SIROLLCIS CM Solutions for cold rolling mills - Industry - Siemens
SIROLLCIS CM Solutions for cold rolling mills - Industry - Siemens
SIROLLCIS CM Solutions for cold rolling mills - Industry - Siemens
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SIROLL CIS <strong>CM</strong><br />
<strong>Solutions</strong> <strong>for</strong> <strong>cold</strong> <strong>rolling</strong> <strong>mills</strong><br />
Technology, mechanics, automation and electrical engineering –<br />
maximum plant per<strong>for</strong>mance to satisfy the highest demands<br />
Metals Technologies<br />
1
The demand <strong>for</strong> <strong>cold</strong> rolled steel continues to grow, and at the same time<br />
requirements <strong>for</strong> product quality, mill productivity, availability and reliability<br />
are increasing.<br />
You expect …<br />
Leading process technology<br />
High <strong>rolling</strong> speed and flexible<br />
production<br />
Complete and individual solutions that<br />
accommodate the increasing quality<br />
requirements <strong>for</strong> <strong>cold</strong> rolled products<br />
Technologies that allow high-quality<br />
products<br />
Future safe investment by expandable<br />
solutions<br />
Low operating costs thanks to high<br />
plant availability<br />
2
Your challenge:<br />
Increasing requirements <strong>for</strong><br />
plant productivity and quality<br />
of rolled products<br />
Continual growth and specialization<br />
According to current <strong>for</strong>ecasts, worldwide<br />
demand <strong>for</strong> steel is set to grow 25% by<br />
the year 2015. This increased demand<br />
must be met with extended capacity,<br />
increased <strong>rolling</strong> speeds and general<br />
increased plant productivity. The global<br />
market is being driven primarily by Asia.<br />
Steady growth requires continuous<br />
optimization of <strong>rolling</strong> processes in order<br />
to stay competitive in the global<br />
economy. Moreover, there is currently an<br />
ongoing consolidation in the iron and<br />
steel industry and a focus on high-quality<br />
products.<br />
Nevertheless all <strong>cold</strong> <strong>rolling</strong> mill<br />
managers seek to optimize their<br />
production and their operation costs. The<br />
steel industry knows only too well that<br />
difficult times and stagnation will return,<br />
and that <strong>mills</strong> must be prepared to<br />
produce successfully under extreme cost<br />
pressure.<br />
High mill availability will be a key<br />
success factor <strong>for</strong> economic operation of<br />
<strong>cold</strong> <strong>rolling</strong> <strong>mills</strong>.<br />
Specialization is the order of the day.<br />
Rolling mill operators are clearly focusing<br />
on high-quality products with which they<br />
can generate better added value on the<br />
market. An example of this is sheet metal<br />
<strong>for</strong> the automotive industry.<br />
Flexibility in terms of product planning,<br />
dimensional and steel grade changes<br />
require fast and precise setup of actuator<br />
and automation systems. To meet the<br />
future demands of their customers, <strong>cold</strong><br />
steel producers will need to install their<br />
new <strong>mills</strong> or modernize their existing<br />
<strong>mills</strong> to be ready <strong>for</strong> the production of<br />
modern steel grades.<br />
Increasing productivity<br />
at high plant availability<br />
Plant operators will have to continue<br />
optimizing consumption parameters in<br />
the future to achieve capacity increases<br />
and quality improvements with<br />
decreasing operating costs. This is the<br />
only way <strong>for</strong> them to strengthen their<br />
market per<strong>for</strong>mance over the long term.<br />
Requirements <strong>for</strong> product quality are<br />
continually growing in terms of<br />
dimensional accuracy, flatness,<br />
mechanical properties and surface<br />
quality. Especially in the automotive<br />
branch, increasingly higher steel quality<br />
is in demand. If producers are to succeed<br />
in this market, they have to use the most<br />
modern technologies and develop totally<br />
new types of steel grades.<br />
In the future, the degree of automation<br />
will ensure process reliability and lowmaintenance<br />
operation<br />
The tolerance limits <strong>for</strong> <strong>cold</strong> rolled steel<br />
are in the range of a thousandth of a<br />
millimeter. The perfect coordination of<br />
process parameters is decisive <strong>for</strong><br />
market success. The more precisely you<br />
meet the requirements of your customers<br />
with your expertise and your products,<br />
the more you can improve your market<br />
position. We invite you to work together<br />
with us in meeting these challenges.<br />
3
Our solution:<br />
Trendsetting technologies <strong>for</strong><br />
<strong>cold</strong> <strong>rolling</strong> <strong>mills</strong><br />
Quality and experience in <strong>rolling</strong><br />
technology<br />
Benefit from our more than 80 years of<br />
experience and expertise that made us<br />
one of the leading suppliers <strong>for</strong> the <strong>cold</strong><br />
<strong>rolling</strong> industry. In every one of our<br />
projects, we have proven ourselves the<br />
optimal partner through excellence in<br />
flexibility, meeting deadlines, precise<br />
execution, top per<strong>for</strong>mance and short<br />
start-up times. We have the process<br />
knowledge to decisively increase your<br />
<strong>rolling</strong> speeds and there<strong>for</strong>e your<br />
capacities, and to lower your plant<br />
operating costs and improve the quality<br />
of <strong>cold</strong> rolled products.<br />
Technologies from a single source<br />
You might be seeking a complete mill or<br />
a single section, modernization,<br />
extension or the construction of a new<br />
plant.<br />
No matter what your needs are, we offer<br />
the complete range of 4-high and 6-high<br />
<strong>cold</strong> <strong>rolling</strong> technologies. From reversing<br />
to tandem <strong>mills</strong> or skin pass <strong>mills</strong>, our<br />
technology corresponds exactly to your<br />
requirements. The range of <strong>cold</strong> <strong>mills</strong><br />
supplied by <strong>Siemens</strong> VAI offers<br />
technology, allowing strip to be produced<br />
at very tight tolerances and high<br />
productivity levels <strong>for</strong> carbon and special<br />
steel grades, e.g. AHSS (Advanced High-<br />
Strength Steel). SIROLL CIS <strong>CM</strong> comprises<br />
technology, mechanics, electrics, drives<br />
and automation from our vast <strong>Siemens</strong><br />
VAI resources.<br />
Innovative technologies<br />
The name <strong>Siemens</strong> VAI stands <strong>for</strong> a<br />
permanent leadership in innovation.<br />
<strong>Siemens</strong> VAI combines the traditions of<br />
four successful companies: Clecim, Davy,<br />
VAI and <strong>Siemens</strong>. All have achieved<br />
remarkable developments in the field of<br />
<strong>cold</strong> <strong>rolling</strong> technology. Many of these<br />
achievements, which have now been<br />
combined, were developed or introduced<br />
with leading steel producers around the<br />
world. The complementary solutions and<br />
skills as well as the additional<br />
contributions from our long lasting<br />
cooperation with institutes and<br />
universities lead to further advances in<br />
<strong>cold</strong> <strong>rolling</strong> technology. We are also well<br />
prepared to develop new mechatronic<br />
solutions <strong>for</strong> even higher productivity and<br />
quality targets. We look <strong>for</strong>ward to<br />
applying our innovative strength to the<br />
optimization of your plant as well.<br />
Life-cycle partnership<br />
As life-cycle partner <strong>for</strong> steel producers<br />
<strong>Siemens</strong> VAI offers the complete range of<br />
products and services necessary <strong>for</strong> new<br />
investments and modernization – from<br />
preliminary studies, site inspections and<br />
feasibility studies up to and including<br />
commissioning the new mill or the<br />
modernized equipment. Your mill<br />
operation can only benefit from service<br />
and maintenance contracts with<br />
<strong>Siemens</strong> VAI.<br />
4
As a globally active full-liner, we possess expertise that is unique in the entire steel<br />
production industry. Backed by this extensive experience, we completely focus<br />
on process optimization <strong>for</strong> <strong>cold</strong> <strong>rolling</strong> <strong>mills</strong> – starting with individual plant and<br />
logistics design, and including proven <strong>rolling</strong> technologies as well as sophisticated<br />
automation packages. And in everything we do, we have one goal in mind:<br />
To increase the per<strong>for</strong>mance of your plant.<br />
Good reasons <strong>for</strong> SIROLL CIS <strong>CM</strong><br />
<strong>cold</strong> <strong>rolling</strong> solutions:<br />
Single source supplier <strong>for</strong> mechanical,<br />
electrical and automation equipment<br />
Proven experience in new plants and<br />
modernization at leading <strong>cold</strong> band<br />
