® Electrics and Automa-tion, the ServicePortal SP/1 from SMS Siemag givesyou special access to fast fault remedy.

Right from the start of commissioning, we set up aservice portal for optimal plant support. It ensures sta-ble, protected communication between your and ourown networks. Via this portal, the SMS Siemagexperts access your plant’s automation system to giveyou immediate support in the form of remote diagno-sis and maintenance – worldwide and from day 1.

ADVANTAGES OF THE

SERVICE PORTAL

Some 70 percent of faults can be corrected immedi-ately. Alternatively, faults are isolated. Take forinstance faulty parts. Our experts can usually identifythem online, possibly deactivate them, and send aservice technician to replace them on site.

DOCUMENTATION

We manage the entire order documentation indetailed Excel-based spreadsheet. It comes completewith a table of contents that gives you an easy andimmediate overview of the complete documentation.All the necessary documents, such as functiondescriptions, circuit diagrams, and operating instruc-tions are saved in this list at one central, structuredlocation. Also integrated are all the documents gener-ated throughout the project. That means every docu-mentation transfer gives you the full current status inelectronic form.

The spreadsheet itself contains all the necessaryinformation on each document, e.g. file format, printformat, language, version, and life cycle. All you haveto do is to go straight to the center of the program,and you’ll find the document you want very quickly,then simply click on a link to open it. This is how theoperator finds his operating manuals, the mainte-nance employee the data sheet for a sensor, and theprogrammer the software details for the automation.Furthermore, once the project is completed, you cancontinue the documentation yourself and administernew documents or document versions.

Spreadsheet-based documentmanagement.

A/318E

1000/06/11 .Ky . P

rinted in Germany

SMS SIEMAG AG

Electrical and Automation Systems Division

Wiesenstrasse 3057271 Hilchenbach, Germany

Phone: +49 (0) 2733 29-5895Telefax: +49 (0) 2733 29-775895

Ivo-Beucker-Strasse 4340237 Düsseldorf, Germany

Phone: +49 (0) 211 881-5895Telefax: +49 (0) 211 881-775895

E-mail: [email protected]: www.sms-siemag.com

“The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have thesecharacteristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and willnot have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.”

MEETING your EXPECTATIONS

Documents

HIGH-PERFORMANCE HOT ROLLING MILLS Electrics and … · CONTENTS X-Pact® Electrics and Automation 4 Modern hardware solutions 6 Energy distribution and drive systems 8 Automation