Solutions for the Global Metals Industry

Solutions for the Global Metals Industrymetalscranesminingtestingoil & gascementutilitiespaper

TMEIC in the Metals IndustryWorldwide Experience with all Types of Metals ProductsThe TMEIC team has been building advanced process control systems for the metals industry for over 100 years. Wehave engineered systems for all types of mills, and we have experience rolling a wide range of ferrous and non-ferrousproducts including:• Plates• Bar and rod• Strip• Galvanized products• Beams• Coated and painted productsTMEIC Covers the GlobeTMEIC has supplied thousands of drive systems around the world; some of our metals customers are listed below.The Americas Europe & Africa Asia Japan & PacificAlgomaAceros PianosAlcanAlcoaAHMSAAPMCalifornia SteelCSH (Talcahuano)CSNCSTDofascoFerrous MetalsIPSCOJ & LLake Erie SteelMittal USANorth American StainlessNovelisNS BluescopeNUCOROABPhelps DodgeSeverCorrSeverstalSicartsaSteel DynamicsStelcoUPI (USS/POSCO)US SteelWeirton SteelWise AlloysAcroniAcineroxArcelorCorusErdemirGalva MetalHelenic SteelHoogovensHuta BatoryHuta CzestochowaHuta KatowiceILVAISCORMagreb TubesMMK (Magnitogorsk)RIVASeverstalSollacSSABTerniAn FengAnshangAnyangAsia AluminumBao SteelBenxiChina SteelCSACDHCEssarHandanHangzhouJen AnLian Yuan SteelMaSteelMeishanNanshan AluminumSouthwest AluminumPanzhihuaPoscoShougangShaoguanSiam Strip MillTaiyuanTangshanTonghuaUnion SteelWuhanYich PhuiAichi SteelALCOMBluescope SteelChubu KohanDaido SteelFurukawaHitachi DensenJFE SteelJLPKawasaki SteelKobe SteelMitsubishi Special MetalNakayama SteelNASCONew Zealand SteelNihon Kinzoku KogyoNikkeiNippon SteelNissin SeikoNisshinseko KureSanyo Special SteelSumitomoTokyo SteelToyo KohanPage 2 of 40© 2011 TMEIC Corporation. All Rights Reserved.

Why Our Systems Set Production RecordsThe advanced features of the TMEIC automation systemallow operation of the mill at a higher rate, often settingproduction records. In addition, we produce higherquality product, based on the superior control featuresSystem Features and Benefitsand physical models developed by our experienced metalsengineering team. The main factors providing this superiormill performance are outlined below.Superior Control Features Result in Higher ThroughputThe metals engineering team has developed advanced control schemes for mill operations resultingin higher mill speeds and the setting of production records.Q rad Q convAccurate Physical Models Result in a Higher Quality ProductAccurate level 2 models based on the physical processes in the rolling operation, use advancedtechniques such as finite element analysis. Models cover heat transfer, plastic deformation, millforce, and mill setup, resulting in improved control and higher quality product.The Engineering Team is World ClassThe metals engineering team has many years of mill experience and has built this extensive knowhowinto the automation system and the system engineering process.The Commissioning Engineers Know the Metals IndustryThe commissioning engineers have years of experience in the mills and are familiar with the millmachinery and the variable speed drive systems used in automation.Micro-Tracking Allows Higher SpeedsData on the micro-tracking list is gathered and tracked at a periodic interval of approximately 25 mm,or a fixed time, resulting in better control accuracy and improved product quality.Simple, Scalable, Open Architecture Brings Lower Cost of OwnershipThe open control architecture uses standard controllers, computers, software, and communicationinterfaces, allowing easy expansion with additional commercially available hardware and software,resulting in a lower system life-time costs.S S S Fewer Sensors Reduce CostsUsing advanced control features, the system requires fewer sensors, resulting in lower initial costand life-time maintenance cost, with an increase in ROI.+X_Unified Engineering Tools Simplify MaintenanceUnified engineering tools for configuring and tuning drives and controllers result in fastercommissioning and simplified maintenance.Robust System Diagnostics Increases AvailabilityIn-depth system diagnostics built into the engineering tools, along with the option to use remotediagnostic services, increase system availability.© 2011 TMEIC Corporation. All Rights Reserved.Page 3 of 40

Total Solutions for Mill AutomationHot Mills Page 7Advanced Control Features Section Page• Shape setup• Object oriented softwaredesign and programming• Highly integrated level 1& 2• Automatic gage control• Eccentricity control• Automatic profile &flatness control• Flying gage change (FGC)• Slab sizing press setup• Dual mode rolling setup(austenitic and ferritic)• Dual mill mode setup(Semi-continuous & batchoperation)• Lubricated rolling• Material propertiesprediction• Ultra-light gage modeling• Thermo-mechanical rolling• Plate pattern optimization• Dual phase/Interruptedcooling• Piece sample tracking• Fast FM thread• Multi-mode coiling controlCaster & FurnaceControl .......................7Slab Sizing Press &Roughing Mill ............8Edge & Bar InductionHeaters ......................9Finishing Mill ........... 10Coiling TemperatureControl ..................... 11Coiler Control ..........12Steckel Mill ..............13Flying Gage Change 14Material PropertiesPrediction System ...15Cold Mills Page 16Advanced Control Features Section Page• Cold mill setup• Shape setup• Object-oriented level 2 design and programming• Highly integrated level 1 and 2• Automatic gage control• Eccentricity control• Automatic profile and flatness control• Flying gage change (FGC)• Differential tension controlFast & EffectiveLevel 1 Controls ......16Integrating Modelsfor Superior Control 17Process Lines Page 18Advanced Control Features Section Page• Product tracking• Weld/seam tracking• Heated/tail tracking for entry/exit automation• Minimum tension control• Maximum tension control• Optimized bridle load distribution• Elongation control (leveler & skin pass mills)• Loss compensation• Position control• Line setup• Setpoint distribution• Data acquisition• Open loop feed-forward tension controlTMEIC’s Approach toProcess LineAutomation .............18Designing the StripTransport ControlSystem ..................... 19Implementing theOpen Loop Feed-Forward Control ...... 19Page 4 of 40© 2011 TMEIC Corporation. All Rights Reserved.

Total Solutions for Mill AutomationLong Products Page 20Advanced Control Features Section Page• Product tracking• Mill pacing• Flexible rolling & coolingschedules• Roll & bearingmanagement• Minimum tension control• Accurate shear control• Cascade speed controlRod Mills:• Sizing block control• Precision laying headcontrol• No Twist Mill controlSection Mills:• Saw management systemsRod Mills ..................20Section Mills ............21Product Tracking &Machine Monitoring 21Modernization Page 225TouchScreenHMI6DCS networkinterfaceInnovation ControllerCPL or Series Six I/O BusSiltronHardwiredoperatordevicesM4I/OSiltronMTM-DC DigitalFront End (DFE)DMC or Series SixMaster ControllerSiltronM123TM-DC ModuleAssemblyTM-SeriesAC DriveAdvanced Control System Upgrades Section PageTMEIC’s control system is a scalable, open architecture readilyallowing future expansion and modernization.Legacy mill control systems are easily upgraded to the latesthardware and software.1970’s LegacySystem .....................22Early 1980’sLegacy System ........23Late 1980’sLegacy System ........24Early 1990’sLegacy System ........25Non-TMEIC System 26Services Page 27World Class Mill Automation Section Page• World-class process and automation specialists for themetal rolling and metal strip processing industries• Years of experience• Broad process knowledge• Project management skills.• Engineering team is supported by world-classcommissioning and field service personnel.Engineering Team ...27Technical Proposal ..28Design andProcurement ............29Factory SystemTest 30SystemCommissioning, .....32Training &Documentation .......32Maintenance &Service .....................33Products Page 35Products Section PageThe family of drives covers the power and supply voltagerequirements for new and legacy systems.Panel-mounted touch stations, pulpit HMIs, and level 1 and 2system software provide for all operator and control needs.AC/DC SystemDrives .......................35Operator Interfaces .36Software Toolsand Utilities .............37Mill Level 2 andModels .....................39© 2011 TMEIC Corporation. All Rights Reserved.Page 5 of 40

Hot MillsTMEIC has many firsts in hot mill automation, including the first use of all AC main drives, the first computer-based hot millsetup, and the first and only implementation of semi-continuous rolling in a hot mill. Our Team has installed over 140 majorbeam, plate, and hot mill systems worldwide. This section discusses TMEIC’s advanced hot mill control system.Caster & Furnace ControlCaster control includes precise mold level control and close drive coordination for various types ofcasting machines. Several furnace control functions are closely coordinated to maximize production,and minimize fuel consumption and the formation of scale on the slab.Slab Sizing Press & Roughing MillThe slab sizing press tailors the width of each slab, and the roughing mills reduce the thickness tothe particular order, based on inputs from the roughing mill models.Edge & Bar Induction HeatersThe edge heater and the bar heater produce a uniform temperature across and along the bar beforeit enters the finishing mill.Finishing MillThe bar’s identity, temperature, thickness, and width are sent via the finish mill tracking function tosetup models, which calculate a set of references for the control functions.Coiling Temperature ControlTo produce required mechanical properties, such as tensile strength and elongation, the rate ofcooling and final temperature of the strip as it enters the coilers is precisely controlled.Coiler ControlThe coiler setup feeds references to the master controller, which then distributes them to theappropriate coiler controller for application.Steckel MillControls for the Steckel coiling furnaces and rolling mill are coordinated and optimized for all passes.Flying Gage ChangePrecise mill control allows for different product to be made continuously from one long slab.Material Properties Prediction SystemThe computerized system improves the microstructure prediction accuracy of hot rolled steel.Page 6 of 40© 2011 TMEIC Corporation. All Rights Reserved.