producers<br />
Proven low maintenance design and<br />
intelligent control systems <strong>for</strong><br />
maximum plant availability and yield<br />
Life-cycle partner making use of global<br />
resources<br />
5
Our <strong>cold</strong> <strong>rolling</strong> <strong>mills</strong>:<br />
Tandem <strong>cold</strong> <strong>mills</strong> .................................................... 8<br />
Coupled pickling lines and tandem <strong>cold</strong> <strong>mills</strong>.............. 10<br />
Reversing <strong>cold</strong> <strong>mills</strong>................................................... 12<br />
Skin pass <strong>mills</strong>........................................................... 14<br />
Cold mill complexes.................................................. 16<br />
Our supplies and services:<br />
Mechatronic packages............................................... 18<br />
Automation solutions................................................ 20<br />
Basic automation...................................................... 22<br />
SIROLL CIS SIAS – surface inspection and allocation....... 24<br />
Motors and drives...................................................... 25<br />
Innovation in <strong>cold</strong> <strong>rolling</strong>........................................... 26<br />
Life-cycle management.............................................. 28<br />
Modernization .......................................................... 29<br />
6
<strong>Siemens</strong> VAI supplies metallurgical plants <strong>for</strong> everything from iron ore processing to<br />
production of coated steel strip (horizontal integration). And we can also deliver the<br />
complete plant – including turnkey equipment, mechanical and hydraulic equipment,<br />
and electrical and automation systems (vertical integration). <strong>Siemens</strong> VAI is your<br />
life-cycle partner from the initial investment idea to planning, layout, engineering and<br />
construction – and we are also there <strong>for</strong> you later, when it is time to modernize to keep<br />
your mill at the leading edge of technology.<br />
7
Tandem <strong>cold</strong> <strong>mills</strong><br />
Competence <strong>for</strong> your success<br />
Principle design of a tandem <strong>cold</strong> mill<br />
From batch to continuous mode<br />
Production capacities of tandem <strong>cold</strong><br />
<strong>mills</strong> using coil to coil operation are<br />
typically in the range of 600,000 to<br />
800,000 tons per year. Today many of the<br />
existing batch <strong>mills</strong> are extended and<br />
modernized to continuous mode<br />
operation and new <strong>mills</strong> are installed <strong>for</strong><br />
continuous operation from the very<br />
beginning. Depending on the product<br />
mix, production capacity of these<br />
continuous <strong>mills</strong> can than reach 1.2 m<br />
tons per year or even more, and many of<br />
the quality parameters can even be<br />
improved.<br />
8<br />
4-high and 6-high technology<br />
Our technological and process<br />
automation experience in 6-high and<br />
4-high technology makes <strong>Siemens</strong> VAI a<br />
unique partner <strong>for</strong> your <strong>cold</strong> mill. Our<br />
goal with SIROLL CIS <strong>CM</strong> is to deliver a<br />
solution that offers maximum added<br />
value <strong>for</strong> your production. Advanced mill<br />
stand actuators will bring the benefits of<br />
improved yield, user-friendly mill<br />
operation and high strip quality.<br />
Both 4-high and 6-high solution bring<br />
specific benefits, and our analysis of the<br />
customer’s overall requirements will<br />
define the best suitable technological<br />
solution. Our approach has been<br />
rewarded, <strong>for</strong> example, by top steel<br />
producers voestalpine Stahl (5-stand,<br />
4-high, SIROLL CIS Smartcrown®) and<br />
CORUS Staal (4-stand, 6-high), which<br />
have selected us to supply the latest<br />
tandem <strong>mills</strong> in Europe. Both companies<br />
are dedicated to producing AHSS<br />
(advanced high-strength steel grades).<br />
Technical features:<br />
CIS<br />
SIROLL<br />
Smartcrown contour roll<br />
associated with axial roll-shifting <strong>for</strong><br />
enhanced flatness control<br />
4-high and 6-high mill stands <strong>for</strong> high<br />
mill flexibility <strong>for</strong> all products<br />
Morgoil® bearings or roller bearings<br />
depending on application<br />
Physical-based analytical online models<br />
supported by neural networks ensure<br />
accurate mill setup to achieve tight<br />
tolerances right from the start<br />
Flexible thread-in and thread-out<br />
strategies <strong>for</strong> all kinds of materials,<br />
such as high-strength steel grades<br />
Patented compensation systems <strong>for</strong><br />
correcting periodic roll and coil<br />
eccentricities<br />
Use of last stand in temper mode <strong>for</strong><br />
smoothing or roughing strip surface<br />
Fully automatic operation allows<br />
operators to concentrate on product<br />
quality; actual operator intervention is<br />
reduced to an absolute minimum
voestalpine Stahl, Linz, Austria<br />
Tangshan Iron & Steel, Tangshan, China<br />
Nonstop production possible<br />
<strong>for</strong> any existing tandem mill<br />
In recent years, the most newly installed<br />
tandem <strong>cold</strong> <strong>mills</strong> have been continuous<br />
operation <strong>mills</strong>, which indicate that this<br />
type has displaced the traditional batch<br />
mill. The reason is clear: the productivity<br />
of a continuous mill is significantly higher<br />
(up 40%) than a batch mill. One<br />
significant factor in this improvement<br />
was the development of laser welders.<br />
The weld seam produced by these laser<br />
welders and the modern control<br />
techniques allow minimum loss of time<br />
and material. As a result, later conversion<br />
of a batch mill into a continuous mill is a<br />
typical market trend of the early decade<br />
of this century. Generally, any existing<br />
non-continuous tandem mill of any line<br />
layout can be converted into a<br />
continuously operating mill with the use<br />
of suitable strip turning units, the right<br />
equipment and careful arrangement of all<br />
mill and logistical facilities.<br />
Additions <strong>for</strong> continuous operation<br />
<strong>Siemens</strong> VAI offers the following<br />
equipment <strong>for</strong> the continuous operation<br />
of your mill:<br />
Welders (flash butt and laser welders)<br />
Accumulators (2-, 4-, or 6-strand) at<br />
one or two levels<br />
Scale breakers<br />
Side trimmers<br />
Bridles <strong>for</strong> decoupling the tension of<br />
the different line sections<br />
Exit sections with flying shear and 2<br />
reels or carrousel coiler depending on<br />
the strip thickness<br />
Main benefits:<br />
High production rates<br />
Optimized yield<br />
Reduced roll consumption<br />
Flexible production<br />
Tight tolerances <strong>for</strong> strip thickness,<br />
shape and high surface quality<br />
Low costs <strong>for</strong> operation, maintenance<br />
and minimum down times<br />
Selected references:<br />
voestalpine Stahl, Linz, Austria<br />
Salzgitter Flachstahl, Salzgitter,<br />
Germany<br />
ArcelorMittal, Bremen, Germany<br />
Essar, Hazira, India<br />
SSAB, Oxelösund, Sweden<br />
P.T. Krakatau Steel, Cilegon, Indonesia<br />
ArcelorMittal, Sagunto, Spain<br />
ArcelorMittal, Ferblatil, Belgium<br />
ArcelorMittal, La Magona, Piombino,<br />
Italy<br />
9
Coupled pickling lines and tandem <strong>cold</strong> <strong>mills</strong><br />
High-capacity production <strong>for</strong> high-quality products<br />
Example of <strong>Siemens</strong> VAI coupled pickling line...<br />
Pickling lines and tandem <strong>cold</strong> <strong>mills</strong><br />
For a wide range of product applications,<br />
the required strip thickness, flatness and<br />
surface quality can be achieved more<br />
economically by linking the pickling and<br />
<strong>cold</strong> <strong>rolling</strong> processes. This delivers<br />
significant improvements with regard to<br />
mill productivity, yield and production<br />
cost savings as a result of the elimination<br />
of strip threading and tailing-out<br />
operations. Reduced strip-head and tailend<br />
losses also contribute to better<br />
overall yield. Our speed optimization<br />
system ensures maximum throughput<br />
rates under all operating conditions, and<br />
maintenance, roll consumption and<br />
manpower requirements are also<br />
lowered. Typical production capacities of<br />
such combined facilities are in the range<br />
of 1.2-2 million t/a.<br />
Pickling line<br />
Pickling lines supplied by <strong>Siemens</strong> VAI are<br />
characterized by high pickling rates, lowcost<br />
pickling operations, flexible<br />
production, a wide range of product<br />
sizes, qualities, reliable plant operation,<br />
and low maintenance requirements, as<br />
well as compliance the highest standards<br />
<strong>for</strong> environmental safety.<br />
The pickling model –<br />
SIROLL CIS Faplac®<br />
The SIROLL CIS Faplac® system (Fully<br />
Automatic Pickle Liquor Analysis and<br />
