INNOVATIVE SOLUTIONS FOR STRIP PROCESSING LINESsms-group.us/files/A-316E_Innovative solutions for... · INNOVATIVE SOLUTIONS One of the main cost factors in production is energy

INNOVATIVE SOLUTIONS FOR STRIP PROCESSING LINESElectrics and Automation

ELECTRICAL and AUTOMATION SYSTEMS

Strip Processing Lines

SMS SIEMAG

Electrics and AutomationSMS SIEMAG

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ELECTRICS AND AUTOMATIONELECTRICS AND AUTOMATION for strip processing lines

ALL-INCLUSIVE

MODERNIZATION STRATEGIES

As an operator of metallurgical plants, you knowhow important it is to constantly add to and renewyour production equipment so you retain your marketstanding with excellent product quality. It's notenough to simply install the latest mechanical equip-ment. Your upgrades must also be integrated into theprocess, and ultimately the automation system,before they can really make a difference to the finalproduct. SMS Siemag supplies seamless revampsolutions that support the technological improvementof your production across the board.

HOLISTIC

SYSTEM EXPERTISE

Central to the automation of metallurgical plantsis today’s focus on high availability and ever-betterquality of the final products. To meet these require-ments, SMS Siemag decided many years ago toinclude in its range not only mechanical equipment,technological controls, and process models, but alsothe entire electrics, automation, and drive technologyfor our plants. That makes us an all-inclusive supplier,giving you engineering, construction, and commis-sioning of your plants – all from one source.

Even more: You can be sure all the mechanical andelectrical system components mesh perfectly. Shortpaths, direct dialog, and everybody working towardthe same goals… all this adds up to the best condi-tions for your success.

CONTENTS

X-Pact® electrics and automation 4

Modular and energy-efficient 6

Energy distribution anddrive systems 8

Level 1-automation 10

Level 2-automation 12

Level 3-production planningsystems 14

Safety strategy 16

Plug & Work test 18

Modernization strategies 20

Services 22

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YOUR PROFESSIONAL PARTNER

FOR STRIP PROCESSING LINES

Interdisciplinary teams of experts from electrics,automation, technology, and engineering work handin hand to ensure everything functions smoothly.That's how we create intelligent, market-centeredsolutions for optimum product quality at maximumproductivity. This approach is reflected directly in ourtechnological solutions: Our entire scope of supplyand services – from plant engineering to processengineering, electrics and automation, manufactur-ing, assembly, Plug & Work testing, commissioning,right through to after sales service – is geared to thespecial requirements of our products and customers.

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X-PACT®X-PACT®

electrics and automation

SMS Siemag automation technology systems aregrouped together under the name X-Pact®. That goesfor all plant types, from steelworks through rollingmills to strip processing lines.

In all of these areas, including X-Pact® for strip pro-cessing lines, we focus on high cost-effectivenessand transparency of the control technology. X-Pact®

covers the automation from Level 0 to Level 3.

Obviously, automation is fundamental to plant perfor-mance and quality of the final products. That’s whycustomers globally demand comprehensive systemcapability. This means: complete plants, including theelectrics and automation (E&A), must come from onesource. As the global market leader in metallurgicalplants, SMS Siemag fits the bill, supplying the fullrange of systems. This interplay of mechanics, tech-nology, electrics, and automation, supported by over-all project management, forms the basis for effectiveproduction plants.

LEVEL 3 SYSTEMS

These are the main performance criteria you expectfrom a Level 3-system: high throughput and produc-tivity, compliance with delivery dates, maximumplant capacity utilization, and optimum energy utiliza-tion. Our Level 3-systems control production acrossall plants. How? By implementing customer orders inspecific production sequences for the individualplants in a process chain. Parallel to this, operationsin the plants are monitored so you can react quicklyand flexibly to any disruptions.

What's more, the Level 3-system distributes the pri-mary data (PDI) to all Level 2 systems. Then, aftercompletion of the order, it receives from these sys-tems the current production data used to draw upand archive reports.