Caster & Furnace ControlCaster ControlFurnace ControlCaster Operator’s Overview ScreenTMEIC’s automation and control of theentire hot mill starts with the businesscomputer download of the mill schedulefor the new ladle. The individual castercontrol functions include:• Ladle handling• Tundish level control• Mold level control and moldcooling• Cooling spray water flow control• Coordinated drive controlincluding anti-sag feature• Width control and shear control• Strand trackingFor the contents of each ladle, completeproduct tracking begins, and a coordinatedsystem of reference distribution is carriedon to the finished coil. The data collectedand distributed includes the chemicalproperties of the steel, the mechanicalproperties, and the product dimensions.The furnaces maintain a steady delivery of temperature-controlled slabs to the mill. The main automation objectives areto maximize production, minimize fuel consumption, and reduce scale formation.TMEIC differentiates its furnacecontrol by integrating physical modelswith the furnace control functions.Product Data Information (PDI) comesfrom the business computer overEthernet.Mill Pacing FunctionLevel 2 mill pacing uses PDI data andtracking data to calculate the optimumextraction time. It is also coordinatedwith the reheating furnace control (inthe figure the white furnace controlblocks may be provided by the furnaceOEM).BUSINESSCOMPUTERSLAB PDI DATAMODELSMILL PACINGTRACKINGFURNACEMODELSROUGHING MILLSETUPFURNACEMODELSREHEATTEMPERATUREFEEDBACKRMTEMPERATURESFEEDBACKZONETEMPERATURESCONTROLCHARGE &EXTRACTBURNER CONTROLBURNERMANAGEMENTFURNACE CONTROLZONETEMPERATURESENSORSFURNACERoughing Mill SetupLevel 2 model provides roughingmill setup data and interfaces to thefurnace control.FEEDBACKPROCESSINGTIMESREHEATFURNACESENSORSROUGHINGMILLSlab TrackingLevel 2 mill tracking function is linkedto the mill tracking and pacing.SENSORSFINISHINGMILL© 2011 TMEIC Corporation. All Rights Reserved.Page 7 of 40

Slab Sizing Press & Roughing MillThe slab sizing press and roughing mill reduce the widthand thickness of the slab in preparation for the finishingmill. With a large width reduction, the slab sizing presstailors each slab to a particular order. The roughing millmodels provide the target width reduction to the level1 controller, which takes each slab to this desired widththrough a series of press actions. The press is electricallydriven by a large medium voltage motor and drive.Hydraulically driven top and bottom hold down rollsprevent buckling of the slab. Width gauges at the pressentry and at the roughing mill exit validate that the targetwidth is achieved. The entire process is monitored byoperators on HMI screens.Significant Improvements to Operation of the Slab Sizing Press & Roughing MillAdvanced features of the TMEIC system includeimproved caster efficiency, increased mill widthreduction capability, improved width uniformity, andimproved control tolerances. Control features includemicro-tracking (fast tracking) of slab position and speed,performed for the position and pressure regulators.The advanced sizing press model calculations include:• Die gap calculations for the anvil control• Head, body and tail draft calculations for widthreduction• Hold down roll force calculations for buckleprevention• Preforming length calculations for the taperedsections• Table lift calculations to compensate for increasingslab height• Slab elongation ratio and travel time calculationsSlab Sizing PressRoughing MillThe roughing mills (RM) reduce the width and thickness of the bar. They can bereversing, continuous, or a combination of both.Roughing Mill ScreenSlab Tracking RM ModelsControl starts with the level 2 slab tracking function, directing the level 1 sequencingand regulators based on which zone the slab is in. Hot metal detectors and othersensors are used to define the zone transitions. Specific mill references distributedfrom the tracking and set-up models include:• Horizontal roll positions, side guide positions, and RM speeds• Vertical roll positions and draft compensations for the RM edgers• Spray selection for each of the millsDynamic References for Roughing MillAfter leaving the sizing press, the slab travels through the universal roughing millstands where the width is further controlled by the edger drafting. Prior to each pass,the level 2 set-up model provides a new set of references to the mill.Reversing Mill ScreenLooperless Tension Control Between Close Coupled Tandem Roughing StandsClose coupled roughing stands further reduce the width and thickness preparing theslab for the finishing mill stands. Low tension control is applied between the closecoupled stands including coupled edgers.Page 8 of 40© 2011 TMEIC Corporation. All Rights Reserved.

Edge & Bar Induction HeatersInduction heating is a fast and efficient method of heating moving metal, and it has been applied to various metalprocessing lines. TMEIC has applied large capacity induction heaters to hot strip mills since 1984. They are used for edgeheating and bar heating to obtain uniform temperature before the bar enters the finishing mill, and have been installed onmany new hot strip mills in recent years.Three types of induction heaters are available:Solenoid TypeThis type has a flat heating characteristic, used inhot strip mills for bar heating.Transverse TypeThis type has a partial heating characteristic andhas been used for bar center heating.C-shape Transverse TypeThis type has high heating efficiency and is usedfor edge heating.Solenoid Type Bar Heater- Power level: up to 9,000 kW- Inductor frequency: 1,400 Hz- Temperature rise: 40°CC-Shape Transverse Type Edge Heater- Power level: up to 4,000 kW- Inductor frequency: 300 Hz- Temperature rise: 50°CTemperature [Deg.C]1120110010801060104010201000980960BAR TEMPERATURE CURVEBAR TEMPERATURE CURVE (Hot Bar 1730 mm - 40 mm T)0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18DistanceAverageCenter-CenterCenter-SurfaceEdge-CenterEdge SurfaceBar Heating Temperature SimulationBefore the edge heaters, thetemperature differential between thebar edge and the center is about 50º C.After the bar heaters, the temperaturedifferential has been reduced to about10º C.EDGE EDGEHEATER HEATER1EDGEHEATER2BARHEATER1BARHEATER2SIDE GUIDECROP SHEAR© 2011 TMEIC Corporation. All Rights Reserved.Page 9 of 40

Finishing MillUsers require strip with close dimensional tolerances and exact metallurgical properties. TMEIC’s control system usesmodels based on physical and material behavior to set up the level 1 controls for the desired strip width, gauge, shape,tension speed, and temperature.Mill Setup Model Includes:Strip Thickness ModelThe finish mill setup model providesinputs to the level 1 roll gap absolutegage control.Strip Width ModelModels for exit spread, edging draft,and width reference provide inputs tothe RM setup and level 1 automaticwidth control.Temperature & SpeedThe temperature setup model (notillustrated here) provides inputs tothe cooling spray controls and themain drive speed.Shape ModelThe shape setup model providesinputs to the level 1 automatic stripprofile control, the automatic stripflatness control, and roll shiftingusing either the Continuously VariableCrown or Pair Cross systems (notillustrated here).Dual Mode Mill Setup has a combinedfunctionality of level 2 modelsfor finishing mills and slab setupcalculations for one (batch mode)or more products (semi-continuousmode) in the slab.Q radiationQ radiation43210Q conductionQ convectionQ conductionQ convectionSlap/Strip Heat Transfer Model for RM,FM, and Coiling Temperature ControlFM Strip Thickness (FM Models)OPERATORINPUTSDESIREDTHICKNESSMODELSHOLDINGTABLETRANSFERFM EXITVERNERFM Strip Width (RM Models)OPERATOR INPUTS: FINISH WIDTH OFFSET EDGER LOAD DISTRIBUTIONHARDNESS &DEFORMATIONFEEDBACKMASS FLOWTHICKNESSMODELSFINISH MILLTEMPERATURESETUPMODELSFINISH MILLTEMPERATURESETUPFEEDBACK FEEDBACK FEEDBACKMODELSEDGING DRAFTDISTRIBUTIONMODELSWIDTHREFERENCECONTROLAUTOMATICWIDTHCONTROLTEMPERATUREMODELSEXIT SPREADFEEDBACKEXIT SPREADFEEDBACKFEEDFORWARDFEEDBACKHEAD & BODYMONITORCONTROLROLL GAP &ABSOLUTEAGCCONTROLFASTADAPTIVETHREADFEEDBACKGAGEMETERTHICKNESSFEEDBACKEXIT VERNIERTemperature SetupSpeed SetupShape SetupSENSORSROLLFORCESENSORSROLL GAPSENSORSMILLSPEEDSENSORSTHICKNESSSENSORSEXITWIDTHSENSORSFORCEPROFILESENSORSWIDTHPROFILEFINISHING MILLSetup ModelsUsing roughing mill exit data, models calculate references:• A roll gap position, speed, and roll bending reference for each stand• Tension and position references for each of the inter-stand loopers• Position references for the finishing stand side guides and roll shifting• X-Ray gauge thickness and alloy compensation values• A reference for the bar’s exit width, gauge, and temperature• Finish mill speed-up rate and limit• A set of automatic gauge control predicted forces and transfer functions• Inter-stand cooling spray patterns and flow references from the outputs ofthe temperature modelPage 10 of 40© 2011 TMEIC Corporation. All Rights Reserved.

