FASCINATING HEAVY PLATE - SMSgroupIncsms-group.us/files/A-319E.pdf · FASCINATING HEAVY PLATE Electrics and Automation ELECTRICS and AUTOMATION Heavy Plate Mills SMS SIEMAG. ... ty

FASCINATING HEAVY PLATEElectrics and Automation

ELECTRICS and AUTOMATION

Heavy Plate Mills

SMS SIEMAG

Electrics und AutomationSMS SIEMAG

2

ELECTRICS AND AUTOMATIONELECTRICS AND AUTOMATION for heavy plate mills

HOLISTIC SYSTEM COMPETENCE

Central to the automation of metallurgical plants istoday’s focus on high availability and ever-better quali-ty of the final products. To meet these requirements,SMS Siemag decided many years ago to include in itsrange not only mechanical equipment, technologicalcontrols, and process models, but also the entireelectrics, automation, and drive technology for ourplants. That makes us an all-inclusive supplier, givingyou engineering, construction, and commissioning ofyour plants – all from one source.

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

CONTENTS

Hardware and softwareautomation solutions 4

Automation layout 6

Modern hardware solutions 9

Energy distribution and drive system 10

Technology for heavy plate mills 12

Level 1-automation 14

Human machine interface (HMI) 17

Level 2-automation 18

Level 3-production planning systems 22

Safety strategy 24

Plug & Work test 26

Modernization strategies 28

Services 30

Electrics and automation for all plant variations 32

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ALL-INCLUSIVE

MODERNIZATION STRATEGIES

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

PROFESSIONAL PARTNER FOR

HEAVY PLATE MILLS

Specialists in electrics, automation, technology andmechanics work hand in hand to ensure everythingfunctions smoothly. That’s how we create intelligent,market-centered solutions with high potential forimproved production. Our entire scope of supply andservices – from plant engineering to process engi-neering, electrics and automation, manufacturing,assembly, Plug & Work testing, commissioning, rightthrough to after sales service – is geared to the spe-cial requirements of plate manufacturing.


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HARDWARE AND SOFTWAREAUTOMATION SOLUTIONSHARDWARE AND SOFTWAREAUTOMATION SOLUTIONS

X-PACT®

The electrics and automation systems of SMS Siemagare grouped together under the brand name X-Pact®.That goes for all process levels.

X-Pact® is a modular system. This means it can be flexi-bly adapted or expanded to meet your particular require-ments. Specifically, X-Pact® links the different levels ofelectrics and automation together. Included here are notonly the technological controls and process models, butalso all tasks of modern plant automation from drivetechnology and sensors (Level 0) right up to productionplanning (Level 3).

So you benefit from a system solution in which the tech-nology, mechanics, hydraulics, electrics & automationform an effective unit.

X-Pact® is a holistic concept.

MULTI-STEP STRATEGY

It’s a significant advantage that X-Pact® electrics andautomation systems use globally available hardware andsoftware, and comply with internationally recognizedstandards.

All systems are based on platforms that have a modulardesign. Naturally, we allow for current trends in hard-ware and software. Due to the extensive separationinto different levels (basic modules, technology mod-ules, system-specific modules,) you only have to makeadjustments and changes where they are actuallyrequired.

If the IT environment changes, for example due to newhardware, all you need to adapt are the basic modules.If new technologies are changed, you merely changethe technology modules.Project-specific functions and processes have beenplaced in the plant-specific modules. So here is a struc-ture that brings you these advantages: It improves boththe maturity level and service life of the technologymodules, plus it ensures the stability of the system-spe-cific modules in the case of new IT modules or device-related changes.

Production planning system

Material tracking, rolling sequence control, production routing

Technological controls, sequence controls, drive controls

Drive technologyEnergy distribution

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Plan of the various module levels.

SYSTEM ENVIRONMENT

It’s important in the automation of heavy plate plants todifferentiate between quick technological process con-trols and drive and sequence controls.There are not only material-accompanying controls,but also controls for auxiliary and ancillary units suchas hydraulic stations, cooling systems, and lubricationsystems.What’s so special about automating our heavy plateplants is that all control functions are grouped togetheron the system platform X-Pact® ProBAS.You won’t find any interfaces between different systemplatforms, since all process variables are immediatelyand simultaneously available to all sub-systems throughthe reflective memory (RFM) architecture.