Control) ensures an efficient operation of<br />
the pickling process by compliance of a<br />
proper acid and iron concentration<br />
(waste acid).<br />
The employment of roll and strip<br />
temperature models ensures the<br />
achievement of tight tempera ture<br />
tolerances and the avoidance of<br />
overheating thus prolonging the life of<br />
the emulsion.<br />
In addition the <strong>rolling</strong> strategies<br />
calculated by the process models are<br />
geared to the minimum use of electrical<br />
energy by making the most efficient use<br />
of the mill with respect to roll <strong>for</strong>ce, roll<br />
torque and roll power.<br />
Main benefits:<br />
High pickling throughput rates<br />
Uni<strong>for</strong>mly pickled surfaces<br />
Closed loops of acid, fume and rinse<br />
circulation reduce operation cost in an<br />
environmental-friendly manner<br />
10
... and tandem <strong>cold</strong> mill<br />
Coupling devices<br />
<strong>Siemens</strong> VAI installs helical turning<br />
devices or turning towers <strong>for</strong> coupling<br />
existing sections or new and existing<br />
sections <strong>for</strong> a pickling line tandem <strong>cold</strong><br />
mill configuration. With these solutions it<br />
is possible to change the direction of the<br />
strip and build a line, such as a 90°<br />
configuration, if the layout requires such<br />
a strip turning.<br />
Helical turning device<br />
Selected references:<br />
SAIL Bokaro Steel Plant, Jharkand, India<br />
Wuhan Iron & Steel, Wuhan, China<br />
Corus, IJmuiden, Netherlands<br />
Liuzhou ISCO, Liuzhou, China<br />
ArcelorMittal, Mardyck, France<br />
Tangshan Iron & Steel, Tangshan, China<br />
Benxi Iron & Steel, Benxi, China<br />
Panzhihua, Panzhihua, China<br />
voestalpine Stahl, Linz, Austria<br />
ArcelorMittal, Sparrows Point, MD/USA<br />
ArcelorMittal, Ferblatil, Belgium<br />
Ilva, Taranto, Italy<br />
Corus, Port Talbot, UK<br />
Angang, Anshan, China<br />
11
Reversing <strong>cold</strong> <strong>mills</strong><br />
Advanced technology<br />
Principle design of a 2-stand reversing <strong>cold</strong> mill<br />
Single-stand reversing <strong>cold</strong> <strong>mills</strong><br />
Depending on the product mix, <strong>rolling</strong><br />
capacities between 200,000 and<br />
600,000 t/a are possible in a single-stand<br />
<strong>cold</strong> <strong>rolling</strong> mill. Rolling schedules can be<br />
carried out with an even or uneven<br />
number of passes to maximize mill<br />
availability and per<strong>for</strong>mance. Flatnessmeasurement<br />
systems mounted on one<br />
or both sides of the mill ensure optimum<br />
flatness control. In addition to work-roll<br />
bending and shifting, <strong>Siemens</strong> VAI<br />
reversing <strong>cold</strong> <strong>mills</strong> are equipped with<br />
multi-zone cooling to meet the highest<br />
demands on flatness.<br />
2-stand reversing <strong>cold</strong> <strong>mills</strong><br />
Following the introduction of mini <strong>mills</strong><br />
in North America, a new generation of<br />
reversing <strong>cold</strong> <strong>mills</strong> has emerged which<br />
combines the flexibility of single-stand<br />
reversing <strong>mills</strong> with the capacity of<br />
conventional coil-to-coil tandem <strong>mills</strong> at<br />
substantially reduced investment costs.<br />
Steel rolled in 2-stand reversing <strong>cold</strong> <strong>mills</strong><br />
from <strong>Siemens</strong> VAI is suitable <strong>for</strong> highest<br />
quality applications, offering the best<br />
possible per<strong>for</strong>mance in terms of product<br />
quality and productivity. Ideal <strong>for</strong> <strong>rolling</strong><br />
capacities from 300,000 t/a of thin-gauge<br />
products to 1,000,000 t/a and higher <strong>for</strong><br />
heavy-gauge products.<br />
4-high and 6-high technology<br />
Depending on the product mix and the<br />
quality requirements, <strong>Siemens</strong> VAI offers<br />
4-high or 6-high mill stands to meet the<br />
customer’s overall requirements. Both<br />
mill stand types are equipped with<br />
flatness control solutions using SIROLL CIS<br />
Siflat or Planicim® <strong>for</strong> measurement and<br />
the SIROLL CIS Smartcrown® roll contour <strong>for</strong><br />
the work or intermediate rolls.<br />
12
Tangshan Iron & Steel, Tangshan, China<br />
ISD Dunaferr, Hungary<br />
Integrated automation solutions <strong>for</strong> consistently<br />
high strip quality<br />
Main benefits:<br />
High production capacity and yield<br />
Flexible, low-cost <strong>rolling</strong><br />
of a wide range of products, especially<br />
<strong>for</strong> small order lots<br />
Tight strip thickness and shape<br />
tolerances<br />
Minimum off-gauge length<br />
High surface quality<br />
Selected references:<br />
Indian Steel, Ghandidham, India<br />
Dunaferr, Dunaijvaros, Hungary<br />
Borcelik, Gemlik, Turkey<br />
Sollac Mediterranee, St. Chely, France<br />
Angang, Anshan, China<br />
Tangshan Iron & Steel, Tangshan, China<br />
Taiyuan Iron & Steel, Taiyuan, China<br />
EBG, Bochum, Germany<br />
Haironville, Contrisson, France<br />
Nucor Steel, Berkeley, SC, USA<br />
Hadeed, Al Jubail, Saudi Arabia<br />
CSN, Terre Haute, IN/USA<br />
13
Skin pass <strong>mills</strong><br />
For a perfect finish<br />
Salzgitter Flachstahl, Salzgitter, Germany<br />
Mittal Steel, Sparrows Point, MD/USA<br />
Supply of single- and<br />
2-stand skin pass <strong>mills</strong><br />
<strong>Siemens</strong> VAI supplies stand-alone and<br />
inline skin pass <strong>mills</strong> of either single- or<br />
2-stand design <strong>for</strong> adjusting the final<br />
mechanical properties, flatness and<br />
surface finish of <strong>cold</strong> rolled strip.<br />
To meet the continually increasing<br />
demands <strong>for</strong> strip flatness, elongation<br />
and roughness, especially <strong>for</strong> hard<br />
material grades, a 2-stand skin pass mill<br />
is the preferred solution because of the<br />
higher <strong>rolling</strong> <strong>for</strong>ces and torques that can<br />
be achieved.<br />
Main benefits:<br />
Tight strip elongation tolerances<br />
Excellent flatness per<strong>for</strong>mance<br />
High surface quality (roughness, peak<br />
count, residuals)<br />
Possibility of wet and dry skin passing<br />
modes<br />
Selected references:<br />
SAIL Bokaro Steel Plant, Jharkand, India<br />
ThyssenKrupp Steel, Dortmund,<br />
Germany<br />
Angang, Anshan, China<br />
Baosteel, Baoshan, China<br />
MaSteel, Maanshan, China<br />
Essar, Hazira, India<br />
Tangshan Hengtong, Tangshan, China<br />
Hadeed, Al Jubail, Saudi Arabia<br />
Dofasco, Hamilton/Ontario, Canada<br />
ArcelorMittal, Mardyck, France<br />
Hunan Valin Lianyuan, Loudi, China<br />
Salzgitter Flachstahl, Salzgitter,<br />
Germany<br />
voestalpine Stahl, Linz, Austria<br />
14<br />
Elongation control with optimized compensation, skin pass mill, Mittal Steel, Sparrows Point, USA
Cleaning brushes<br />
Adjustment cylinders<br />
Backup roll<br />
Flatness-measurement roll<br />
Deflector roll<br />
Work roll<br />
Brushes<br />
<strong>Siemens</strong> VAI solution <strong>for</strong> dry-type skin passing<br />
Skin pass control to meet highest<br />
quality demands<br />
The expectations of end customers <strong>for</strong><br />
steels are constantly rising. Deep-drawing<br />
sheet steel, <strong>for</strong> example, needs to be<br />
almost 100% flat and should not exhibit<br />
any stretcher strains. All this makes skin<br />
pass <strong>rolling</strong> an important process that<br />
calls <strong>for</strong> optimization. Our skin pass<br />
control with self-optimizing parameters<br />
can help you safely master these<br />
challenges – in different modes to suit<br />
different requirements:<br />
Skin pass control via the <strong>rolling</strong> <strong>for</strong>ce<br />
Skin pass control via the strip tension<br />
Skin pass control in mixed tension-<strong>for</strong>ce<br />
mode<br />
Skin pass control on the basis of the<br />
patented advanced mass-flow concept<br />
This results in a uni<strong>for</strong>m elongation and a<br />
texture – across the entire strip – that<br />
your customers want.<br />
And what is more: Our process models<br />
always have the skin pass mode under<br />
control – whether <strong>for</strong> 2-stand or singlestand<br />
and inline skin pass <strong>mills</strong>.<br />
Dry-type skin pass <strong>rolling</strong><br />
For exposed automotive parts and a wide<br />
range of household appliances, strip<br />
producers are increasingly required to<br />
supply final products which are skin<br />
passed and free of wet skin passing<br />
agents. SIROLL CIS <strong>CM</strong> improved solution<br />
<strong>for</strong> dry-type skin passing is based on roll<br />
cleaning which features the use of<br />
rotating and oscillating wire brushes <strong>for</strong><br />
the work rolls and oscillating cleaning<br />
brushes <strong>for</strong> the backup rolls.<br />
Main benefits:<br />
Cost savings since no wet skin passing<br />
agents are required<br />
Improved adhesiveness of strip surface<br />
<strong>for</strong> painting<br />
No more „brown staining“ during<br />
storage<br />