Coiling Temperature ControlSteel customers today demand that mills produce specific mechanical properties for their products, such as yield strength,tensile strength, and elongation. The coiling temperature control maintains the rate of cooling and the final temperature(the temperature-time profile) of the strip to obtain the desired metal properties as it enters the coilers.TMEIC’s Coiling TemperatureControl (CTC) features:Physics-based ModelsThe model of the coolingprocess generates coolingwater flow setpoints,which are sent to the level1 control to produce thedesired temperature-timeprofile as the strip movestoward the coilers. A processmodel encompasses variouscoiling temperature controlstrategies.Metallurgical-based ModelsThe CTC model includesthe effects of the steelphase transformation foraccurate prediction of thetemperature-time profilerequired for the optimummechanical properties.MODELSSTRIP SPEEDPROFILEMILL EXITSENSORSTRACKINGPIECE SAMPLEFEEDBACKIN-COILFEEDFORWARDFINISHINGSPEEDSENSORSFM EXITTEMP.EARLY COOLINGZONEMODELSCOILINGTEMPERATUREFEEDBACKIN-COILFEEDBACKINTERMEDIATECOOLING ZONEFEEDBACKFEEDBACKSYSTEMPARAMETERSIN-COILFEEDFORWARDS ENSORSBOTTOMPYROTRACKINGPIECE SAMPLEMODELSCOILINGTEMPERATUREFEEDBACKIN-COILVERNIERSENSORSBOTTOMPYROSENSORSCOILINGTEMP.LATE COOLINGZONE - VERNIERCoiler Temperature Control SystemEarlyCoolingDUAL PHASE COOLINGRadiationLateCoolingDetails of the Coiling Temperature Control ModelThe rate of cooling, the intermediate, and final temperature, are tied tothe desired mechanical properties, thus precise cooling control is critical.TMEIC’s Dual Phase Cooling model illustrated above is described here.Early Coiling Temperature Cooling ModelThe CTC model takes finishing mill exit speed and temperature plus feedback from the intermediate zone and calculatesthe level 1 cooling water flow setpoints for the early cooling zone to achieve the desired quench rate and intermediatetemperature.Dual Phase/Interrupted CoolingThe combination of interrupted cooling and modeling of low target temperatures achieves specific steel structures such asthe bainitic and martensitic.Late Coiling Temperature Cooling ModelThis model takes the final and intermediate temperatures and calculates the late (vernier) cooling flow setpoints. Thecoiling temperature control model utilizes several techniques including feedback, feedforward, and vernier temperaturecontrol to meet the process objectives.© 2011 TMEIC Corporation. All Rights Reserved.Page 11 of 40

Coiler ControlCoiler technology has advanced overthe last ten years bringing many newfeatures including:• Various coiler side guidesoperating and coiling modes• Various coiler pinch roll gapoperating and coiling modes• Various wrapper roll gapoperating and coiling modesTMEIC provides advanced level 1controls to support these new features.This page describes how a typicalnew automatic coiler operates. Theoperator HMI screen shows real timedata with animated coiler graphics.Coiler Operator ScreenCoiler MachineCoiler Control Functions Deliver Completely Automated OperationSetup References Sent From ModelsCoiler operation starts with the associated setupfunction feeding several references to the level 1 controlpreparing for a given coil. The coiler master referencecontrol function then distributes these references to theappropriate coiler controller for application.Hydraulic Jump ControlInitially, the unit rolls are positioned to a pre-set gap.As the strip passes by the roll, it applies a pre-set force,bending it around the mandrel. To avoid marking thestrip, the rolls jump clear of the strip head as it passesunder each roll. This is commonly called automatic jumpcontrol. When the strip is tight around the mandrel, theunit rolls are retracted.Tail-end Slow Down and SpottingThere is a strip position calculator and tail-end spottingfunction that calculates the position of the strip’s tail-endas it progresses down the run-out tables and computesthe slow-down point for the end of the coil.Telescoping ControlAnother function in modern coiler systems is the coilpresentation or telescopicity control. This is accomplishedwith sophisticated multi-mode hydraulic regulators onthe entry side guides and stepless mandrel expansioncontrol.Completely Automated Coil DeliveryAt the output of the coiler control system, each of the coilsis automatically:• Banded• Weighed• Inspected by the shape meter• Marked for shipmentThe overhead crane then moves the finished coils to thestorage area.Page 12 of 40© 2011 TMEIC Corporation. All Rights Reserved.

Steckel MillThe Steckel mill is a unique type of reversing rolling mill,which can roll very large slabs to produce high qualityplate and strip. Furnaces on both sides of the mill provideheated space to store the increased length of coiledmaterial produced during strip rolling. These coilingfurnaces allow for additional heat retention and thermalconsistency in the rolled piece, which in turn producesimproved uniformity throughout the rolled product.Steckel Mill with Coiling Furnaceslocated on either sideOn right - Operator’s Screen showing:- Alarms & Manual Control buttons- Steckel Mill graphic- Real-time data- Screen navigation buttons at the bottomWorld Class Features of TMEIC’s Steckel Mill Control SystemTriple Adaptive ModelThe model contains three separate control setups forthe head, body, and tail of the slab.Wide Product RangeControls can handle rolling both plate and coil withthicknesses from 1 mm to 70 mm, with complexsequences and auto recovery from manual intervention.Pass to Pass AdaptationAll critical material parameters are measured and thecontrol setup calculated for the next pass.Tapered Thickness RollingThe thickness is fully programmable so that the headand tail can be reduced to a different amount than thebody. Uniform thickness is produced in the final pass.Absolute Hydraulic Automatic Gage ControlThe AGC works to achieve constant target thicknessand/or follow a predetermined thickness trajectory.Temperature Controlled RollingThe metal temperature is controlled so the desiredmechanical properties can be achieved.Coiling Furnace Temperature ModelThe temperature model calculates the heat transfer tothe coil in the furnace.Finishing Temperature ControlThe model calculates the desired speed of each passbased on the target temperature in the coil body.Coiling Temperature ControlThe run out table sprays are controlled to produce thetemperature-time profile for the desired metallurgicalproperties.© 2011 TMEIC Corporation. All Rights Reserved.Page 13 of 40

Flying Gage ChangeThis page gives an overview of an advanced control technology applied to hot strip mills producing light and ultra-lightgage strip. These mills work with long slabs and produce many coils of various thicknesses from one slab. Flying gagechange (FGC) technology is used to change the strip thickness.The diagram shows three products A, B, and C continuouslyrolled from one slab without de-threading strip from thestands. In the case of a hot mill, the mill cannot be sloweddown to make changes, so FGC is a highly coordinatedcontrol procedure involving multiple process actuators. Thefirst semi-continuous hot mill FGC system, implemented byTMEIC, was in 2000.CoilA-1CutPointCoilA-2CutPointCoilA-3CutPointCoilB-1CutPointCoilC-1Product A Product B Product CThe level 2 models, which control and optimize this change, as well as the mill functions affected, are shown below.TFTCCasterShearTUNNEL FURNACETEMPERATURECONTROLTunnelFurnaceCropShearFSBEdgerRTWROLLTEMPERATUREAND WEARSSUSHAPESETUPDMMSDUAL MODEMILL SETUPFDTCFINISHING DELIVERYTEMPERATURECONTROLOptional CoilerF1 F2 F3 F4 F5 F6 F7HighROTSpraysCOILINGTEMPERATURECONTROLSpeedShearCTCRotaryCoilerROTSpraysCoilerTunnel FurnaceTemperature Set-pointsExtract TimeDescale Flows SetupStand Strip exit thicknessStand SpeedMill Spray FlowsLooper TensionRoll ForceLead SpeedDual Mode MillEdge draftHead & Tail AWC ref'sRoll profile actuator positionvs. bending transfer functionsScans scheduleRoll ShiftRoll BendingRunout TablesSpray ActionsTMEIC has implemented two types of FGC:Type 1. Constant Finishing Mill Exit SpeedWith this strategy, the mill speed is raised to the targetlevel prior to the transition, then the gap and up-millstand speeds are transitioned using a ramp. During thechange, the looper, speed, gap, and profile adjustmentsare tracked and tightly controlled, and the finishing millexit speed is held constant.Type 2. Constant Finishing Mill Exit Strip Mass FlowWith this strategy, control of strip speed at the run-outtable and exit mass flow control are required. The gapand stand speeds are progressively transitioned downmillusing a ramp. The looper, speed, gap, and profileadjustments are tracked and tightly controlled, and thefinishing mill entry speed is held constant.Page 14 of 40© 2011 TMEIC Corporation. All Rights Reserved.