LEVEL 2 SYSTEMS

Our level 2 systems control the production processin the individual plants. Working with the primarydata (PDI), they generate target values for the openand closed-loop controls in Level 1. These values aredefined using tables or mathematical and physicalprocess models. That creates all the right conditionsfor achieving optimum geometric and metallurgicalproduct properties. The actual values reported backfrom Level 1 are applied to automatically adapt theprocess models, and are summarized in productionreports. Furthermore, the Level 2-system feeds pro-duction data back to the Level 3-system.

LEVEL 1 SYSTEMS

Our Level 1 control systems are designed to ensurean excellent technological and functional implementa-tion of the target values determined by Level 2. Theyprecisely control the hydraulic and electronic settingactuators.


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Automation and operation.

There are even more stand-out features built intoour Level 1-systems, for example: maximum avail-ability and a high degree of process automation cou-pled with effective service functions. Furthermore,our Level 1-automation ensures best dynamics andprecision when it comes to controlling mechanical,drive technology, and hydraulic equipment. Our soft-ware specialists work closely with our engineeringteams to develop the right program modules foreach mechanical unit. We exclusively use compo-nents that comply with industry standards. Includedamong the latest technology applied here is real-time ethernet.

HMI SYSTEMS

When it comes to plant visualization, it's importantthat all the essential parameters, even in complexprocesses, are shown in a clear, understandable way.

That's exactly what our new method does. Wehave pooled our experience from a large number ofplants in operation to devise our ergonomic, com-fortable operating and visualization solution. Work-ing at their control desks, operating and mainte-nance personnel can see all the relevant processand plant data in a structured way. Right from thestart, in the project planning stage of a new plant orrevamp, we specially tailor the visualization to yourwishes and requirements. You also benefit from themodular development of the entire visualization sys-tem, because it can be upgraded and modified asneeded at a later date.

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MODULAR ANDENERGY-EFFICIENTMODULAR ANDENERGY-EFFICIENT

MODULAR SYSTEMS FOR STRIP

PROCESSING LINES

Our electrical and automation solutions come in mod-ular design. What does that mean for you? Not onlycan you implement these systems in stand-alonemachines but also in complete lines and further moreplus they can be seamlessly integrated into existingplants.

Here, we cover the entire range of strip treatmentplants for carbon steel, Si steel, stainless steel, andaluminum:

Continuous pickling LinesPickling lines combined with tandem millsPush-pull pickling linesAnnealing and pickling lines for stainless steelCombined pickling and galvanizinglines for hot stripContinuous annealing linesDe-greasing linesHot-dip galvanizing linesHot strip coating linesElectrolytic coating linesColor coating linesProcessing lines for aluminum andother nonferrous metalsRecoiling untis for hot and cold stripCross-cut and slitting shearsfor hot and cold strip

CUTTING COSTS WITH

INNOVATIVE SOLUTIONS

One of the main cost factors in production is energy.As a result of close teamwork between our engineersfor electrical systems, mechanics, and metallurgicaltechnology, we at SMS Siemag continually developtools and process models that slash energy costs andgive you a decisive competitive edge.

To ensure sustained cost reductions and meet evertougher environmental and resource-saving standards,we supply a whole raft of technologies:

Effective, low-loss drive systems that meshperfectly with the mechanical equipment Energy-optimized plant operationForward-looking production planning to optimizemanufacturing in terms of energy, qualityand quantityProcess models based on decades of experiencethat enable energy-efficient productionPowerful diagnostic tools that identifysavings potentials

PRECISION FUNCTIONS

ARE IN DEMAND

Operating a plant automated by SMS Siemag is easybecause it is equipped with plain, easy-to-understandand straightforward controls. All functions aredesigned to make working at the control desk easier.