No disposal costs <strong>for</strong> wet skin passing<br />
agents<br />
15
Cold mill complexes<br />
Experience is the basis <strong>for</strong> optimized production roots<br />
Hadeed, Al Jubail, Saudi Arabia<br />
Our outstanding supply record <strong>for</strong><br />
turnkey <strong>cold</strong> mill complexes highlights<br />
<strong>Siemens</strong> VAI’s overall process<br />
expertise.<br />
We have supplied tandem <strong>cold</strong> <strong>mills</strong>,<br />
reversing <strong>mills</strong>, skin pass <strong>mills</strong>, strip<br />
processing lines, heat treatment facilities,<br />
layout and logistic planning, as well as all<br />
related automation and production<br />
control (MES) systems and auxiliary<br />
facilities (roll shops, storage, finishing<br />
lines such as slitting and recoiling lines,<br />
packing and dispatch equipment).<br />
As part of its scope of services, <strong>Siemens</strong><br />
VAI also trains operating and<br />
maintenance personnel. We also offer<br />
maintenance <strong>for</strong> the entire plant.<br />
Main benefits:<br />
Single point of responsibility<br />
Optimized layout solutions <strong>for</strong><br />
technological key equipment and<br />
auxiliary equipment<br />
Savings in spare parts and maintenance<br />
cost over the entire life-cycle<br />
Selected references:<br />
SAIL Bokaro Steel Plant, Jharkand, India<br />
Borcelik, Gemlik, Turkey<br />
Essar, Hazira, India<br />
ArcelorMittal, Sparrows Point, MD/USA<br />
Hadeed, Al Jubail, Saudi Arabia<br />
Duferco, Saldanha Bay, South Africa<br />
CSN, Terre Haute, IN/USA<br />
P.T. Krakatau Steel, Cilegon, Indonesia<br />
voestalpine Stahl, Linz, Austria<br />
Pickling line<br />
Processing lines<br />
16
Cold mill complex <strong>for</strong> 600,000 t/a<br />
Tandem <strong>cold</strong> mill<br />
Reversing <strong>cold</strong> mill<br />
Skin pass mill<br />
Slitting line<br />
Packing line<br />
Coil storage<br />
17
Mechatronic packages<br />
Unique solutions to improve the per<strong>for</strong>mance of your mill<br />
SIROLL CIS Siflat – flatness measurement and control<br />
Flash-butt welder<br />
Mechatronic knowledge <strong>for</strong> optimized<br />
per<strong>for</strong>mance<br />
One of our main strengths is the<br />
combination of technology, mechanical<br />
engineering and automation expertise. It<br />
is the best recipe <strong>for</strong> creating mechatronic<br />
packages, which we offer <strong>for</strong> new <strong>mills</strong> as<br />
well as <strong>for</strong> modernization projects. Our<br />
packages comprise proven mechanical<br />
solutions, the optimization of all required<br />
actuator systems, modern control systems<br />
and optimized sensors and measurement<br />
systems. SIROLL CIS <strong>CM</strong> mechatronic<br />
packages are available <strong>for</strong>:<br />
Flatness<br />
AGC<br />
Welders<br />
Scale breaker<br />
Anti-chatter<br />
Strip inspection<br />
Flatness packages<br />
Our flatness solution includes all required<br />
mechanical actuators, control and<br />
measurement systems to ensure highest<br />
flatness per<strong>for</strong>mance. Depending on mill<br />
type and product mix, the mill stands are<br />
equipped with work roll bending and<br />
shifting, SIROLL CIS Smartcrown® work-roll<br />
contour and multi-zone cooling. The<br />
flatness control system features selflearning<br />
parameter optimization <strong>for</strong><br />
adaptation to the <strong>rolling</strong> conditions and<br />
material properties. To complete our<br />
package we can either use the<br />
contactless SIROLL CIS Siflat system or the<br />
SIROLL CIS Planicim® flatness measurement<br />
roll depending on technical and ambient<br />
conditions.<br />
AGC package<br />
The automatic gauge control package of<br />
<strong>Siemens</strong> VAI combines the hydraulic<br />
capsules, servo-valves, transducer and<br />
the control system to create a<br />
comprehensive solution. SIROLL CIS <strong>CM</strong>’s<br />
advanced mass flow control ensures<br />
thickness precision to a few thousandth<br />
of a millimeter.<br />
Our improved REC (roll eccentricity<br />
compensation system) also contributes to<br />
a further improvement of thickness<br />
per<strong>for</strong>mance, especially <strong>for</strong><br />
modernizations.<br />
18
Heavy laser welder – view to welding area<br />
Heavy laser welder<br />
AGC system<br />
Welder package<br />
<strong>Siemens</strong> VAI supplies a range of welders<br />
to handle the though requirements of<br />
coupled pickling tandem <strong>mills</strong> and<br />
continuous tandem <strong>cold</strong> <strong>mills</strong>:<br />
LW21H: Laser welder capable of<br />
processing grades up to 1,300 MPa with<br />
no weld over thickness, with welding<br />
flexibility over a large grade range.<br />
FB21C: The flash-butt technology has<br />
been very successful and is widespread<br />
around the world. Our SIROLL CIS<br />
Weldamatic® process ensures the best<br />
results and high flexibility with respect to<br />
new grades.<br />
FB21S: This flash-butt welder with<br />
integrated shear delivers perfect weld<br />
geometry and minimization of the strip<br />
break rate. DC current ensures very<br />
smooth flashing and the possibility <strong>for</strong><br />
pre- and post-weld heating. Oxygen-free<br />
and adapted weld confinement<br />
guarantee good welding of high strength<br />
and high carbon steel grades.<br />
In-house manufacturing and testing<br />
Key components of our mechatronic<br />
packages and other core equipment <strong>for</strong><br />
our <strong>mills</strong> are manufactured and tested in<br />
the <strong>Siemens</strong> VAI workshop at Montbrison,<br />
France.<br />
Our workshop in Montbrison, France<br />
19
Process automation solution<br />
Complete process control at every level<br />
Main pulpit, voestalpine Stahl, Linz, Austria<br />
Sophisticated automation concept<br />
Technological controls and process<br />
models are the core of any sophisticated<br />
automation concept with the goal of<br />
maximizing utilization of the mechanical,<br />
hydraulic, and other positioning<br />
elements. The control concepts have<br />
evolved with the increasing per<strong>for</strong>mance<br />
of the equipment – from simple analog PI<br />
controllers to highly complex and<br />
interlinked control systems. These<br />
controls and process models are an<br />
integral part of SIROLL CIS <strong>CM</strong>. The value of<br />
the SIROLL CIS <strong>CM</strong> concept is visible in the<br />
rolled strip: improved gauge tolerances,<br />
less off-gauge material, perfect flatness<br />
to meet growing demands worldwide.<br />
Setup and <strong>rolling</strong> directives<br />
The core of the automation system is the<br />
set-point calculation with the aid of the<br />
process models and the <strong>rolling</strong> directives.<br />
The advantages of online process models<br />
in combination with neural networks <strong>for</strong><br />
20<br />
adaptation in the process automation<br />
system include the more accurate setpoints<br />
and easy matching of new<br />
materials. <strong>Siemens</strong> VAI process<br />
automation also optimizes product<br />
quality by permitting a very high degree<br />
of flexibility in the parameterization of<br />
<strong>rolling</strong> directives. Rolling directives are<br />
derived automatically from specific<br />
material characteristics.<br />
The process <strong>rolling</strong> models<br />
The mechanical <strong>rolling</strong> model<br />
Rolling <strong>for</strong>ce, <strong>rolling</strong> torque and <strong>for</strong>ward<br />
slip are among the technological <strong>rolling</strong><br />
parameters governed by the interaction<br />
between elastic flattening of the work<br />
rolls and vertical pressure distribution<br />
along the strip/work-roll interface. The<br />
differential equations associated with this<br />
interaction are resolved within the<br />
mechanical model. <strong>Siemens</strong> VAI opted to<br />
develop a fast online model based on<br />
Fleck/Johnson’s noncircular arc roll-gap<br />
theory meeting higher demands.<br />
The yield-stress and friction model<br />
The principal input variables <strong>for</strong> the<br />
mechanical model are friction and<br />
material hardness. The yield-stress model<br />
describes the material’s yield-stress as it<br />
relates to chemical composition,<br />
incoming hardness depending on hot<br />
<strong>rolling</strong> history, and hardening caused by<br />
<strong>cold</strong> <strong>rolling</strong> de<strong>for</strong>mation.<br />
The friction model describes the friction<br />
between the strip and the surface of the<br />
roll, taking into account all relevant<br />
factors such as lubrication, roll-surface<br />
roughness and strip speed.<br />
The bending model<br />
A bending model with online capability is<br />
the central function <strong>for</strong> calculating the<br />
roll-gap profile. Flattening between work<br />
roll and supporting rolls, roll bend and<br />
roll contour are all taken into account in<br />
calculating roll-gap profile.<br />
<strong>Siemens</strong> VAI uses a highly accurate FEM<br />
method to verify the results of the fast<br />
online model.