Material Properties Prediction SystemMaking High-Strength Steels at Lower CostSteel researchers are continually developing high-strength rolled steels for applications such as automobile bodies. A wayto predict the microstructure and mechanical properties of these steels would allow the production of fine grain size withhigh strength using lower grade metal. Only small quantities of additional alloying elements would be required.An integrated system combining simulation of the hot rolling process withprediction of the microstructure of the hot rolled steel has been developed byTMEIC, enabling the development of new production processes for fine grain sizesteel. The system has been proven in predicting grain size.The two steel micrographs shown here illustrate coarse grain structure (lowstrength) and fine grain structure (high strength).Course GrainStructureFine GrainStructureThe Material Properties Prediction System has Two Main PartsRolling Process Modeling SystemThis system evaluates rolling force, torque, power, etc., using equations modeling the rolling process. The calculation usesnumerical methods and is based on a specified distribution of roll forces and temperatures among the stands.Rolled Steel Microstructure Prediction SystemThis system performs metallurgical calculations taking into account the rolling and subsequent cooling processes. Theprocess phenomena include static and dynamic recrystallization, grain growth, and the austenite-ferrite transformation.Typical Prediction ResultsFinisherLaminarCoolingTemperature1050-grainCASE -B750 -grainCASE-A680880 Deformed- grainFerrite+pearlite structure720640Sub- grainsin- grain Fine ferrite+pearlite structureTimeEffect of Rolling & Cooling on Grain StructureTransition of austenitic graindiameter with deformation.Upper plot 850°, Lower 950°C.Transition of volume fractionin each structure withdeformation.Upper plot 850°, Lower 950°C.© 2011 TMEIC Corporation. All Rights Reserved.Page 15 of 40

Cold MillsTMEIC has automated over 100 cold mills worldwide. This vast experience includes controls for tandem mills, single andmulti-stand reversing mills, temper mills, and Sendzimir mills. TMEIC’s automation system provides superior control basedon accurate process models and tightly integrated level 1 control. Some examples are illustrated here.Tandem MillFast and Effective Level 1 ControlsCoordinationCoordinated in-coil adjustments use measured andcalculated values to maintain targets.Automatic Gage ControlAutomatic Gage Control (AGC) employs mass flowcalculation, feedforward, feedback, tension, and slipcompensation.EccentricityEccentricity control reduces the effect of backup rollirregularities on thickness using Fourier Series Analysis.Single Stand MillAutomatic Flatness ControlAdvanced data filtering, parabolic flatness control, tiltcontrol, segmented coolant spray control, and shapemaintenance.Flying Gage ChangeFast coordinated control changes minimize strip breaksand mass flow disturbances.Micro-trackingHigh-speed data acquisition and tracking allows fasterand more accurate control action.GageDeviation[um]50Last Last Stand stand Exit exit FGC taper length < 5m < 5m-5050EccentricityOutput[um]Switch EccentricityControlControloffoffThickness [um]-500 10 20 30TimeResults of Eccentricity Control Time (sec)Fast Flying Gage Change ControlPage 16 of 40© 2011 TMEIC Corporation. All Rights Reserved.

Integrating Models for Superior ControlTMEIC’s automation system provides superior cold mill control based on accurate level 2 process models and integratedlevel 1 controls. Some process models are listed below along with the shape control block diagram.Level 2 Process Models Ensure Production of Quality ProductForce and Power ModelsForce, torque, and power modelswith the effects of tension andfriction.Flow Stress ModelsFlow stress models with thematerial chemistry and workhardening effects on elongation.Friction ModelsCompensation for coefficient offriction variations.Strain ModelIn-coil strain distribution.Thermal and wear effects on rolldiameter profile.InteractionsInteractions between tension,forward slip, friction, and speed.Textured RollsThe coefficient of friction effectof textured rolls.Product VariationsProduct dependent transferfunctions for level 1 control.DeformedRollRadiusEntryThicknessEntryTensionRollRadiusMetal Deformation ModelRollForceExitThicknessNRollForceDeformationPowerPressure due toroll-strip frictionExit TensionRoll Wear ModelPressure due tometal deformationresistanceReferences from the model provide the setup forlevel 1 controls, as shown in the diagram below.ShapeControlBlockDiagramOperatorRB AdjustRoll Side-ShiftPositionModelCMSetupModelThread/RunFeedbackFlatnessFeedbackType of RollBending andShiftRoll ForceRollContourModelRollWearModelRollThermalModelGround Roll CrownStack Crown VerniersStripTensionRollDeflectModelModelStripBucklingModelStrip PropertiesProfileVernierPDI EntryProfileRoll profileactuatorBucklingThresholdModelRoll GapContourPhysicalModelModelStripPhysicalModelRollGapCrownStrip Recalculation for Limit ConstraintsPass #Max/Min Roll Gap CrownsStripStrainRangePassConstraintsStrip ConstraintsPass #Per Unit Profile andStrip ConstraintsNo TensionThreadRunModelStripFlatness&ThicknessStrategy1. Run Condition2. Mill Fully Threaded3. Post Entry ThreadFlatnessRoll SensorBending &ShiftingReferencesControlClosed LoopFlatnessControl© 2011 TMEIC Corporation. All Rights Reserved.Page 17 of 40

Process LinesIn recent years, changes in strip processing line mechanicalconfigurations and increasing customer expectations forstrip quality and line productivity have combined tocreate demands on the capabilities of electrical drive andcontrol systems. TMEIC has responded with an approachthat addresses the unique requirement of effectivestrip transport in strip processing line applications. Thebenefit to customers is a level of performance that cansupport high line speeds and a broad range of productsprocessed on a single line. In addition, TMEIC helpsinsure a level of performance that eliminates strip breaks,bridle slippage, furnace necking, catenary scratching, andother performance problems that result in degradation offinished strip quality.TMEIC’s Approach to Process Line AutomationFor superior process line control, it must beunderstood that the main function of the controlsystem is to provide effective strip transportunder all line operating conditions. To achievethis, TMEIC:• Analyzes the line control in terms of thepower required by the strip transportequipment, then models the line in terms ofpower elements:a. Power source – positive motor torqueb. Power sink – negative motor torque• Applies an understanding of the powerrequirements for each strip transportmachine to create a control system based ona feed forward tension referencing systemthat minimizes dependency on closed loopregulator performance.ENTRY ACCUMULATORPAYOFFREELPINCH ROLL(THREAD ONLY)FLATTENER PRE-CLEANER#1 BRIDLERINSE#2 BRIDLE #3 BRIDLEKG/mm^2TENSION ZONE 1#1 BRIDLEENTRY TENSIONTENSION ZONE 2 TENSION ZONE 3#2 BRIDLEENTRY TENSION(ZONE 1 BASE)FLATTENERLOSSESCLEANINGLOSSESNORMALIZEDACCUMULATORTENSION(ZONE 2 BASE)#1 BRIDLEEXIT TENSION1/2 TOWERLOSSES1/2 TOWERLOSSES#2 BRIDLEEXIT TENSIONPROCESS TENSION(ZONE 3 BASE)PROCESSLOSSES#3 BRIDLEENTRY TENSIONCLEANINGLOSSES#3 BRIDLEEXIT TENSIONProcessing Line Tension ProfilePage 18 of 40© 2011 TMEIC Corporation. All Rights Reserved.

PAYOFF REELMOTOR POWER (KW)BRIDLE 1 ROLL 1MOTOR POWER (KW)BRIDLE 1 ROLL 2MOTOR POWER (KW)ACCUMULATORMOTOR POWER (KW)BRIDLE 2 ROLL 1MOTOR POWER (KW)BRIDLE 2 ROLL 2MOTOR POWER (KW)INERTIALOSSES (KW)+INERTIALOSSES (KW)INERTIA+ +LOSSES (KW)INERTIALOSSES (KW)+INERTIALOSSES (KW)+INERTIALOSSES (KW)+FRICTIONLOSSES (KW)FRICTION+LOSSES (KW)+FRICTIONLOSSES (KW)+FRICTIONLOSSES (KW)+FRICTIONLOSSES (KW)+FRICTIONLOSSES (KW)+ROLL 1 LOADCONSTANT (%)XROLL 1 LOADCONSTANT (%)XROLL 1 LOADCONSTANT (%)XROLL 2 LOADCONSTANT (%)XTENSIONPOWER (KW)TENSIONPOWER (KW)TENSIONPOWER (KW)TENSIONPOWER (KW)XLSCONSTXLSCONSTXLSCONSTXLSCONST–+ +–+ –+–ROLLS DOWNBRUSHES DOWNFLATTENERLOSSES (KG)PRECLEANERLOSSES (KG)0.5* TOWERLOSSES (KG)ZERO (KG)0.5 * TOWERLOSSES (KG)ZERO (KG)PAYOFFTENSION (KG)LS = LINE SPEED (METERS/MINUTE)ACCUMULATORTENSION (KG)LS = LINE SPEED (METERS/MINUTE)TANKTENSION (KG)Designing the Strip Transport Control SystemTMEIC executes three major steps in designing an effective striptransport control system:• Analyze the primary strip transport machines (reels, accumulators,and bridles) using off-line models to determine the capacitiesand limitations of each.• Develop a tension profile one-line diagram to outline therequirements for tension reference distribution, losscompensation, tension limits, and regulator configuration.• Develop a run/jog matrix showing which drive and/or drivegroups are involved in each run or jog function, the regulatorconfigurations for each mode, and the drive loading requirements.Implementing the Open Loop Feed-Forward ControlThe feed-forward network consists of on-line control algorithmsproviding:• Compensation for the inertia of the motors, gearboxes, anddirectly connected mechanical equipment.• Compensation for friction and windage losses of motors,gearboxes, and directly connected mechanical equipment.• Strip tension referencing to load the drives with the torquesdetermined from line tension setpoint data and process losscalculations.The complete system consists of closed loop regulators and openloop feed-forward elements. However, the main element is the feedforwardcontrol which minimizes the need for reactive correctionby the closed loop regulators. The result is superior strip transportperformance.ModelsOff-lineAlgorithmsOn-lineDrivesLine parametersStrip flattenersTension levelersTemper millsReduction millsSide trimmers/slittersStrip bendingCatenary tension/positionConfiguration ParametersControlTorqueBridle load distributionFriction & windage loss compensationInertia compensationStrip bending loss compensationStrip catenary/position controlSide trimmer/slitter loss compensationWeld trackingSetpoint distributionAutomation System Delivers Significant Customer BenefitsTMEIC’s advanced process line controls have been applied to metal processing lines with excellent results. Our experienceincludes controls for galvanizing lines, pickle lines, tinning lines, coating, and painting lines. Actual system operation andline performance data obtained from operating mills have demonstrated the following customer benefits:• Reduced operator intervention• Zero product quality degradation• Maximized line throughput and uptime• Maximized product capacity• Seamless product transitions© 2011 TMEIC Corporation. All Rights Reserved.Page 19 of 40