To achieve this level of comfort, SMS Siemag hasdeveloped an all-new, production-centered operatingphilosophy. This is reflected in the clear layout of theoperating desks according to the latest ergonomicprinciples. Using the precise function designations,the operator can go straight to the relevant productionstep and focus on it. This approach makes the operat-ing process much simpler, safer and more reliable.


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Easy and efficientoperation.

VISUALIZATION FOR

REDUCED STANDSTILL TIMES

SMS Siemag also effectively applies visualization tech-nology for quality assurance. Here is how it works:The plant and operation-relevant data are displayed inreal-time in a graphic representation of the plant. Thismeans, for example, that in process chains, the nec-essary conditions for further switching are shown, orthe switch-on conditions for drives and controls arevisualized. Logging and evaluation of the plant statesenable any problems to be quickly pinpointed.

DIAGNOSIS AND MONITORING

Crucial for increasing reliability is technological diag-nostics. The production parameters detected andmapped by our diagnosis tools are the key to energyand quality-optimized running of a plant.

With our monitoring tools it is easy to rapidly locatefaults, rectify them, or take appropriate maintenanceand repair action.

Industrial blueprints

Ergonomic measurementsfor concentration overlong periods

Unique design with clear,consistent company integration

Various types of control deskwith clear overview of theproduction process

Analysis ofoperating processes

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ENERGY DISTRIBUTION and DRIVE SYSTEMSENERGY DISTRIBUTION and DRIVE SYSTEMS

SCOPE OF SUPPLY FOR

ENERGY DISTRIBUTION AND

DRIVE TECHNOLOGY

Included in our supply range for energy distributionare high and medium-voltage switchgears, distributortransformers, compensation and filter systems, emer-gency power generators, UPS systems, as well aslow-voltage main distributors and the associatedEmergency Off strategies.

We supply all controlled drives for our strip processinglines. Also available are constant drives of all powerclasses. You fully benefit from low investment andoperating costs due to optimum layout, a smaller foot-print, and low maintenance. It is an added advantagethat we can select components from any manufactur-er and draw up solutions in consultation with you.

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. The result? We opti-mally dimension all components, from overhead linefeeds to mechanical control elements.

RELIABLE DRIVE SYSTEMS

It's important to consider a whole range of parame-ters when designing drive systems, especially drivesthat are closely linked in a strip processing line. Thestrategies applied here depend on the type ofprocess, the local conditions and the parameters ofthe supply grid. We exclusively use practice-proven

Power track system foran electrolytic process.

Medium-voltageswitching plant.


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Single-line diagram.

standard components from renowned manufacturersfor our solutions. To maintain our quality standards,we carefully select these components, then optimizethem for the intended function. So you can be surewe configure the best solution for each plant – basedon our experience and know-how. Depending on theapplication, it’s your choice to opt for drive systemswith separate infeed units and a common direct-cur-rent intermediate circuit or intermediate circuit con-verter. We design our systems by taking into accountlocal conditions, and ensure that generated powercan be used in normal operation as motor power.

All drive-related technological functions are includedin the X-Pact® electrical and automation package. Thebasic functions of strip travel control are standardizedand adapted to suit the plant layout and processes.

There is a special reason why we use standard solu-tions. They make global service provision possible –both physically on site and remotely online. Drive side of a

tin-plating line.

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LEVEL 1–AUTOMATIONLEVEL 1–AUTOMATION

Stability, simple maintenance, uncomplicated adapta-tion to new conditions, and high-tech solutions –these are the demands modern automation systemsmust meet. Our X-Pact® systems are completely mod-ular in structure. As a result, we can easily adapt themto the different requirements of individual strip pro-cessing lines. What do our control solutions mean foryou? Quite simply, excellent technology and function-ality that ensure you achieve your target values bymeans of hydraulic and electrical control elements.

Other outstanding features of our Level 1-systems aremaximum availability and a high degree of processautomation coupled with effective service functions.Teaming up with the design department, our automa-tion experts develop and practically test softwaremodules for each mechanical unit.