Rolling strategy<br />
Process control models<br />
Set-up calculation<br />
(“pre-calculation“)<br />
Process<br />
automation<br />
Physical models<br />
Neural networks<br />
to adapt<br />
physical parameters<br />
“Post-calculation“<br />
Adaption<br />
Basic automation<br />
Measured data<br />
acquisition<br />
Analytic process models in combination with neural networks<br />
Process automation server<br />
The strip-temperature model<br />
Strip temperature is modeled and<br />
controlled <strong>for</strong> two reasons: to produce<br />
specific material properties and to avoid<br />
excessive lubricant temperatures that<br />
could cause surface defects.<br />
The strip-temperature model<br />
incorporated into <strong>Siemens</strong> VAI process<br />
control employs a finite-difference<br />
method based on Fourier’s equation of<br />
heat conduction.<br />
The roll-temperature and<br />
roll-wear model<br />
The roll-temperature and roll-wear model<br />
calculates the time-dependent thermal<br />
roll contours (roll contour – diameter as a<br />
function of axial position) of all the rolls<br />
in a mill stand: the work rolls,<br />
intermediate rolls and back-up rolls.<br />
The roll contour is also affected by wear,<br />
the second aspect factored into the rolltemperature<br />
and roll-wear model.<br />
<strong>Siemens</strong> VAI has developed a special<br />
online solution method to optimize the<br />
tradeoff between precision and speed of<br />
calculation.<br />
The material flow and gap model<br />
Material flow across the width of the strip<br />
as it passes through the roll gap provides<br />
the data <strong>for</strong> calculating strip flatness,<br />
strip profile and edge drop.<br />
The roll gap model calculates threedimensional<br />
de<strong>for</strong>mation in the roll gap.<br />
Small as it is in <strong>cold</strong> <strong>rolling</strong>, lateral flow is<br />
an important factor in determining strip<br />
shape, particularly at the edges of the<br />
strip.<br />
Speed optimization<br />
Flexible production planning can result in<br />
the necessity to run different process<br />
speeds in the pickling plant and tandem<br />
mill. Speed optimization aims to<br />
maximize the production rate while<br />
maintaining the high quality of the<br />
finished strip. This function also covers<br />
planned stops of mill sections, e.g. due to<br />
trimming knife changes or roll changes;<br />
measured values and signals from the<br />
line; technological prescriptions;<br />
individual strategies; and reaction to<br />
detected strip defects.<br />
Coil building<br />
SIROLL CIS <strong>CM</strong> enables data management<br />
and provides set-point <strong>for</strong> “m to n coil<br />
handling”. An incoming coil consisting of<br />
m welded sections can be rolled and<br />
divided to n outgoing coils. At the end,<br />
SIROLL CIS <strong>CM</strong> incorporates advanced cut<br />
control <strong>for</strong> building coils. The options<br />
include manual cutting, inspection<br />
cutting, and jumbo-coil <strong>rolling</strong> by cut<br />
criteria such as coil weight or coil<br />
diameter. The ability to change target<br />
gauges on the fly (flying gauge change)<br />
is essential <strong>for</strong> cost-effective continuous<br />
<strong>cold</strong> <strong>rolling</strong>.<br />
21
Basic automation<br />
Our controls – <strong>for</strong> a perfectly running process<br />
Electrical room with automation and drive systems<br />
High per<strong>for</strong>mance automation system<br />
Setting the mill right at the right time<br />
The material tracking function images the<br />
movement of the strip through the plant<br />
and automatically per<strong>for</strong>ms the following<br />
tasks:<br />
Supplies in<strong>for</strong>mation on the sequence<br />
of the individual coils and their<br />
positions in the plant, keeping the<br />
operator up to date by means of<br />
graphics<br />
Triggers the pass-schedule calculation<br />
Assigns measured values to striprelated<br />
database<br />
Initiates transmission of data with<br />
production control system<br />
Technological control<br />
The advanced mass flow control concept<br />
<strong>for</strong> tandem <strong>mills</strong>, developed by<br />
<strong>Siemens</strong> VAI controls reduction at the<br />
individual stands, decouples the stands by<br />
means of strip-tension controllers, and<br />
achieves very close strip gauge tolerances.<br />
A highlight of the <strong>Siemens</strong> VAI concept is<br />
the structured, robust multivariable<br />
coupling of gauge and strip-tension<br />
control. Intelligent control replaces<br />
expensive instrumentation.<br />
The large number of low frequencies in<br />
the typical entry-gauge error spectrum<br />
results from the hot <strong>rolling</strong> process;<br />
gauge control must compensate <strong>for</strong> these<br />
errors. Roll- and coil-eccentricity<br />
compensation systems counteract the<br />
roll-stack and coil eccentricities within<br />
the tandem mill itself.<br />
Special control modes in the mill exit<br />
section<br />
The last two stands have the following<br />
selectable gauge control modes:<br />
Tension optimum mode A <strong>for</strong> soft and<br />
thick strips<br />
Tension limited mode B <strong>for</strong> hard and<br />
thin strips<br />
Surface optimum mode C, in which the<br />
penultimate stand achieves the<br />
specified exit gauge and the last stand,<br />
assumes the function of a smoother or<br />
skin pass stand<br />
Automatic gauge control<br />
Automatic gauge control implements the<br />
software functions <strong>for</strong> each stand scaled<br />
to suit to instrumentation:<br />
Feed-<strong>for</strong>ward and feed-back control<br />
Mass-flow control by strip speed<br />
metering<br />
Roll efficiency compensation<br />
Additional acceleration correction <strong>for</strong><br />
the entry bridle or tension reel<br />
Corrective values <strong>for</strong> stand modulus CG<br />
and material stiffness <strong>CM</strong><br />
22
Automation levels and functions in continuous pickling lines and tandem <strong>mills</strong><br />
Production<br />
control<br />
• Order management<br />
• Production scheduling<br />
• Material management<br />
• Job processing<br />
• Storage management<br />
• Transport control<br />
• Quality assurance evaluation<br />
• Statistics<br />
• Protocols<br />
• Resource management media<br />
• Consumables<br />
Process<br />
automation<br />
Material data administration,<br />
data acquisition and<br />
logging, roll data processing<br />
Pass schedule calculation and optimization,<br />
flatness pre-adjustment, model adaption, neural<br />
networks, dynamic program change models <strong>for</strong><br />
<strong>rolling</strong>, temperature, bending, roll-wear and<br />
edge-drop control, pickling control model<br />
• Plant supervision<br />
• HMI operation<br />
• Visual display<br />
• Process data analysis<br />
• Quality data analysis<br />
Fast Ethernet<br />
100 Mbit/sec.<br />
Global Data Memory (GDM)<br />
Basic<br />
automation<br />
• Automatic<br />
sequence<br />
• Coil tracking<br />
• Speed-master<br />
• Looper control<br />
• Strip tracking<br />
• Welding<br />
• Pickling process control<br />
• Tension leveller control<br />
• Turbulence and<br />
temperature<br />
processing<br />
• Mill Master Control<br />
• Flying gauge change and automatic<br />
gauge control<br />
• Advanced mass flow control<br />
• Edge drop control, flatness control<br />
• Rolling modes<br />
• Automatic<br />
sequence<br />
• Coil build up<br />
and cutting<br />
• Automatic<br />
sequence<br />
Basic<br />
electrical<br />
equipment<br />
Entry section pickling line<br />
• Line drives<br />
• Single movements<br />
• Coil transportation<br />
Pickling section<br />
• Acid concentration<br />
• Fe-control<br />
• Line drive and<br />
sequencing<br />
Mill section<br />
• Main drive speed-, vector-, and<br />
torque controls<br />
• Gap and inter-stand tension controls<br />
• Bending<br />
• Roll shifting<br />
• Roll eccentricity<br />
Exit section<br />
• Coiler drives<br />
• Single<br />
movements<br />
• Inspection<br />
Media systems<br />
• Emulsion<br />
• Hydraulic<br />
• Lubrication<br />
• Auxiliaries<br />
Automation levels and functions of continuous pickling lines and tandem <strong>cold</strong> <strong>mills</strong><br />
Strip tension control<br />
The tandem mill stands are rigidly<br />
coupled by the strip. The strip tension<br />
controllers synchronize the inter-stand<br />
sections – without this feature the<br />
powerful mill drives would break the strip<br />
immediately. Strip tension control<br />
comprises three different control<br />
strategies:<br />
Advanced mass flow <strong>rolling</strong> includes<br />
the strip tension controller acting on<br />
the screw-down system of the<br />
downstream stand which affects the<br />
pull-in-speed of the strip. So the pullin-speed<br />
of the downstream stand is<br />
adjusted to the leaving strip speed of<br />
the upstream stand. The model-based<br />
tension controller adapts automatically<br />
to material properties and <strong>rolling</strong><br />
conditions.<br />
Usually the last stand in a tandem mill<br />
is operated in the surface optimum<br />
mode C. Since the last stand is<br />
operated by constant roll <strong>for</strong>ce the<br />
upstream inter-stand tension is<br />
controlled by a separate tension<br />
controller acting on the next-to-last<br />
mill drive speed.<br />
For restarting the mill a further tension<br />
controller acts on the downstream mill<br />
drive speed until the <strong>rolling</strong> speed is<br />