Long ProductsRod MillsRod MillsTMEIC has extensive experience automating rod mills worldwide.Our advanced rod mill control system provides customers withmany advantages including:Looperless Minimum Tension ControlLow tension is obtained using predictive control by measuringtorque and controlling stand speed, with upstream stands undercascade control. Tension-free rolling is achieved between millsections to assure safe rolling and close tolerance to bar geometry.Precision Laying Head ControlPrecision control and coordination of the pinch roll and layinghead combination provides the highest quality rings from millequipment.The Latest Drive TechnologyThe medium voltage TMdrive-70, employed for the no-twist block,uses IEGTs in the converter and inverter. These provide highreliability, low voltage gating losses, and high-speed switching forfast drive response.A Fully Integrated Automation SystemThe architecture combines level 1 and 2 control and data acquisitionin one easily expandable system.Mill ExperienceIn-depth mill engineering experience and field service capability,is available worldwide.Product Tracking and Machine Monitoring through the Rod MillHigh Speed Rod and Bar TechnologyMorgan Construction Company, USAThe automation system tracks billets from the furnace, through the rolling stands, cooling bed, no-twist block, and shears,to the finished coils. This product data is sent to the level 1 controls at each stage of the process. Real-time processdata is immediately available to the operators in the various sections of the mill. The HMI screen below is an exampleof an operator’s screen for a mill section showing the drive current, rod velocity, and reduction for each stand, as well asnavigation buttons to access other screens.Roughing StandsIntermediate StandsFinishing StandsRod SizingNo Twist BlockCooling BedLaying HeadTypical Operator’s Screen for Roughing Mill SectionTypical Rod Mill showing Product Flow and Operator StationsPage 20 of 40© 2011 TMEIC Corporation. All Rights Reserved.

Section MillsTMEIC has automated many beam mills around the world using its advanced mill control system. This system providesmany advantages:Minimum Tension ControlLow tension is obtained using predictive control by measuring torque and controlling stand speed, with upstream standsunder cascade control. Tension-free rolling is achieved between mill sections to assure safe rolling and close shapetolerance.Precision Shear CuttingHigh-speed control of the shear blades and accurate time synchronizationto line speed provides exact beam lengths.Latest Drive TechnologyThe medium voltage TMdrive-30, employed for many mill applications,uses IGBTs in the PWM inverter, with high-speed switching for fastdrive response, and heat pipe cooling to provide high reliability.Fully Integrated Automation SystemThe universal control architecture combines level 1 and 2 control,product tracking, and data acquisition in one easily expandable system.ExperienceWorldwide mill engineering experience and field service capability areavailable wherever your mill is located.Diagram of H-Beam Finishing MillProduct Tracking and Machine Monitoring throughout the MillThe stored schedule from the mill computer contains the desiredbeam size and length, initial setup for each stand, and the rollspeeds. The automation system tracks billets from the furnace,through the rolling stands and shears to the cooling bed andstacks of finished beams. This product data is sent to the level 1controls at each stage of the process. Real-time process data isimmediately available to the operators in the various sections ofthe mill by means of the color graphic HMI screens.SCHEDULESETUP PERBEAM SIZECONTROLCONTROLTRACKINGMILL WIDEPER ORDERCONTROLSPEEDTORQUEPRECISIONCUTTINGFINISHEDLENGTHShearsMill Stands`ColdSawCooling BedStackingSimplified Beam Mill Control SchematicOperator’s Mill Drives HMI Overview Screen© 2011 TMEIC Corporation. All Rights Reserved.Page 21 of 40

ModernizationWhen it’s time to modernize existing drives and control systems, TMEIC has the technology and project engineeringteam to assure a smooth migration path. The following pages chronicle the system architectures implemented and theopportunities for modernization.1970’s Legacy System Architecture561423Item Equipment Notes Benefits123456Page 22 of 40Drive Modernization- Modernize Siltrol drives with the TMdrive-DC or TM-Series AC drives. The DC modernization can occur atone of three levels:• Digital Front End (DFE)• Panel with DFE• Complete drive replacement- Both the TMdrive-DC and TM-Series AC drives canbe controlled from I/O or one of several local areanetworks (ISBus, Profibus-DP, DeviceNet,TOSLINE-S20)- Configuration from the ToolboxMaster Control Modernization- Replace the electromechanical relay and TTL logic witha new Controller & I/O- The VME rack allows a wide variety of third-partymodules to interface with virtually any industrial LANColor Touch Screen Operator Interface- Graphical touch screens for operator control of thedrives- Hardwired-like performance using a high-speedEthernet communications linkHuman Machine Interface (HMI)- Graphical overview of drive system status anddiagnostic information- Integral historian provides flight recorder-likefunctionality© 2011 TMEIC Corporation. All Rights Reserved.- More precise and consistent control with the digitalregulators- The local area network interface between the drivesand master control provides for an accurate speedreference distribution to the drives- With the TM-Series AC and TMdrive-DC drives sharingcommon control hardware components, spare partcosts are minimized in AC-DC hybrid systems- Digital solid state electronics are far more reliable andprecise than electromechanical relay and TTL logic- The open architecture of a VME rack provides aseamless interface with the rest of the control system- Vast improvement in flexibility of the design, allowingthe interface to evolve without impacting hardware- Diagnostic data for process operation and drive status- Intuitive interface for system status and diagnostictools- Historian provides powerful insight into processevents

Early 1980’s Legacy System ArchitectureController641523Item Equipment Notes Benefits123Drive Modernization- Modernize Siltron drives with the TMdrive-DC orTM-Series AC drives. The DC modernization canoccur at one of three levels:• Digital Front End (DFE)• Panel with DFE• Complete drive replacement- Both the TMdrive-DC and TM-Series AC drivescan be controlled from I/O or one of several localarea networks (ISBus, Profibus-DP, DeviceNet,TOSLINE-S20)- Control can operate with a digital tachometer orwithout a tachometer- Configuration of the control from the Toolbox- Siltron drives transitioned to AC technologywill eliminate the periodic expense of DC motormaintenance- Drives modernized with TM-DC controls providemore precise control and improved diagnostic data- With the TM-Series AC and TM-DC sharing commoncontrol hardware components, spare part costs areminimized in AC-DC hybrid systems456Master Control Modernization- Replace the dated Series Six and/or DMC with anew Controller & associated I/O- The VME rack allows wide variety of third-partymodules to interface with virtually any industriallocal area network- Controller is programmed in function blocklanguage using the ToolboxColor Touch Screen Operator Interface- Graphical touch screens for operator control of thedrives- Hardwired-like performance using a high-speedEthernet communications linkHuman Machine Interface (HMI)- Graphical overview of drive system status anddiagnostic information- Integral historian provides flight recorder-likefunctionality- Open architecture of VME rack provides a seamlessinterface with the rest of the existing controlsystem- The Toolbox provides a common application forboth the controller and all of TMEIC’s system drives- Vast improvement in flexibility of the design,allowing the interface to evolve without impactinghardware- Diagnostic data for both process operation anddrive status- Intuitive interface for system status and diagnostictools- Historian provides powerful insight into processevents© 2011 TMEIC Corporation. All Rights Reserved.Page 23 of 40

Late 1980’s Legacy System ArchitectureHMIDCS networkinterfaceControllerTM-DC DFEDigital Front EndTM-DCModuleAssembly4DMC & Series SixMaster Controller6I/OCSF & C-Bus15HardwiredoperatordevicesDC300SiltronSilco2TM-SeriesAC DriveTouchScreenMMM3Item Equipment Notes Benefits123456Drive Modernization- Modernize DC300, Siltron, and SILCO drives withthe TMdrive-DC or TM-Series AC drives. The DCmodernization can occur at one of three levels:• Digital Front End (DFE)• Panel with DFE• Complete drive replacement- Both the TMdrive-DC and TM-Series AC drivescan be controlled from I/O or one of several localarea networks (ISBus, Profibus-DP, DeviceNet,TOSLINE-S20)- Control can operate with or without a digitaltachometer- Configuration of the control from the ToolboxMaster Control Modernization- Replace the dated Series Six or DMC with a newController and associated I/O- The VME rack allows wide variety of third-partymodules to interface with virtually any industriallocal area network- Controller is programmed in function blocklanguage using the ToolboxColor Touch Screen Operator Interface- Graphical touch screens for operator control of thedrives- Hardwired-like performance using a high-speedEthernet communications linkHuman Machine Interface (HMI)- Graphical overview of drive system status anddiagnostic information- Integral historian provides flight recorder-likefunctionality- DC300, Siltron, and SILCO drives transitioned to ACtechnology will eliminate the periodic expense ofDC motor maintenance- Drives modernized with TMdrive-DC controlsprovide more precise control and improveddiagnostic data- With the TM-Series AC and TMdrive-DC drivessharing common control hardware components,spare part costs are minimized in AC-DC hybridsystems- Open architecture of VME rack provides a seamlessinterface with the rest of the existing controlsystem- The Toolbox provides a common application forboth the controller and all of TMEIC’s system drives- Vast improvement in flexibility of the design,allowing the interface to evolve without impactinghardware- Diagnostic data for both process operation anddrive status- Intuitive interface for system status and diagnostictools- Historian provides powerful insight into processeventsPage 24 of 40© 2011 TMEIC Corporation. All Rights Reserved.