CONFIGURATION OF THE

CONTROL SYSTEM

The Level 1-system consists of various automationfunctions. Each function works independently and islinked electrically with the corresponding sensorsand actors.

Here are the main functions:Open and closed-loop controls ofthe strip processing operationsDrive controlsMaterial trackingProcess data analysis (PDA)Sequence and auxiliary controlsHMI systems

OPEN AND CLOSED-LOOP

CONTROLS OF THE STRIP

PROCESSING OPERATIONS

The open and closed-loop controls in the process sec-tion of a strip processing line are key to the quality ofthe final product and the consumption of resourcessuch as energy and raw materials. Due to an intensivedialog with our engineers and the implementation ofour control systems in your plants, we provideprocess technology which is precisely geared to yourrequirements. Take for example our pickling model foran ideal pickling result and maximum productivity atminimum energy and acid consumption, or our tin-plating controls for optimum transitions upon productchangeover.

Combined inspection and exitcontrol station.


S-roll unit with direct tension control.

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DRIVE CONTROLS

Essential for reliable, low-wear operation of strip pro-cessing lines is a well coordinated, service-friendly,and proven strip travel control system.

As a standard, our controls come with these extras:S-ramps for smooth travelThe master in master/slave drives can be pre-selected in the PLC without changing the wiringThe drive switches to open-loop control whenthe speed sensor failsAutomatic re-set of load compensation coefficientsScalability of strip tension measurement in the PLCAdjustment of roll parameters using the HMIAutomatic recording of friction curvesActual thickness correction on the coiler withoutthickness measurementSlack control using laser and tension measurement

It is to your advantage that we build our control sys-tems with standard components and add extra servicefunctions. Why? Because you can rely on fast trou-bleshooting and optimum service.

MATERIAL TRACKING

The material and weld seam tracking feature followsthe coils from entry to exit of the plant. What happenshere is that it reacts for example to the weld seam bydefining new tension target values or reduced rollingforces in the skin-passing mill. Furthermore, the solu-tion generates measuring impulses for the differentplant parts to deliver measured values for qualityanalysis along the entire length of the line.

Allocation of stripsegments.

PROCESS DATA ANALYSIS (PDA)

The PDA system constantly logs the measured valuesonline. This ensures up the scope for a time-relateddiagnosis and analysis of the process events. Wherethis solution really comes into its own is during com-missioning, maintenance and plant optimization.

SEQUENCE AND AUXILIARY

CONTROLS

Crucial for the productivity of a strip processing lineare the automation functions. They must be easy tocontrol, especially in the entry and exit sections. Ourautomation solutions offer you maximum comfortwith advanced software and user-friendly diagnosissystems.

HMI SYSTEMS

Our HMI systems link the plant and the operator. Theymap the production process including everything todo with materials and technology. Armed with theinformation from the process observation, the opera-tor uses the latest graphical methods to manuallyinfluence sequences and control the machine groups,e.g. media units. In line with our operator-centeredapproach, our employees work closely with your oper-ating personnel. Involving your team in the Plug &Work tests is another effective way to prepare themfor their new tasks.

Temperature measurementStrip position 231 m

Strip n+1 Weld seam Strip n

Tension measurementStrip position 234 m

Weld seam

Strip divided into1-m segments

Strip direction of travel

TECHNOLOGICAL PROCESS MODELS

SMS Siemag strip processing lines cover practicallythe entire scope of strip treatment, further processingand quality assurance. They are modular in design,so you can choose the plants that fit your purposesexactly, also for modernizations of your existing sys-tems.

This high degree of flexibility owes a great deal to theLevel 2-process models that are perfectly geared toour plants. Working with the input data, they calculatethe target values of individual plant parts and deter-mine the right strip tensions and speeds.

That maximizes the rate of production for the desiredproduct quality. To do their job accurately, the processmodels take into account the limits of the plant aswell as the current plant situation, material properties,product dimensions, and temperature. The result?Low operating costs and products that stand out fortheir excellent tolerances and qualities and are highlyin demand, for instance in the automotive industry.

