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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

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