Early 1990’s Legacy System ArchitectureController461523Item Equipment Notes Benefits12345Drive Modernization- Modernize your DC2000 drives with the TMdrive-DC or TM-Series AC drives. The DC modernizationcan occur at one of three levels:• Digital Front End (DFE)• Panel with DFE• Complete drive replacement- Both the TMdrive-DC and TM-Series AC drivescan be controlled from one of several localarea networks (ISBus, Profibus-DP, DeviceNet,TOSLINE-S20)- Configuration of the control is from the ToolboxMaster Control Modernization- Replace the dated IOS or OC2000s with a newController and associated I/O- The VME rack allows wide variety of third partymodules to interface with virtually any industriallocal area network- Controller is programmed in function blocklanguage using the ToolboxColor Touch Screen Operator Interface- Graphical touch screens for operator control of thedrives- Hardwired-like performance using a high-speedEthernet communications link- DC2000 drives transitioned to AC technologywill eliminate the periodic expense of DC motormaintenance- Drives modernized with TMdrive-DC controlsprovide more precise control and improveddiagnostic data- With the TM-Series AC and TMdrive-DC sharingcommon control hardware components, spare partcosts are minimized in AC-DC hybrid systems- Open architecture of VME rack provides a seamlessinterface with the rest of the existing control system- The Toolbox provides a common application forboth the controller and all of TMEIC’s system drives- Vast improvement in flexibility of the design,allowing the interface to evolve without impactinghardware- Diagnostic data for both process operation and drivestatus6Human Machine Interface (HMI)- Graphical overview of drive system status anddiagnostic information- Integral historian provides flight recorder-likefunctionality- Intuitive interface for system status and diagnostictools- Historian provides powerful insight into processevents© 2011 TMEIC Corporation. All Rights Reserved.Page 25 of 40

Non-TMEIC System ArchitectureLevel 2ControlL2TouchScrTouchScr eeneen TouchScreenHMIViewerWorkStationControllerOtherControllersNew Control network3New EquipmentHMIBridgeControllerFiberOpticLinkFullControlNew I/OControllerFiberOpticLinkNo Control(SignalsMapping)New I/OControllerFiberOpticLink2DRVDRVDRVTMdrive®TMdriveTMdriveOld Equipment- System “S”PartialControlControllerNo Control(SignalsMapping)ControllerOld System NetworkFullControlController4Old I/ODRIVEA VOld I/ODRIVEDRIVEA VA VOld I/O1The modernization or replacement of an old control systemsupplied by another vendor presents an implementationchallenge. The replacement project has to minimize:• Additional shutdown periods• Post-switchover production disturbances• Installation complexity and costDue to incompatibility of old networks and components,the standard approach is to install a complete new system,remove the old one, and execute the switchover in one bigstep.Approach to Replacement of System “S”Item1234Page 26 of 40Equipment NotesEstablish Controller Connectivity- Install interface boards in the old controllers; (these may be two types, for example MultiBus I and II)- Install matching interface boards in the new controllers (VME rack) and establish the data exchange usingfast fiber optic links (with some other vendors’ systems, DECNET communication may be used for dataexchange)- Map the data to and from the old system to and from the new global control networkNew HMI System- The new HMIs and level 2 computers are easily implemented and are initially tested in passive mode, thenswitched to bidirectional data flow (with other vendors’ systems, the new level 2 computer acts as thecommunication gateway, both for HMI and level 1 control)Drive Modernization- The new drives are installed and connected to the new controller. In the initial stage, the new controller only actsas a drive bridge since the old controller is still in active operation- In some cases the old drives temporarily run with the new controller. In this case, the old controller justbidirectionally maps all drive and I/O signals to the new controller (with other vendors’ systems, some of the oldcontrollers and drives may be retained and kept active, and may communicate through the level 2 gateway to theHMIs)- By switching over small sections of I/O and associated functionality during brief shutdowns, no productionstoppages or interruptions are introduced© 2011 TMEIC Corporation. All Rights Reserved.This requires an extended shutdown period and introducessignificant risks because all system levels must be startedand tuned up at the same time. A way of minimizing risk isto connect all the new I/O in parallel with the existing I/O,but this is very costly due to the additional engineeringand installation materials and labor.TMEIC’s approach to these problems uses connectivityto the old system components and a step-by-step controltakeover. The figure above shows an intermediate stagein an implementation.

ServicesTMEIC’s Metals Engineering Team in VirginiaDedicated Metals Engineering TeamThe metals engineering team is dedicated to the industry. Many of the metals engineers have over 30 years of mill andcontrol system experience. This background, combined with state-of-the-art technology, enables TMEIC to consistentlymeet the demanding requirements of the metals industry.Our experienced mill application engineers jointly define the equipment and control strategy with our customer’s engineers.This is followed by detailed design of the operator stations, and configuration of the drives, the mill models, and thecontrollers. The phases of the project engineering work are illustrated below. Success is guaranteed by close coordinationbetween the factory team, the customer team, and the field engineering team as indicated by the icons in the diagram.TechnicalProposalSpecificationCustomer TeamSystem FunctionalSpecification+ Customer ReviewDetailedSoftwareDesignFactoryAcceptanceTestSystemCommissioningSystemMaintenanceandServiceField TeamFactory TeamDetailedHardwareDesignSystemComponentProcurementTraining Team© 2011 TMEIC Corporation. All Rights Reserved.Page 27 of 40

Technical Proposal and Functional SpecificationDuring the planning stage of the project,experienced application engineers preparea technical proposal that includes:ONLINE DATAGATHERINGPRIMARY & SECONDARYLEVEL-2 COMPUTER • Customized system architecture foryour project• Detailed equipment specificationsINFORMATION LANCONTROL LAN• Formal bid documentationREMOTEI/OENTRYPLCREMOTEI/OCENTER 1PLCREMOTEI/OCENTER 2PLCREMOTEI/ODELIVERYPLCSpecificationsOur application engineers are highlyqualified for this proposal work, and manyof them have over 30 years of metalsindustry experience. In addition, theyare actively involved in industry technicalorganizations, in which they author papersand conduct training seminars at variousforums, for example:• IEEE – Institute of Electrical & ElectronicsEngineers• AIST – Association for Iron & SteelTechnology• China International Steel CongressAfter project approval, our application engineers prepare a system functionalspecification that includes:• Customized system architecture with an electromechanical one-linediagram for your project• Detailed equipment specification:- Motors- Drives- Controllers- I/O devices and modules• Complete operational descriptionTo ensure we meet your requirements, a thorough review of the specificationis held with your project team.Page 28 of 40© 2011 TMEIC Corporation. All Rights Reserved.

Detailed Hardware/Software Design & ProcurementBased on the functional specification, theproject engineering team proceeds with fourmain tasks:Software DesignControl engineers use tool and utilitysoftware to configure the level 1 controllerlogic, sequencing, and drives. The adjacentillustration shows a typical function blockdiagram with logic in relay format. Theconfigurations are loaded into the controllersin the test lab.Process models for each mill function aredesigned, configured, and put into the level2 computers.Operator Screen DesignOperator interface screens are designed,configured, and loaded into the pulpit HMIsand panel mounted touch screens.Hardware DesignAll equipment is specified per the projectrequirements, and the power distributionsystem is designed. A complete set ofelementary diagrams, layout, and outlinedrawings are created.Component ProcurementTMEIC works with its manufacturing plantsand vendors to provide the highest qualitycomponents for your application.• Drives• Motors• Controllers and I/O racks• Computers and servers• Miscellaneous mechanical and electricalequipmentEquipment Drawing, Toolbox Screen, and Operator Screen© 2011 TMEIC Corporation. All Rights Reserved.Page 29 of 40

Factory System TestA thorough integrated system factorytest is extremely important. TMEIC hasmade an investment in test technology andequipment. The TMEIC engineering teamconducts an exhaustive test in the large,fully-equipped system test lab, featuring:• Complete staging of the system withthe controllers, servers, networks, HMIsystem, and all drive controllers, whichcontain the controller board set, keypad,LAN interface, and I/O board.• Unique to the industry, the drivecontroller includes a motor and loadsimulator (refer to the next page fordetails) allowing lifelike simulation ofthe mill operation.• Validation of all network interfaces tothird-party PLCs and DCS systems.• Customer operators and the TMEICcommissioning team are integratedinto the factory testing for training andfeedback.The picture above shows one of the four test labs in our Virginia facility,which has an extensive selection of test equipment, including:• 200-plus drive controllers comprising the past 20 years of driveproducts• 64 HMI and touch-screen operator stations• 12 Innovation Series and V-Series controllersTypical Factory Test Setup in the LabControlServerHMIServerHMIOperatorTouchPanelsMasterControllerMachineControllerMachineControllerSimulatedI/ODrive Controller/SimDrive Controller/SimDrive Controller/SimMLoadMLoadMLoadMotor/Load Simulators on all TMEIC Drives (AC and DC)Page 30 of 40© 2011 TMEIC Corporation. All Rights Reserved.