The bottom line is that X-Pact® Level 2 comes in amodular design flexible enough to adjust to anyrequirements.

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LEVEL 2-AUTOMATIONLEVEL 2-AUTOMATION

HIGH PRODUCTIVITY

The X-Pact® Level 2-systems are the key to increasingthe efficiency of modern strip processing lines.Improving product quality as well as increasing pro-duction volume and flexibility are the main tasks ofthe Level 2-systems, which are based partly on math-ematical and physical process models. To fulfill theirrole in quality assurance, process control systemsmust not only optimize processes but also ensure effi-cient product and production data capture.

Just like the elements of the other automation levels,SMS Siemag Level 2-solutions are independent of thehardware structure. They provide for distribution ofthe individual functions over several computers orconcentration on one powerful computer. To do this,the system uses a CORBA-based abstraction level,the SMS Siemag CBS framework.

The CBS framework features its own communicationfunction with the external systems, for example a pro-duction planning system spanning several plants, soas to maintain high connection and network flexibility.

Modules of theLevel 2 system.


Reporting system HMI

Data transfer

Perfo

rman

ce evaluatio

n

Internal m

aterial tracking

Coordination

(event han

dlin

g) Process dataStrategy

Process model shell

Technologicaltables Archive

database

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Production Report.

Structure of a strip processing line(e.g. hot-dip galvanizing line).

Entry area

Payoff reelThickness measur-ing equipmentShearsWelding machineNotcherPre-cleaningDrying

Process section

FurnaceHot-dip galvanizingCoolingIntermediate looperSkin-passing millTension levelerCoatingCoating thickness measurement

Exit area

InspectionShearCoilerCoil transport

Entr

y looper

Exit looper

PRODUCTION DATA CAPTURE

QUALITY DATA REPORTING (QDR)

Operating and product data capture is based on theprocess events of the Level 1-system. What happenshere is that the Level 2-system tracks all products inthe entry area of the strip processing line, along withtheir current status.

This provides data for plausibility checks for the pro-duction sequence and the calculation of product-spe-cific processing values. The relevant production andproduct data are saved in a database where they aremade available for product evaluation as well as quali-ty and product reports.

Equally flexible is Level 2 QDR. You can use it on thego, with reports accessible via secure links in anybrowser and on internet-capable smartphones.

It takes detailed planning of the production processto achieve the multiple goals of a large product vari-ety, top quality, fast delivery times, and minimumenergy consumption. You also need linkage with theproduction systems of suppliers and customers forseamless adjustment to new situations. Develop-ment here focuses on "Real Time Enterprise" (RTE),a method that checks and responds to thesechanges in real time.

What restricts the available options are the technicaland technological limits of the plants themselves,and we have to take this into account during programplanning. All this adds up to a need for comprehen-sive production planning systems.

BENEFITS OF X-PACT® LEVEL 3

X-Pact® Level 3 provides plant operators with all thetools they need for planning and control of the pro-duction processes in metallurgical plants, rolling millsand strip processing lines. An effective link betweenthe commercial side of the business and the techno-logical process automation systems, Level 3 produc-tion planning offers these benefits:Maximization of overall production ratePlanning and minimization of inventoriesfor interim products

LEVEL 3 – PRODUCTION PLANNING SYSTEMLEVEL 3 – PRODUCTION PLANNING SYSTEM

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Analysis of energy supply conditions for reducedenergy consumptionUniform product tracking throughoutthe production line Overall quality assurance up to finalquality approvalIncreased compliance with delivery dates

MANUFACTURING ORDERS

You can rely on our systems to convert your ordersinto technically executable manufacturing projects.That means, according to your specifications, anextensive calculation model generates the manufac-turing data for the product. Included here above allare the following steps:Definition of the necessary production stepsand possible plant alternativesDefinition of the dimensions and qualityof the initial and intermediate productsPlanning of the output of every production stageto determine the necessary quantities of inputmaterialDefinition of sample taking and test regulations

From customer order tomanufacturing order.