Integrating other systems, for example stored program-mable controls for drive and sequence controls e.g. inthe shear section, is no problem at all.It’s equally simple to incorporate a PDA system as anintegral part of the overall system with RFM.To respond flexibly to your standards or special require-ments such as modernizations, we can easily integrateyour existing controls.

SIMPLE SYSTEM MAINTENANCE

Due to the open system architecture of the X-Pact®

system, there is no need for proprietary solutions. Theautomation systems are fully implemented in logi.CADon the basis of the internationally valid standardIEC61131-3. This is important for international projectsand ensures that either we or you yourself can main-tain, service and further develop our systems.

In terms of structure and handling, the FBD (functionblock diagram) technology used in logi.CAD is absolute-ly comparable with the CFC (continuous flow chart)technology used in the PLC programming environment.

FBD function block diagram.


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AUTOMATION LAYOUT OF A HEAVY PLATE PLANTAUTOMATION LAYOUT OF A HEAVY PLATE PLANT

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8

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MODERN HARDWARE SOLUTIONSMODERN HARDWARE SOLUTIONS

HARDWARE AND SOFTWARE

PLATFORM

We use ultra-modern computer technologies for ourLevel 1 real-time controls. Tried and tested for graph-ic programming and diagnosis is our ProBAS soft-ware. A typical configuration consists of:

one or more engineering stations (MS Windows) an X-Pact® ProBAS development serverone or more X-Pact® ProBAS systems

X-PACT® EMBEDDED

AUTOMATION PC

Within the X-Pact® ProBAS system, X-Pact® Embed-ded is a cutting-edge hardware platform for modern,sophisticated control and regulations systems in hotrolling. It’s based on the modern Core™ 2 Duo tech-nology from Intel® and provides the maximum com-puter power for all your applications.

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

ETHERNET-BASED

FIELDBUS SYSTEMS

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

Much higher performanceReal-time-capability for fast controlExtensive diagnosis optionsWide-scale use with very good acceptanceInterfaces to classic bus systems

Furthermore, using this technology drastically cutshardware engineering requirements because for thefirst time signals for the highly dynamic actors/sen-sors can be picked up close to the mill by the non-central periphery devices. That eliminates masses ofcable as well as the associated adaptation of processsignals. The technological regulation systems fromSMS Siemag use EtherCAT (from Beckhoff) as a real-time-capable fieldbus. All this goes to show that,with our new technology we harness a modern,powerful and real-time-capable communication medi-um for our automation systems. Flexible tree struc-tures ensure you can expand the network as youwant, when you want.

Electrics and AutomationSMS SIEMAG

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ENERGY DISTRIBUTIONAND DRIVE SYSTEMSENERGY DISTRIBUTIONAND DRIVE SYSTEMS

Our Electrics and Automation Division also suppliesall the equipment you need for energy distributionand drive technology in heavy plate mills.

SCOPE OF SUPPLY FOR

ENERGY DISTRIBUTION

Included in our supply range for energy distributionare high and medium-voltage switchgears, distributortransformers, compensation and filter systems, emer-gency power generators, USV plants, as well as low-voltage main distributors and the associated Emer-gency Off strategies.

ENERGY DISTRIBUTION FROM ONE

SOURCE

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

SCOPE OF SUPPLY

FOR DRIVE SYSTEMS

Whatever drive system you want for your heavyplate mill, we supply not only the full range of varia-ble drives, but also constant drives in all power clas-ses. The main benefits of our energy distribution anddrive systems are low investment and operatingcosts because of minimal power losses, plus com-pact design, and low maintenance.

Transformer rooms.

Medium-voltage switching plant.

Mill stand with rollertable motors.