Industry Leading Process SimulationReal-World/Mill EnvironmentFactory Test SimulationLocal Area NetworksPower BridgeMotorLocal Area NetworksDigital MotorSimulatorDrive ControllerMLoadDrive ControllerM LoadDigital LoadSimulatorPowerPowerPowerDrive Cabinet,Controller,Power Bridge,& MotorMModelLoad ModelInertia K 1dN/dtFriction K 2NWindage K 3N 2In the Mill, the AC and DC Drives Control the Speed of theMotor & Mechanical LoadEach AC drive has a controller with I/O and a gate driver,which controls the power IGBTs in the power bridge. Thepower bridge generates the variable frequency AC voltagesupply to the three-phase motor, controlling its speed andtorque.In the case of a DC drive, the power thyristor-based powerbridge converts the AC power to a variable DC voltage,which is applied to the motor armature. This controls the DCmotor’s speed and torque.In the Factory System Test, the Drives Control a Motor &Mechanical SimulatorEach AC/DC drive in the system test has its own digitalmotor simulator based on a dynamic mathematicalmodel. The drives control the simulators, not real motors.All drive simulators are networked with the controllersand operator stations to test the entire system in realtime. Starts, stops, speed changes, response to manualinputs, LAN continuity, control interaction, and driveconfiguration are all validated.This unique capability allows the entire team to obtainan intimate understanding of the system prior to thecommissioning, ensuring a smooth, on-time startup.TransportDirectorScreenMill Process SimulationProcess inputs such as sensors, pyrometers, and loadcells are simulated in the lab by the Transport Director(TD). The same TD software can be applied later forcontrol of the real process.The TD can be switched “on the fly” between real andprocess simulation modes. This allows for very easyimplementation of Ghost Bar rolling where only the realmetal is simulated, while real mill equipment is beingcontrolled (moved). Ghost Bar functionality contributesto shorter startup periods, saves possible material lossesand aids in system and mill maintenance procedures.© 2011 TMEIC Corporation. All Rights Reserved.Page 31 of 40

System CommissioningIn the commissioning phase, the TMEIC team includesthe field engineers you know and trust, alongside theengineer who designed and tested the system. Thisoverlap of teams between engineering design and thesite ensures a smooth and on-schedule startup.The TMEIC service engineer, who is responsible forstartup and commissioning, and for any future servicerequired at the site, is part of the project team andparticipates in the factory system test to becomefamiliar with the system. Commissioning is supportedby TMEIC design and service engineers.Commissioning PhasesCommissioning1. Oversee Installation ofElectrical Equipment: 2. Check Out all Wiring &- Motors - Controllers Communication Links, Load- Drives - Cabling & Wiring all Software, & Commissionthe Drives & Motors123. Mill Section Commissioningusing Shadow testing ifnecessary4. Entire Rolling Mill ControlSystem Commissioning usingGhost Rolling if necessary34Teams InvolvedCommissioning Time LineTMEIC offers a single source for installation and commissioning. Phases 2, 3, and 4 above are compressed by:• The exhaustive factory acceptance test that includes drives and control system functionality• Training and familiarization of the entire team with the system at the factory• Using shadow testing at the mill with system inputs (not outputs) connected to the operating plant• Using timesaving Wizards for commissioning and drive tune-up• Using ghost rolling to test the complete control system without rolling actual productsPage 32 of 40© 2011 TMEIC Corporation. All Rights Reserved.

Drive Training at our Training Center or in Your FacilityCustomer engineers, maintenance and operationspersonnel are trained on the drives and control systemat the TMEIC Training Center in Virginia. This world-classfacility includes large classrooms and fully-equippedtraining labs.Classroom and hands-on training consists of 50% classtime and 50% hands-on lab time. Topics include:• Overview of the drive system• Function of the main assemblies• Technical details of the components• Drive and control system tools• System diagnostics and serviceCustomized Training at the Customer’s SiteAs an alternative to the standard factory training in Virginia, TMEIC can offer a course tailored to your project and held atyour location. In this case, a project engineer trains your operators, maintenance technicians and engineers in your facility.Complete and Detailed Drive System DocumentationTMEIC delivers complete system documentation:• An electronic instruction book with all theprints on CD with a hyperlink index• System configuration on CD• Detailed system manual• Recommended wiring and groundingprocedures• Renewal parts list• Standard third-party vendordocumentationAt the end of the project, the system drawingsare updated to reflect the final changesHard-Copy Documentation and Electronic Insturction Book© 2011 TMEIC Corporation. All Rights Reserved.Page 33 of 40

Global Customer Support NetworkComprehensive technical service is provided by our Customer Support Organization, staffed by TMEIC service engineerswith offices and spare parts depots across the globe.In North and South AmericaCustomers are supported by the TMEIC Corporationservice personnel, design engineers and Spare PartsDepot in Virginia, and the TMEIC Factory in Japan.In EuropeTMEIC service engineers service all drive systemsin Europe, supported by the European TMEIC SpareParts Depot.In Asia and the Pacific RimTMEIC services drive systems throughout China,India and the Pacific, supported by multiple FieldEngineers, Spare Parts Depots, and the TMEICfactory in Japan.Remote Drive DiagnosticsTMEIC Corporation supports drive customers throughthe Remote Connectivity Module (RCM), a remotediagnostic service link with the TMEIC design andservice engineers in Roanoke, Virginia. The RCMenables seamless integration between your drives andour engineers.Remote System DiagnosticsTMEIC’s remote system diagnostics tool, includedin level 1 software, offers a quick path to problemresolution. System faults are automatically identified,and provide an integrated view of product, processand system information. TMEIC design and serviceengineers in Roanoke, Virginia, can analyze the dataand provide steps for resolution.For Service or Parts, call1-877-280-1835INTERNATIONAL:+1-540-283-201024 Hours / 7 daysRemote Diagnostic Service reduces Mean Time To Repair (MTTR)Remote diagnostic service offers protection for your investment, by reducing downtime, lowering repair costs and providingpeace of mind. Remote diagnostics requires an internet connection between your plant and TMEIC Corporation for retrievalof fault logs and files to diagnose drive or system issues.Features• Reduced downtime andMean-Time-to-Repair• Secured connection• Fault Upload UtilityBenefitsQuick support saves thousands of $ in lost productionTMEIC engineers can quickly connect to the drive and diagnose many issues in amatter of minutes.Customer-controlled accessAll remote activity is conducted with permission of the customer. Drive start/stop isnot permitted remotely.Proprietary Fault Upload SoftwareHistorical drive faults are identified; TMEIC design and service engineers can analyzethe issue resulting in the fault and provide a solution.Page 34 of 40© 2011 TMEIC Corporation. All Rights Reserved.

ProductsA Family of AC & DC System DrivesTMdrive-10e2TMdrive-30TMdrive-70TMdrive-DCVolts3300 AC1250 ACTMdrive-30TMdrive-50TMdrive-80TMdrive-70690 AC440 ACTMdrive-10e21200 DC500 AC500 DC TMdrive-DC101001,00010,00013 134 1,34013,40020,00026,80050,00067,000kWHpFeaturesCommon Control HardwareAll TMdrive products share a common architecture:• Common I/O boards• Common LAN interface boards• Common front panel display and keypad optionsCommon ToolboxA common Windows®-based toolbox used to configure andmonitor all TMEIC system drives featuring:• Integrated trending• Animated function block diagrams• Commissioning and tune-up wizardsBenefitsReduced Parts InventoryTMEIC reduces the spare parts investment with acommon set of control hardware for all of your lowvoltage AC, medium voltage AC, and DC system drives.Simplified MaintenanceCommissioning and tune-up wizards ensure that thesystem drives are not the critical path item in the start-up.In ongoing maintenance work, the integrated trendingtools provide an in-depth view into the regulationfunctions.Legacy System InterfaceTMEIC system drives integrate with legacy systems using:• ISBus LAN interface for Innovation Series Controllerbasedsystems• Profibus-DP and DeviceNet LAN interface boards forother controller-based systemsReduced EngineeringThe majority of control system projects involve someform of modernization. The coordinated interfaces ofTMEIC systems to legacy system drives reduces the costof engineering, commissioning, and training.© 2011 TMEIC Corporation. All Rights Reserved.Page 35 of 40