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THE FACTORY MODEL

A uniform planning system covering all areas isbased on a factory model. The factory model isimplemented in the planning system in the formof an electronic planning 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 aresult, you get a sequence plan for the individualplants as well as a plan of the available input materi-als for each manufacturing order.

Material flow in acold rolling mill.

QUALITY TRACKING

There is a data exchange between the Level 2-sys-tems of the overall plant and the Level 3-system.That means Level 3 is informed at all times aboutevery production step and the product quality aftereach step. Inspection and lab data add to the accu-racy of the result. This forms the basis for qualityapproval of the final products before delivery.

Annealingline

Cross-cut shear

Coupledpickling-tandem mill

Hot-dipgalvanizing line

Slitting shear

Packagingline

Packed,annealed,galvanizedcold strip

Customer

Plates

Customer

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SAFETY STRATEGYSAFETY STRATEGY

Worldwide, the importance of machine and plantsafety is growing. It's not just plant operators them-selves, but also laws and standards that demand per-sonal and environmental protection.

Essential for safe operation of our products is a coor-dinated approach during planning and design. Ourengineering and electrics divisions work together onthe main elements in our safety strategy:

The layout of the danger zoneThe risk assessmentThe electronic-mechanical function "Safety"The Emergency Stop plan

The hazard area 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.

An in-depth Emergency Stop plan is drawn up foreach plant.

Together with you, we work out a practical solutionwith safety control functions that operate indepen-dently from the machine controls. This strategyalso complies with all safety laws and regulations.And it reduces the time and cost of testing, docu-mentation, and commissioning. The safety controlfunctions are extensively tested early on – duringthe Plug & Work process.

Monitoringof a danger zone.


Level 1 (unsafe partof controlsystem)

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Extract from a dangerzone layout plan.

Separation of safety functionsand control functions.

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PLUG & WORK TESTPLUG & WORK TEST

Our long-established Plug & Work service is increas-ingly popular among our customers. At the heart ofPlug & Work are production simulations that mimicreality down to the smallest detail. You can benefitfrom our years of experience in engineering andprocess technology, because we know exactly howprocesses behave and what regulators achieve whichproduct qualities. The simulation system we use inour Plug & Work strategy reflects this complex inter-play of factors.

MODULE AND INTEGRATION TEST

Plug & Work starts with module tests that put theindividual hardware and software componentsthrough isolated function checks. Next in line are inte-gration tests that examine the fault-free interaction ofthe modules. The usual procedure in the industry is toend pre-testing here, then continue trials after theplant has been erected on the construction site. Wego one step further. That’s because, even beforedelivery, we install the entire automation system inone of our test fields and link it up to a simulationsystem. First, the functions and the customer-specificconstruction models of the plant, including all thekinematic and dynamic parameters of the plant behav-ior and the sensors, are set up. That creates a com-puter-aided simulation model ideal for testing thefunctioning and process sequences of the plant.

To the operator, it feels like working on the real plant:All the sequences and processes are visualized inreal-time. He can control production virtually, and alsolearn maintenance routines. Using this hands-onmethod, we fine-tune the automation system inadvance so you benefit from smooth running and per-fect operability.

The solution palpably reduces commissioning times,as well as on-site corrections. Equally beneficial, youroperators appreciate the real-life training opportunityprovided during testing because it's an ideal way forthem to prepare for their future work on the plant.

Training.

Operator training on theoriginal control panel.


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A Plug & Work test set up in the test field.

TRAINING

We take training of your personnel seriously. Thatinvolves intensive learning about the new, complexsystems.

First comes the theory in the classroom, where ourexpert employees pass on their know-how to yourteam. We hand over detailed training material, so ifnecessary members of staff can look things up later.

We always plan an extra instruction session for theoperation and maintenance of the measuring sys-tems installed in our automation solutions. Thatmakes sure your specialists know the ropes. Second,

after the basics, operator training continues duringthe Plug & Work phase.