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RELIABLE

DRIVE SYSTEMS

There are many parameters that play an importantrole in designing the drives, particularly when largeoutputs are involved. Teaming up with reputable sup-pliers, we have in recent years developed and optimi-zed our drive design concepts. Intelligent circuitsreduce the network harmonic load to such as extentthat a filter system is not required on the networkrail. We dimension these drive trains (medium-volta-ge circuit breaker, static converter transformer, con-verter and motor) on the basis of the real processrequirements. These can be found in SMS Siemag’sown pass schedules. An optimized drive systemmeans we offer our customers a plant with the hig-hest possible flexibility for designing production pro-grams.

The technological functions related to the drive, suchas ski formation or load sharing control between theupper and lower motor, are also covered by our X-Pact® electrics and automation so that the interfacewith the drives is lean and standardized.

The drive media system developed by us controlsand monitors all media in the motors and drive trans-formers. This allows us to offer a continuous connec-tion to our plant automation whichever companysupplied the drives.

2 x 12-MW twin drive of aheavy plate rolling mill.


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The development of high-strength steels has led toaltered rolling processes that also make higherdemands on plate cooling as well as the downstreamlevelers. That’s why, in recent years, we have res-ponded by upgrading and optimizing our rolling, coo-ling, and leveling technologies.

MAIN CHARACTERISTICS

OF HEAVY PLATE

When it comes to heavy plate production, we distin-guish between these characteristics:

It’s vital to keep all this in mind when choosingautomation and model calculation systems for yourplate production. There are various strategies forachieving the properties you want by influencing theshaping process and temperature.

ROLLING STRATEGIES

Apart from different rolling strategies, several types oflongitudinal and lateral rolling modes are available.These modes work on the basis of the geometries ofthe input slab and the finished product. What’s more,they use lateral rolling to stretch the material cross-ways.

PROCESS MODEL

FUNCTIONALITIES

The main process model functionalities are:

PacingPass schedule calculation model (PSC) Profile and flatness control model (PFC) for CVC plus Roll temperature modelRoll wear modelControl for optimizing the plate rectangularity (ASC)Adaptation model

Required plate properties.

Property Characteristics

Strength Yield strengthTensile strengthYield strength ratioBrinell hardness

Toughness Notch resistanceTransition temperatureFinal fracture area

Processing capability(weldability, coldformability)

Carbon equivalent CeqPre-heating temperature

Product shape FlatnessGeometry

Resistance to media

Weather-resistant platesResistance to sour gases

Processing capability(weldability, cold-formability, machinability)

„St 52-3 N”S355ML450 M sour

Reference: Paper presented at Iron and Steel Conference (Eisenhüttentag) AG der Dillinger Hüttenwerke, Dr.-Ing. Alois Streißelberger, Dr.-Ing. Franz Hanus, Dipl.-Ing. Wolfgang Schütz, Dr.-Ing. Ralf Hubo

Strength(Rm, ReH, hardness)

(M... TM steelN... Normal-annealed)

Resistanceto media

Product shape(flatness, geome-try ...)

Toughness,resistance tobrittleness

TECHNOLOGY FOR HEAVY PLATE MILLSTECHNOLOGY FOR HEAVY PLATE MILLS

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Rolling strategies.

Multi-plate rolling.

Pre-phase

Intermediate phase

Final phase

ACC cooling

Air cooling

Waiting phase 1

Waiting phase 2

Temperatur waiting - rolling - waiting rolling cooling

Rougher Finishing stand ACC cooling

FerriteAustenite and ferriteNon-recrystallized austenite

Recrystallizedaustenite

Time


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LEVEL 1 – AUTOMATIONLEVEL 1 – AUTOMATION

Area Control System

The Area Control System coordinates the rollingprocess and the communication between all theautomation systems involved. These can be the Level 2-system, the technological systems for the millstands, levelers, and plate cooling, as well as the adja-cent Level 1 automation systems such as for reheat-ing furnaces, cooling beds, the HMI system, and safe-ty system. Essential here is continuous plate trackingand control.

Technological Control System

The technological control systems ensure perfectproduct quality, a stable process, and high plant avail-ability.