sufficient <strong>for</strong> switching to advanced<br />
mass flow <strong>rolling</strong>. This controller also<br />
establishes the initial tension be<strong>for</strong>e<br />
mill start. A new feature <strong>for</strong> which a<br />
patent is pending applies a<br />
superimposed control strategy which<br />
selects the best matching tension<br />
control strategy <strong>for</strong> each stand while a<br />
weld-seam passes the mill.<br />
Main benefits:<br />
Fully automatic control of thread-in and<br />
tail-out as well as restarts after<br />
stoppages<br />
Continuous <strong>rolling</strong> when handling<br />
materials of different qualities, gauges<br />
and widths by flying gauge change<br />
Excellent tolerances <strong>for</strong> strip gauge and<br />
strip flatness are possible in all mill<br />
operating states<br />
The operator only monitors the<br />
automated production process; actual<br />
operator intervention is reduced to an<br />
absolute minimum. Operator guidance<br />
through diagnosis<br />
23
SIROLL CIS SIAS – Surface inspection and allocation<br />
Surface quality under control<br />
Operator station(s)<br />
Real time HMI, live<br />
image display<br />
SIROLL CIS SIAS cameras +<br />
acquisition units<br />
Image acquisition and<br />
processing<br />
Switch<br />
SIROLL CIS SIAS server<br />
Processing interface<br />
management sequencing<br />
and storage<br />
Off-line station(s)<br />
System administration,<br />
calibration, commissioning.<br />
result review<br />
Live image display<br />
Process network<br />
System messages and communication<br />
Intranet<br />
Off line station(s) <strong>for</strong> result review<br />
Coil report<br />
Schema system (diagram)<br />
Rounding out our portfolio,<br />
<strong>Siemens</strong> VAI integrates its own surface<br />
inspection solution – SIROLL CIS SIAS<br />
into the process automation concept.<br />
As the market increasingly focuses on<br />
strip surface quality, surface inspection<br />
has become a must in new or existing<br />
<strong>mills</strong>.<br />
SIROLL CIS SIAS offers the following<br />
advantages:<br />
Immediate detection of defects (scale,<br />
roll marks)<br />
Warnings <strong>for</strong> downstream process<br />
(holes, edge cracks)<br />
Improvement of surface quality control<br />
practices and increased safety<br />
Yield improvement by reduction of tailend<br />
inspection<br />
Data available on 100% of the strip<br />
surface quality studies<br />
A surface inspection system could be<br />
installed at the exit of the pickling<br />
sections, behind the tandem mill or on<br />
both locations. Identified defects are<br />
directly assigned to the strip segments<br />
and can be used <strong>for</strong> the overall sequence<br />
control and downstream process steps.<br />
As an example defects (e.g. edge cracks)<br />
are divided into several classes and the<br />
strip segment is then rolled under<br />
restricted conditions.<br />
<strong>Siemens</strong> VAI offers this inspection system<br />
as a standalone package or as part of our<br />
SIROLL CIS <strong>CM</strong> solution <strong>for</strong> complete<br />
installations.<br />
Main benefits:<br />
Fast increase of production during the<br />
start-up phase, which has been proven<br />
in numerous projects<br />
High accuracy, thanks to gained from<br />
<strong>rolling</strong> hundreds of thousands of strips<br />
Highly reproducible strip properties<br />
over the length of the strip as well as<br />
from strip to strip<br />
For optimized product throughput,<br />
setup is calculated to make maximum<br />
use of installed power in conjunction<br />
with dependable automatic routines <strong>for</strong><br />
the shortest possible tooling times (roll<br />
changes, threading)<br />
24
Motors and drives<br />
Moving and cont<strong>rolling</strong> your product<br />
Synchronuous motors <strong>for</strong> maximum mill utilization<br />
Medium voltage source converter<br />
Robust long-lasting motors<br />
At <strong>Siemens</strong>, a wide range of motors<br />
especially suitable <strong>for</strong> the harsh <strong>rolling</strong><br />
mill environment are available. Based on<br />
decades of experience, the design of<br />
<strong>Siemens</strong> motors has been continually<br />
improved in order to withstand the rigid<br />
<strong>for</strong>ces in a <strong>rolling</strong> mill application.<br />
Based on our low-maintenance and<br />
reliable non-salient rotors we are able to<br />
offer the most attractive synchronous<br />
motors <strong>for</strong> main drive systems.<br />
High availability and low maintenance<br />
Compact design without fixing<br />
elements and screw connections<br />
Fewer electrical connections<br />
Vacuum impregnation of whole rotor<br />
Extremely rigid and robust design<br />
Optimal to withstand extreme <strong>for</strong>ces<br />
SINAMICS – Our latest converter<br />
technology<br />
With the introduction of the new<br />
SINAMICS drive technology into the<br />
<strong>rolling</strong> mill sector, <strong>Siemens</strong> offers<br />
solutions <strong>for</strong> nearly all market<br />
requirements, including special design<br />
and layout <strong>for</strong> motor revamps, all<br />
compliant with the above requirements.<br />
SINAMICS is orchestrating a unique<br />
change in drive technology. Based on a<br />
single plat<strong>for</strong>m, SINAMICS drives combine<br />
to <strong>for</strong>m a complete and consistent drive<br />
family that spans the entire per<strong>for</strong>mance<br />
range with regard to flexibility,<br />
functionality and engineering design.<br />
For the <strong>rolling</strong> mill main drive, the<br />
medium voltage source converter<br />
SINAMICS SM150 is already operational<br />
in several mill applications. The SINAMICS<br />
SM150 uses low to high-speed<br />
applications with regenerative supply.<br />
This requires high output power, torque<br />
and dynamic response.<br />
Thanks to its modular design and<br />
superior per<strong>for</strong>mance, the SINAMICS<br />
S120 low-voltage converter meets drive<br />
challenges in a very wide range of <strong>rolling</strong><br />
mil applications, including drives <strong>for</strong><br />
hydraulics, bridles, loopers and tension<br />
reels. Whether synchronous or<br />
asynchronous, all motors and<br />
applications receive optimal support from<br />
SINAMICS S120.<br />
Trans<strong>for</strong>mers – Key equipment <strong>for</strong><br />
reliability and energy consumption<br />
Our holistic approach <strong>for</strong> the design and<br />
layout of competitive <strong>mills</strong> considers<br />
more than the process equipment alone.<br />
The dimensioning of trans<strong>for</strong>mers is<br />
calculated based on the installed motor<br />
power and environmental conditions. The<br />
overload requirements defined by the<br />
operational process and production are<br />
also considered, as is the impact of<br />
energy conversion losses over the years.<br />
25
Innovation in <strong>cold</strong> <strong>rolling</strong><br />
Continuous process per<strong>for</strong>mance<br />
REC – Roll eccentricity compensation system<br />
Innovation as the driving <strong>for</strong>ce<br />
The name <strong>Siemens</strong> VAI stands <strong>for</strong> active<br />
innovation leader along the entire addedvalue<br />
chain. We have a decisive<br />
competitive advantage in the area of<br />
R&D, not the least due to the location of<br />
our headquarters near one of the most<br />
modern steel production facilities. We<br />
understand your technological needs and<br />
the future expectations of your<br />
customers.<br />
26<br />
REC – new vitality in <strong>cold</strong> <strong>rolling</strong><br />
Achieving narrow strip thickness<br />
tolerances is particularly important.<br />
Thickness variations of the final strip<br />
arising from thickness variations in the<br />
incoming strip are caused by <strong>for</strong>ward slip<br />
effects with an impact on the tension.<br />
Eccentric rolls are frequently the cause of<br />
strip thickness deviations and can reach<br />
up to10 µm.<br />
Older <strong>cold</strong> <strong>rolling</strong> mill stands may be<br />
often be affected by eccentricities of<br />
back-up rolls and of work rolls. In the<br />
case of back-up rolls, the source of these<br />
disturbances is usually the shells of the<br />
oil bearings adjusted asymmetrically via<br />
drive keys. Thermal asymmetry or<br />
grinding imprecision of the back-up or<br />
work rolls can also cause eccentricities.<br />
Since both the back-up and work rolls<br />
(and also the intermediate roll on a<br />
6-high stand) are usually not in pairs of<br />
rolls with exactly identical diameters,<br />
each roll creates oscillations with an<br />
eccentricity frequency.<br />
Up to now, compensation systems using<br />
the <strong>rolling</strong> <strong>for</strong>ce or the strip thickness<br />
were mainly used to address this<br />
problem. The improved roll eccentricity<br />
compensation system (REC) from<br />
<strong>Siemens</strong> VAI uses not only control<br />
variables such as measured thickness<br />
deviations, <strong>rolling</strong> speed and <strong>rolling</strong><br />
<strong>for</strong>ce, but also the tension in front of the<br />
stand.<br />
Surveys in 5-stand tandem <strong>cold</strong> <strong>mills</strong><br />
have proven that using the REC function<br />
in stands 1-4 reduce amplitudes of the<br />
exit thickness fluctuations by about onethird.<br />
REC has become a standard feature<br />
in our technological control package <strong>for</strong><br />
modernization projects.