Only then do we follow up with on-site training atthe construction location. We make a point of includ-ing your employees in plant commissioning, and as aresult they get to know the systems and processeson the ground.

Each training module builds on the last so that by theend of commissioning your staff is able to operatethe plant reliably and independently. If faults occur,they know how to pinpoint the cause and what to doabout it.

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MODERNIZATION STRATEGIESMODERNIZATION STRATEGIES

SMS Siemag has developed a strategy that enablesproduction to continue 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.

REASONS FOR

MODERNIZATION PROJECTS

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 systems Proven quality of product properties usingtechnological values in the entire process

PROCEDURE

These are the main steps in a revamp project: cur-rent-state analysis, adaptation to plant operating pro-cedures, alteration work planning, plant test, switch-over plan, re-commissioning, and optimization.

CURRENT-STATE ANALYSIS

The first step to successful modernization is anin-depth assessment of the current state of theautomation system. That includes an examination ofthe sensory systems installed to find out whetherthey can be re-used.

This check simultaneously determines how new sen-sory and measuring systems can be installed. Signifi-cant here is that the current-state analysis examinesall the relevant electrical and automation system com-ponents as well as the complete technologicalprocess sequence.

The second key stage is considering and selectinginterfaces to the automation systems and IT infra-structure that will stay in place. Essentially, the knowl-edge gained here goes into a motor and componentlist, a technological process description, and a docu-mentation of the interfaces for each alteration phase.

ADAPTATION TO THE

OPERATIONAL PROCEDURES

Over time, all plants develop their own standardoperational procedures. Yet it’s imperative to exam-ine these SOPs during the current-state analysis.They are drawn up and documented on site with theoperating and maintenance crews. Taking this as abasis, SMS Siemag and the people who work on theplant develop and agree on the new procedures.

PLANNING THE ALTERATION PHASES

We plan the phases for the major revamp stages ofmechanical, media, and electrical systems in closecooperation with you. These plans are mapped out indetail prior to the individual alteration steps. It allmeans you save time and money, because carryingout more operations in parallel before, during, andafter production standstills slashes overall stoppagetimes. According to pre-defined milestones, eachstandstill is tracked and if necessary re-planned byexpert construction managers working hand in hand.


Old

PPS/I 3

Process models / L2

Process control / L1

Remote IO’s

Remote IO’sPIOS

Process models / L2

Process control / L1

New

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SWITCHOVER PLAN

Simply switching the signals at the interfaces is theeasiest way of changing plant operations over fromold to new automation systems. To do this, the fieldsignals are shifted from the old to the new automa-tion system during the modernization standstill. Wecan test individual functions in advance – i.e. in thecourse of maintenance standstills before the upgrade.However, changeovers during standstills have a cer-tain finality. It's almost impossible to change back tothe old plant.

What we devise, especially in the case of complexinterfaces and production-critical plant parts, is aswitching plan. Following this plan, we can test par-

tial functions of the new automation system overseveral scheduled maintenance standstills prior tothe conversion standstill itself.

Furthermore, the electronic version of the switch-over plan makes monitoring operation possible. Thisis how the relevant data and signals from the exist-ing automation system are captured and analyzed bypowerful monitoring systems. Plus, in highly criticalcases, the switch-over technology is designed sothat the entire plant can be switched over from theold to the new automation system without any majorproduction interruption.

We cooperate closely with you to make sure theswitchover plan is transparent, and you make thefinal decision, taking into account all the economicand technological aspects.

RE-COMMISSIONING

The steps described above reduce many of the risksinherent in alterations. Due to our many years' expe-rience in commissioning metallurgical plants, we canget your plant up and running again within a mini-mum timeframe.

The high point of the whole project is the plant run-up after the revamp. Yet, before this happens, weteam up with you to carefully plan production of thematerial quality and dimensions you require. The datarecorded during monitoring operation is applied topre-optimize our process models, clearing the wayfor immediate production start with marketable prod-uct quality.