Operator InterfacesThe HMI provides operators, technicians, and maintenance personnel with a clear window into the operation of themill and control system, with interactive real-time process control and drive data, plus trends for performance analysis.A typical rolling mill overview screen is shown below.Indicators forUpmill EquipmentStatusAlarmsPermissiveOverrideSensor Status,Green is NormalRunout Table SprayCooling statusPermissive Indicators,click for detail popupscreensRun GhostMode at anyTimeLooper SpeedCorrectionFM ExitSpeedNavigationButtons pull upSeparate ScreensWork Roll Bendingscreen, click WRBRoll Gaps screen,click Gaps buttonRoll Speed screen,click Speed buttonTrend RecorderScreen withhigh speeddata fromprocess(every 20 ms)and drives(every 1 ms)A Panel-Mounted Local Operator Station & Centralized HMI Interface are availableFeaturesPanel-Mounted Touch ScreenThe compact, panel mounted touch screen provides asimple display and hardwired-like control action foroperator inputs such as start and stop.Machine Permissive DiagnosticsViewing the Boolean logic permissive block display showsthe contact preventing the machine sequencing.BenefitsConvenient, Reliable Equipment Control PanelPanel-mounted close to the mill, the touch screenprovides an intuitive display and fast operator controlaction, plus rugged construction to stand up to the millenvironment.Faster Operator ResponseVisual diagnostics reduce the time to resolve permissivelogic problems and/or operator training issues.HMI Trend RecorderHigh-speed real-time and historic data from the controlsystem and drives is available on the HMI trend screen.Convenient Drive and Process DiagnosticsThe high-resolution HMI screen trends live data from thecontroller and drive capture buffers for accurate processequipment performance analysis and diagnostics.Page 36 of 40© 2011 TMEIC Corporation. All Rights Reserved.

nv Series ControllerThe Unified nv Series Controller‘s capabilities includehigh-speed logic, sequencing, motor speed control, andcontinuous control. High-speed I/O communication usesthe industry’s first 100 Mbps double loop network “TCnetI/O”, linking remote, field mounted I/O.The main features of this powerful controller are:• Redundant loop 100 Mbps I/O communication• Enhanced speed by direct execution of IEC standardcontrol languages in ASIC hardware• Higher reliability using redundant modules, and errorchecking and correcting ECC memory• Gigabit supervisory control networknv Controller board, upto three per chassisSecond nv Controller TC-net 100 board Ethernet boardPower supplyThird nvControllerInput/Output LAN TC-net I/O Loop, 100 MbpsInput/Output LAN TC-net I/O Loop returnSystem Network – Ethernet, 1 GbpsControl Network TC-net 100 – Fiber-optic, 100 MbpsFeatureHigh-speed processingShort control cycleLarge program capacityHigh data capacityInterruptsMultiple controllersProgramming flexibilityMemory reliabilityDetailsBit and integer processing: 20 ns; floating point add/multiply: 120 nsThree separately scheduled periodic tasks: 0.5 ms to 1,000 msPrograms up to 256 kilo steps (instructions), up to 385 periodic programsLocal/global variables 256 K words; I/O variables 16,384 16-bit wordsTotal of 16 interrupt tasksUp to three controllers per chassis; up to 4 communication modules; redundantcontroller and network configurations possibleFour IEC 61131-3 standard languages: LD, FBD, SFC, and STAn error-correcting ECC circuit in the internal memory of each module© 2011 TMEIC Corporation. All Rights Reserved.Page 37 of 40

TMdrive-Navigator - Simple Configuration and MaintenanceThe TMdrive-Navigator tool helps youmaintain TMEIC drives yourself. Engineersand technicians are empowered to understandhow the drive works and what the drive isdoing. Any user can easily access currentdrive expertise and know-how.Desk-top like search technology links topicalsignal lists, block diagrams, help files, productdocumentation, change history, and user notes.Windows techniques facilitate navigationwithin a drive and across the system. Thestatus of all drives is always in view.High-speed data is automatically captured andsaved in the event of a drive fault. Users mayalso capture high speed data based on their owntrigger conditions or perform high resolution realtimetrending.Fault data can be automatically “pushed” to keyusers. The client-server architecture allows accessto high performance data from remote locations– with the same resolution as if you were in theplant.Wizards support tuning of drive functions.Live block diagrams provide a real-timegraphical view of drive functions. Functionscan be configured directly from the graphicalview. Product documentation is integratedright into the tool. Users may evencapture their own notes to benefit futuretroubleshooting. Compatible with:• Windows XP, Vista 7• Windows Server 2003, 2008Page 38 of 40© 2011 TMEIC Corporation. All Rights Reserved.

Mill Level 2 Software and ModelsLevel 2 provides mathematical process models and the required software infrastructure for them to function. Level2 distributes references to the level 1 controllers in a timely manner, and receives process feedbacks for modelupdates and data collection. Typical level 2 functions include:• Material tracking through process zones• Distribution of references• Process feedback scans and process setups• Production logging• Engineering logging• Performance classification and reportsSoftware and hardware (if necessary) is split into two basic parts: process control (executables) and data storage(databases).StatisticalAnalysis &ReportingDevelopment OfficesSimple SQLDatabaseQueriesModelTablesDBProcess HistoryDBProcess models functionality is presented in the application sections of this brochure. The following are basic andcommon features of level 2 and models software, and the customer benefits.FeaturesOpen ArchitectureThe hardware platform is based on industrial standards (PCservers), software platform C++, open communication linksvia Ethernet, and database (MS SQL or Oracle) accessed viaODBC.Structured Software ProductsBased on OOD and OOP concepts, the suite of softwareproducts is fully configurable. The functions are configuredfor various applications, NO CODE CHANGES are required.Platform Independence and Distributed ComputingThe same source of software products is used for variousOS platforms: Windows, OVMS, or Linux. The sameapplications can run on the centralized computer or can bedistributed onto various units as required.Customer Benefits of Level 2 Software and Models• High product quality• Low cost of system ownership• Simple maintenance and troubleshootingBenefitsScalabilityThe software products can be simply “instanced” andadded to the application software for easy expansion.Cohesion of all Control LayersThe concept of global signals (Signal Data Base) andcentral data structure definition (data Dictionary DB)simplifies the system design and maintenance.Comprehensive Analysis Tools and ReportingSystem diagnosis utilities allow monitoring of processexecution and detailed communication diagnostics.Process data can be accessed via ODBC, analyzed, andreported using standard applications such as: Excel,Access, MathCAD, and Statistica.• Minimum downtime• Short system startup and tune-up• Comprehensive reporting & record keeping system© 2011 TMEIC Corporation. All Rights Reserved.Page 39 of 40

Worldwide NetworkGlobal Supplier of Drive & Automation SystemsTMEIC is built on the combined and proud heritage ofToshiba and Mitsubishi-Electric (TMEIC) in the industrialautomation, control and drive systems business.Headquartered in Roanoke, Virginia, USA, TMEICCorporation designs, develops and engineers advancedautomation and variable frequency drive systems.The factory for the World’s factoriesTMEIC delivers high quality advanced systems andproducts to factories worldwide, while serving as aglobal solutions partner to contribute to the growth ofour customers.A Global networkTMEIC’s global business includes more than 2,200employees, with sales exceeding U.S. $2.4 billion, andspecializes in Metals, Oil & Gas, Material Handling,Utilities, Cement, Paper and other industrial markets.Customer ServiceWe focus on the customer, working to provide superiorproducts and excellent service, delivering customersuccess every project, every time.Global Office Locations:TMEIC CorporationOffice: 1325 Electric Road, Suite 200Roanoke, VA, United States 24018Mailing: 2060 Cook DriveSalem, VA, United States 24153Tel.: +1-540-283-2000 Fax: +1-540-283-2001Email: metals@tmeic.comWeb: www.tmeic.comTOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMSCORPORATIONMita 43 MT Bldg.13-16 Mita 3 chome, Minato-ku Tokyo108-0073 JapanTel.: +81-3-5441-3828 Fax: +81-3-5444-3820Web: www.tmeic.co.jpTMEIC Industrial Systems India Private LimitedUnit # 03-04, Third Floor,Block 2, Cyber Pearl, HITEC City, Madhapur,Hyderabad, 500081, Andhra Pradesh, IndiaTel.: +91-40-4434-0000 Fax: +91-40-4434-0034Email: inquiry_india@tmeic.comWeb: www.tmeic.inTOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS(Beijing) CORPORATION21/F., Building B, In.do Mansion48 Zhichunlu A, Haidian District,Beijing 100098, PRCTel.: +86 10 5873-2277 Fax: +86 10 5873-2208Email: sales@tmeic-cn.comTMEIC Europe Limited6-9 The Square, Stockley ParkUxbridge, Middlesex,United Kingdom, UB11 1FWTel.: +44 870 950 7220 Fax: +44 870 950 7221Email: info@tmeic.euWeb: www.tmeic.comTMdrive is a registered trademark of Toshiba Mitsubishi-Electric Industrial SystemsCorporation.TMEIC is a registered trademark of Toshiba Mitsubishi-Electric Industrial SystemsCorporation.TM is a registered trademark of Toshiba Mitsubishi-Electric Industrial SystemsCorporation.All other products mentioned are registered trademarks and/or trademarks oftheir respective companies.All specifications in this document are subject to change without notice. Thisbrochure is provided free of charge and without obligation to the reader or to TMEICCorporation. TMEIC Corporation does not accept, nor imply, the acceptance of anyliability with regard to the use of the information provided. TMEIC Corporationprovides the information included herein as is and without warranty of any kind,express or implied, including but not limited to any implied statutory warrantyof merchantability or fitness for particular purposes. The information is providedsolely as a general reference to the potential benefits that may be attributable to thetechnology discussed. Individual results may vary. Independent analysis and testingof each application is required to determine the results and benefits to be achievedfrom the technology discussed. If you have any questions regarding your projectrequirements, please contact TMEIC Corporation at 540-283-2100.© 2011 TMEIC Corporation. All Rights Reserved. I-1104