Typical chatter record<br />
Active chatter reduction<br />
in <strong>cold</strong> <strong>rolling</strong> <strong>mills</strong><br />
Chatter, a self-excited vibration<br />
phenomenon generated during the strip<br />
<strong>rolling</strong> process, can mean very high<br />
amplitudes and always leads to a<br />
negative impact on the rolled product.<br />
Coils have to be frequently rerouted or<br />
repaired, involving high additional costs.<br />
The chatter phenomenon is widespread<br />
in <strong>cold</strong> <strong>rolling</strong> <strong>mills</strong>. It has been shown<br />
that it can appear independently of the<br />
mechanical equipment, the electrical<br />
configuration, the product and the <strong>rolling</strong><br />
process. It is well known that chatter<br />
negatively affects mill productivity,<br />
product quality and mill equipment.<br />
Recent <strong>Siemens</strong> VAI research conducted a<br />
thorough analysis of the physical<br />
mechanisms responsible <strong>for</strong> the chatter<br />
phenomenon, especially focusing on “3rd<br />
octave chatter”.<br />
The analysis delivered a clear picture of<br />
the underlying physical effects. Efficient<br />
computer-simulation models were<br />
developed as a basis <strong>for</strong> the studies, and<br />
various innovative solutions were<br />
analyzed to reduce mill chatter.<br />
Active control of chatter offers the<br />
highest potential <strong>for</strong> reducing mill<br />
chatter. A patented concept has now<br />
been developed which offers a number of<br />
promising possibilities <strong>for</strong> finally solving<br />
the chatter problem.<br />
27
Life-cycle management<br />
Partnership never ends<br />
• Investigation/inspections & feasibility study<br />
• Design<br />
• Layout<br />
• Construction<br />
• Installation<br />
• Commissioning<br />
• Service contracts<br />
• Spare parts and components<br />
• Consulting and training<br />
• Online and offline<br />
maintenance<br />
• Maintenance contracting<br />
Consulting | Planning | Financing<br />
• Migration packages<br />
• Upgrading and<br />
modernization<br />
<strong>Siemens</strong> VAI Life-cycle Services<br />
As a plant operator, you have conflicting<br />
needs. On the one hand, your<br />
per<strong>for</strong>mance is measured each quarter<br />
against short-term profitability<br />
expectations. On the other hand, you<br />
have to think on a totally different<br />
timescale compared with the capital<br />
market. Depending on the lifetime of<br />
your plant, you have to take 15 years or<br />
more into account. At the very least,<br />
that’s 60 full quarters.<br />
But thanks to our comprehensive<br />
expertise and integrated approach to<br />
solutions, you benefit both short-term<br />
and long-term from our life-cycle<br />
services.<br />
In the short term: Backed by our<br />
extensive experience with many<br />
reference plants, we provide you with the<br />
certainty of fast, dependable production<br />
start-up and shorter amortization<br />
periods.<br />
In the long-term: Our master plan<br />
guarantees competitive per<strong>for</strong>mance <strong>for</strong><br />
your plant in every phase of its life-cycle.<br />
Whether we are providing 24/7 technical<br />
support, optimizing maintenance, or<br />
making permanent plant improvements,<br />
we are always working to ensure the<br />
cost-effective operation of your plant.<br />
Be<strong>for</strong>e …<br />
28
Modernization<br />
Fit <strong>for</strong> the future<br />
Systematic approach <strong>for</strong> target-oriented modernizations<br />
...and after skin pass mill modernization,<br />
Dunaferr, Dunaijvaros, Hungary<br />
Putting our innovation to work <strong>for</strong> you<br />
Modernizing <strong>cold</strong> <strong>rolling</strong> <strong>mills</strong> can be an<br />
effective way to adapt to market<br />
requirements and decrease conversion<br />
costs. <strong>Siemens</strong> VAI approaches range<br />
from incremental improvements to major<br />
modernizations in one stage.<br />
Strong increasing demands on product<br />
quality and lower cost production <strong>for</strong>ce<br />
<strong>cold</strong> strip producers to constantly seek<br />
equipment improvements and more<br />
efficient <strong>rolling</strong> operations. At a certain<br />
point, this adaptation cannot be done by<br />
the operators themselves in the course of<br />
normal maintenance, and a comprehensive<br />
review has to be considered.<br />
Generally, these targets can be<br />
subdivided into the following parts:<br />
Decrease operating costs (energy,<br />
maintenance and consumables,<br />
operation personnel)<br />
Improvement of product quality<br />
(thickness, flatness, surface)<br />
Extension of the product mix in terms<br />
of steel grades and dimensional range<br />
<strong>Siemens</strong> VAI has vast experience in<br />
upgrading and modernization of <strong>cold</strong><br />
<strong>rolling</strong> <strong>mills</strong>. With a systematic approach,<br />
we work closely with our customers to<br />
develop a tailored modernization concept<br />
based on their individual needs, taking all<br />
boundary conditions fully into account.<br />
The result is a solution that utilizes<br />
components of the SIROLL CIS <strong>CM</strong> concept.<br />
The solution may be purely electrical,<br />
automated, mechanical or a combination.<br />
Based on the selected concept, the<br />
modernization can be carried out in<br />
several steps or during a mill shutdown.<br />
<strong>Siemens</strong> VAI’s experience minimizes<br />
down times and ensures a fast<br />
production start-up and top quality.<br />
29
Excellence from experience<br />
Selected success stories with <strong>Siemens</strong> VAI <strong>cold</strong> <strong>rolling</strong> technology<br />
New turn-key continuous tandem <strong>cold</strong> mill –<br />
For the production of high-quality AHSS – advanced high-strength steel grades<br />
Customer: voestalpine Stahl GmbH, is an important supplier to the European automotive, household appliance and<br />
construction industries. The most modern production plants allow the manufacture of high-quality <strong>cold</strong><br />
rolled steel strip with narrow thickness tolerances.<br />
The task: The constantly increasing demand of AHSS (such as TRIP, etc.) and quality standards require new<br />
technological solutions which will be implemented in this new continuous <strong>cold</strong> <strong>rolling</strong> tandem mill.<br />
Our solution: This mill is designed to produce AHSS which are determined <strong>for</strong> the automobile industry.<br />
Highest quality standards have to be met in terms of dimensional tolerances, strip surface, strip<br />
cleanliness, strip roughness and peak counts. Prior to the decision, intensive studies were carried out by<br />
the customer and <strong>Siemens</strong> VAI. As result voestalpine Stahl decided that the 4-high technology would fit<br />
best to their product mix.<br />
The result: In April 2007 the start-up of the tandem <strong>cold</strong> mill took place. From the very first coil high-quality saleable<br />
strip was produced. The annual capacity of this tandem <strong>cold</strong> mill is approx. 1,220,000 t.<br />
Plant data: The tandem <strong>cold</strong> mill is designed <strong>for</strong> a wide range of steel grades including also AHSS. Some of these<br />
ultra-high-tensile steel grades are still under development and will be produced by means of special heat<br />
treatment. To roll the complete product mix just one work-roll grinding per mill stand based on SIROLL CIS<br />
Smartcrown® system is necessary. Main focus of the technical layout of this mill and in particular in the<br />
drives is on low vibrations during the <strong>rolling</strong> process.<br />
Technical data: Width: 700-1,750 mm, thickness: 0.5-3.0 mm<br />
30
Customer:<br />
Type:<br />
The full scope of production facilities<br />
Essar Hazira, India<br />
Turnkey <strong>cold</strong> <strong>rolling</strong> mill complex<br />
Our solution: Engineering and delivery of a new pickling line, 5-stand tandem<br />
<strong>cold</strong> mill, electrolytic cleaning line, batch annealing line, skin pass<br />
mill.<br />
The result: High-quality and cost-efficient production.<br />
Annual capacity: approx. 1,450,000 t, start-up: 2006<br />
Technical data: Width: 600-1,525 mm, thickness: 0.2-3.0 mm<br />
Customer:<br />
Type:<br />
Our solution:<br />
The result:<br />
The full scope of production facilities<br />
Mittal Steel, Sparrows Point, MD/USA<br />
Turnkey <strong>cold</strong> <strong>rolling</strong> mill complex<br />
Engineering and delivery of a new linked pickling and <strong>cold</strong> <strong>rolling</strong><br />
tandem mill, skin pass mill and tension leveler<br />
High-quality and cost-efficient production.<br />
Annual capacity: 1,480,000 t/a <strong>cold</strong> rolled strip, start-up: 2000<br />
Technical data: Width: 560–1,550 mm, thickness: 0.25–2.54 mm<br />
Customer:<br />
Type:<br />
Our solution:<br />
Expanding product mix with SIROLL CIS <strong>CM</strong> 6-high technology<br />
Corus, Ijmuiden, Netherlands<br />
New 4-stand, 6-high tandem <strong>cold</strong> mill<br />
SIROLL CIS <strong>CM</strong> 6-high technology, linking new tandem <strong>cold</strong> mill to<br />
an existing pickling line, new hot-dip galvanizing line<br />
The result: The SIROLL CIS <strong>CM</strong> solution allows the <strong>rolling</strong> of a wide range of<br />
products – from soft steel to high-strength steels of tomorrow<br />
(up to 1,000 MPa). Annual capacity: 1,600,000 t, start-up: 2008<br />
Technical data: Width: 700-1,650 mm, thickness: 0.3-3.0 mm<br />
Automation and drive systems <strong>for</strong> maximum mill per<strong>for</strong>mance<br />
Customer: Wuhan Iron & Steel, Wuhan, China<br />
Type:<br />