Furthermore, 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 improvements and sign a coop-eration agreement that might even lead to excitinginnovations! There are a large number of successfulprojects we have carried out that confirm the effec-tiveness of our revamp strategies.

Switchover plan between oldand new automation systems.

PIOS = process IOserver “electronicterminal strip”

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SERVICESSERVICES

COMMISSIONING

Early on, during the Plug & Work tests, our experi-enced commissioning teams are on the spot in thetest field. Here, they prepare for successive transferof responsibility for the plant. As the final stage ofthe Plug & Work test, when the scope of supply andfunctioning has been confirmed, they test theautomation to make sure it's absolutely ready forcommissioning.

Essentially, commissioning on site consistsof the following stages:Cold commissioningHot commissioningSystem optimization during productionPerformance tests

Cold commissioning

Included in cold commissioning are all the activitiesnecessary for producing the first strip. The drive sys-tem is pre-optimized. Cold commissioning concludeswith the first strip.

Hot commissioning

Hot commissioning starts with production of the firststrip. In this phase, all the mechanical and electricalfunctions are tested under load to check that theopen and closed-loop controls are working properly.

System optimization during production

During this phase, the parameters of all the systemsare adjusted to ensure the new facility achieves therequired performance.

Performance tests

Finally, a test program we run through together withyou demonstrates that the plant meets the contractspecifications.

AFTER SALES SERVICE

There is even more we can do for you in the form ofour after sales service. This gives you continuedaccess to our expert know-how. Specifically forX-Pact® electrics and automation, the SP/1 serviceportal from SMS Siemag offers you the option ofrapid support in troubleshooting – 24/7.

Even during commissioning, we set up a serviceportal for optimal plant support. It is responsible forstable, protected communication between two net-works. Via this portal, the SMS Siemag expertsaccess your plant's automation system to give youimmediate support in the form of remote diagnosisand maintenance – worldwide and from day 1.

Benefits of the service portal

Some 70 percent of faults can be corrected immedi-ately. Alternatively, faults are isolated. Take forinstance defective parts. Our experts can usuallyidentify them online, possibly deactivate them, andsend a service technician to replace them on site.

The service portal is ideal for fast andsecure remote maintenance.


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DOCUMENTATION

Central, continuous administration of

project documentation

We manage the entire order documentation in anExcel-based spreadsheet. It comes complete with atable of contents that gives you an easy and imme-diate overview of the complete documentation. Allthe necessary documents, such as function descrip-tions, circuit diagrams, and operating instructionsare saved in this list at one central, structured loca-tion. Equally useful, the solution integrates all thedocuments generated throughout the project. Everydocumentation transfer gives you the full currentstatus in electronic form.

The spreadsheet itself contains all the necessaryinformation on each document, e.g. file format, printformat, language, version, and life cycle.

You go straight to the heart of the program, so youfind the document you want very quickly, and simplyclick on a link to open it. This is how the operatorfinds his operating manuals, the maintenanceemployee the data sheet for a sensor, and the pro-grammer the software details for the automation.

Once the project is completed, you can continue thedocumentation yourself and administer new docu-ments or document versions.

Document managementusing spreadsheets.

A-316E

1000/01/14 .Ky . Printed in Germany

SMS SIEMAG AG

Electrical and Automation Systems Division

Wiesenstrasse 3057271 Hilchenbach, Germany

Phone: +49 2733 29-5895Telefax: +49 2733 29-775895

Ivo-Beucker-Strasse 4340237 Düsseldorf, Germany

Phone: +49 211 881-5895Telefax: +49 211 881-775895

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

MEETING your EXPECTATIONS

“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.”

Documents

INNOVATIVE SOLUTIONS FOR STRIP PROCESSING LINESsms-group.us/files/A-316E_Innovative solutions for... · INNOVATIVE SOLUTIONS One of the main cost factors in production is energy