5-stand tandem <strong>cold</strong> mill linked to a pickling line<br />
Our solution: Conversion to a continuous tandem <strong>cold</strong> mill. Design and supply<br />
of mechanical equipment and SIROLL CIS <strong>CM</strong> automation solution.<br />
The result: Increase of production capacity up to 1,700,000 t/a.<br />
Start-up: 2002.<br />
Technical data: Width: 700-1,600 mm, thickness: 0.3-3.0 mm<br />
31
Excellence from experience<br />
Selected success stories with <strong>Siemens</strong> VAI <strong>cold</strong> <strong>rolling</strong> technology<br />
Customer:<br />
Type:<br />
Refurbishment and conversion to continuous mode<br />
Liuzhou ISCO, Liuzhou, PR China<br />
5-stand, 4-high tandem <strong>cold</strong> mill<br />
Our solution: Relocation and upgrading of a second hand tandem <strong>cold</strong> mill. New<br />
key process equipment is integrated in the continuous pickling line<br />
and tandem <strong>cold</strong> mill.<br />
The result: First quality strip in terms of thickness and flatness.<br />
Annual capacity: 1,400.000 t, start-up: 2008<br />
Technical data: Width: 600-1,450 mm, thickness: 0.3-2.5 mm<br />
Customer:<br />
Type:<br />
Our solution:<br />
The result:<br />
Fit <strong>for</strong> future demands<br />
Salzgitter Flachstahl, Germany<br />
5-stand tandem <strong>cold</strong> mill<br />
Electric and automation, modernization of technological<br />
equipment<br />
High-quality and cost efficient production of 1,100,000 t/a <strong>cold</strong>rolled<br />
strip. Start-up: 2006.<br />
Technical data: Width: 600-1,525 mm, thickness: 0.2-3.0 mm<br />
Customer:<br />
Type:<br />
Our solution:<br />
Up-grade continuous T<strong>CM</strong> into a PLT<strong>CM</strong><br />
Sollac Antlantique, Mardyck, France<br />
5-stand tandem <strong>cold</strong> mill<br />
Conversion to a linked pickling and <strong>cold</strong> <strong>rolling</strong> tandem mill<br />
The result: Extension of the annual capacity up to 2,100,000 t.<br />
start-up: 2006<br />
Technical data: Width: 600-1,955 mm, thickness: 0.17-3.0 mm<br />
Optimized production with 6-high technology<br />
Customer: Tangshan Iron & Steel, Hebei province, China<br />
Type:<br />
5-stand tandem <strong>cold</strong> mill<br />
Our solution: New tandem <strong>cold</strong> mill linked to a pickling line. Stands 1 to 4 are<br />
equipped with 4-high technology and stand 5 is equipped with<br />
6-high technology.<br />
The result: Annual capacity of 1,500,000 t/a, start-up: 2005.<br />
Technical data: Width: 820-1,650 mm, thickness: 0.3-2.00 mm<br />
32
Customer:<br />
Type:<br />
Our solution:<br />
The result:<br />
<strong>Siemens</strong> VAI – competence and long-term support<br />
Dunaferr, Dunaijvaros, Hungary<br />
New single-stand, 4-high reversing <strong>cold</strong> mill<br />
Reversing <strong>cold</strong> mill along with a pickling line and acid regeneration<br />
plant.<br />
Increase of capacity, improved and more homogeneous quality<br />
of the finished product. Annual capacity: 536,000 t/a,<br />
start-up: 2008<br />
Technical data: Width: 750-1,550 mm, thickness: 0.25-3.0 mm<br />
New 6-high technology <strong>for</strong> increasing capacity<br />
Customer: Borcelik, Gemlik, Turkey<br />
Type:<br />
New single-stand, 6-high reversing <strong>cold</strong> mill<br />
Our solution: Reversing <strong>cold</strong> mill equipped with SIROLL CIS <strong>CM</strong> technology<br />
The result: Annual capacity: 450,000 t, start-up: 2008<br />
Technical data: Width: 700-1,550 mm, thickness: 0.25-3.0 mm<br />
For a perfect finish<br />
Customer: Hunan Valin Lianyuan, Loudi, Hunan Province, China<br />
Type:<br />
Skin pass mill<br />
Our solution: Single-stand, 4-high skin pass mill<br />
The result: Capacity: 850,000 t/a of <strong>cold</strong> rolled strip, start-up: 2005<br />
Technical data: Width: 850-1,600 mm, thickness: 0.3-2.5 mm<br />
Customer:<br />
Type:<br />
Our solution:<br />
The result:<br />
Tailor-made solution <strong>for</strong> a unique product mix<br />
Salzgitter Flachstahl, Salzgitter, Germany<br />
Skin pass mill<br />
New 2-stand, 4-high skin pass mill <strong>for</strong> extremely soft to extremely<br />
hard materials<br />
Production of 900,000 t/a of high-quality <strong>cold</strong> rolled strip<br />
Start-up: 2003<br />
Technical data: Width: 800-1,895 mm, thickness: 0.3-3.5 mm<br />
33
Completely Integrated <strong>Solutions</strong> with <strong>Siemens</strong> VAI<br />
Integrated offerings <strong>for</strong> higher plant per<strong>for</strong>mance<br />
Higher availability<br />
Measurable process improvement<br />
Greater productivity<br />
Integrated in<strong>for</strong>mation technology<br />
Reduced life-cycle costs<br />
Maximum protection of your investment<br />
Optimized processes<br />
We lay the foundation <strong>for</strong> optimized<br />
processes with proven, leading products<br />
worldwide, including mechanical and<br />
technological engineering <strong>for</strong> metal<br />
production, <strong>rolling</strong> and strip processing<br />
as well as process control engineering,<br />
drive engineering and power supply. Integrated<br />
online and offline process models<br />
reflect decades of practical experience<br />
and help to ensure reliable, reproducible<br />
quality.<br />
Our process engineering expertise fuses<br />
these products into complete plant solutions<br />
that also accommodate the upstream<br />
and downstream processes. These solutions<br />
are the basis <strong>for</strong> optimal resource<br />
use, minimized waiting times and reduced<br />
maintenance and spare parts costs, as<br />
well as wide flexibility with respect to raw<br />
materials and the resulting products.<br />
Efficient production control<br />
A further factor <strong>for</strong> competitive production<br />
is the quality of in<strong>for</strong>mation processing.<br />
Production data must be consolidated<br />
and compared with planning data<br />
to ensure optimal production flow.<br />
As a leading supplier <strong>for</strong> the metals industry<br />
<strong>Siemens</strong> VAI offers integrated in<strong>for</strong>mation<br />
technology across all automation<br />
levels – from the technological equipment<br />
to the Enterprise Resource Planning<br />
system. Patented solutions, such as <strong>for</strong><br />
iron and steelmaking, hot-<strong>rolling</strong>,<br />
<strong>cold</strong> <strong>rolling</strong> <strong>mills</strong> or processing lines,<br />
enable systematic quality assurance, efficient<br />
logistics, flexible production planning<br />
and scheduling, end-to-end tracking<br />
and tracing from raw materials to the end<br />
product and back, and much more.<br />
Maximized life-cycle returns<br />
Services from <strong>Siemens</strong> VAI help to ensure<br />
high profitability <strong>for</strong> your plant throughout<br />
the entire life-cycle. Reliable project<br />
implementation by our specialists sets<br />
the course <strong>for</strong> quick start-up and repayment<br />
of funds as scheduled.<br />
During the operating phase, preventive<br />
maintenance, standardized components<br />
and component design that meets the<br />
requirements of <strong>rolling</strong> mill operators<br />
help keep maintenance costs low. A reliable<br />
spare parts supply – with in-house<br />
workshops <strong>for</strong> key components – ensures<br />
high availability. And modernization at<br />
the right time guarantees a high level of<br />
competitiveness and compliance with environmental<br />
regulations in the future.<br />
34
Completely Integrated <strong>Solutions</strong> offer<br />
a comprehensive range of products<br />
and services, tailored and refined to the<br />
specific requirements of your plant.<br />
The key to this approach is the close interlinking<br />
of plant construction, process<br />
engineering, electrical and automation<br />
engineering, sensors and actuators, as<br />
well as in<strong>for</strong>mation technology and<br />
life-cycle services, seamlessly integrated<br />
by <strong>Siemens</strong> VAI.<br />
Perfect integration of every aspect<br />
Completely Integrated <strong>Solutions</strong><br />
from <strong>Siemens</strong> VAI – your benefits<br />
from an integrated concept:<br />
K High quality, lower energy costs and increased<br />
throughput – by taking all process steps into account<br />
K Reproducible high product quality and efficient<br />
use of materials processed – thanks to online<br />
process models and sophisticated technological<br />
controls<br />
K High enterprise quality, low life-cycle costs and<br />
unique investment protection – through flexible<br />
production based on intelligent plant design,<br />
integrated production planning and maintenance<br />
support<br />
35
For further in<strong>for</strong>mation,<br />
please contact:<br />
<strong>Siemens</strong> VAI<br />
Metals Technologies GmbH & Co<br />
P.O. Box 4, Turmstr. 44<br />
4031 Linz, Austria<br />
Phone: +43 732 6592-76809<br />
E-mail: <strong>cold</strong><strong>rolling</strong>mill.metals@siemens.com<br />
The in<strong>for</strong>mation provided in this brochure<br />
contains merely general descriptions or<br />
characteristics of per<strong>for</strong>mance which in<br />
actual case of use do not always apply<br />
as described or which may change as<br />
a result of further development of the<br />
products. An obligation to provide the respective<br />
characteristics shall only exist if<br />
expressly agreed in the terms of contract.<br />
Order No.: E10001-M4-A2-V3-7600<br />
Printed in Austria<br />
Dispo No.: 21661 K-No.: 28104<br />
SPS SVAI-08-00085 WS 09081.5<br />
Subject to change without prior notice<br />
©<strong>Siemens</strong> AG 2008.<br />
All rights reserved.<br />
SIROLL is a trademark of <strong>Siemens</strong> AG<br />
CIS = Completely Integrated <strong>Solutions</strong><br />
www.siemens-vai.com