Chief among the technological controls are fast con-trol loops for the actuators, and superordinate processcontrol loops. These include thickness control in themill stand, and profile and flatness control. Just asimportant are the controls for the levelers, consistingof hydraulic adjustment, load equalization for the dri-ves, and a process-driven threading in/out function.What makes all the difference in plate cooling is pre-cise control of the pinch rolls and the water circuits.

Support Control System

This is all about the media systems, such as:hydraulic stations, oil lubrication systems, grease sys-tems, and water supply system.

Drive systems

Included here are the main drives of the mill stands,plus drives for the levelers, plate cooling system, androller tables. The "Speedmaster" in the area controlsystem coordinates all the drives involved in thematerial flow.

Stability, simple maintenance, uncomplicated adapta-tion to new conditions, and high-tech solutions –these are the demands modern automation systemsmust meet. To achieve all this, they require a straight-forward yet effective basis. Our X-Pact® systems arecompletely modular in structure. As a result, we caneasily adapt them to different levels of complexity.

What do our control solutions mean for you? Quitesimply, excellent technology and functionality thatensure you achieve your target values with hydraulicand electrical control elements.

Other stand-out features of our Level 1 systems aremaximum availability and a high degree of processautomation coupled with effective service functions.

This applies to the systems for the entire hot-rollingsection, consisting of edger, mill stand, pre-leveler,plate cooling, and hot plat leveler, as well as for thecold area with its cooling beds, shear lines, and finish-ing lines including cold plate levelers.

HOT AREA

The Level 1 system consists of various automationfunctions. Each function works independently and islinked with the corresponding sensors and actors.Here are the main functions:Area Control SystemTechnological Control SystemSupport Control SystemDrive systems

Automation structurefor hot rolling.

Level 2 - Automation HMI

Area Control System

TechnologicalControlSystems

SupportControlSystems

Level 1-Automation

Drive Systems

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Plate cooling: Combination ofspray and laminar cooling.

Multi-plate rolling

It goes without saying that our automation systemssupport "normal rolling" and "temperature-controlledrolling" modes for single or multiple plate production(static and continuous batch).

SPECIAL CHARACTERISTICS

OF PLATE COOLING

Plate cooling sections often consist of both spray andlaminar cooling units. There’s a good reason for this,because the combination of the two cooling systemsand the pinch rolls allows for extremely fast coolingwith optimum flatness. That makes the configurationan excellent tool for producing high-strength plates.

Key to the process is exactly metering the quantity ofcoolant to achieve the cooling rates and temperaturedevelopment calculated by the Level 2 cooling model.

As a rule, the head and tail ends of the plates arecolder than the centers. The plate ends are maskedto reduce this effect and to influence the effectivecooling length.

A special function available here is intermediate cool-ing of the plates before they go on to thermo-mechanical rolling.


IN THE MILL STAND AREA

Thickness control

To achieve the target thickness at the exit of the millstand you can rely on not only the spindle andhydraulic adjustment systems, but also on these func-tion modules:

Automatic Gauge Control (AGC)Roll Alignment Control (RAC) Dynamic Disturbance Compensation (DDC)

Profile and flatness control

This module covers all the systems for the mechanicalcontrol elements:CVC plus - work roll shifting Work roll bending

Thickness controlmethod.

Set values

Roll alignment control RAC

Automaticgauge control

AGC

Dynamic disturbancecompensation

(DDC)

Hydraulic roll-gap control

HGC

Electro-mechanicalscrew down

positioning EMP

Thickness measuring device

Thickness control

Roll-gapcontrol


Automation structure ofthe cold rolling mill.


OF LEVELERS

You can choose from a variety of levelers to ensurethe flatness quality you want throughout the platemanufacturing process: pre-levelers, hot plate levelersand cold plate levelers. Installed at different locationswithin the production process, they guarantee the fin-ished plate flatness quality that makes all the differ-ence.

The technological control system (TCS) developed bySMS Siemag controls all the adjusting elements suchas parallel adjustment, skew adjustment, tilt adjust-ment, bending and individual roll adjustment, as wellas variables such as leveling speed and drive torque.Everything depends on the properties of the materialat the current plate temperature, the plate dimensions,and the waviness of the plate to be leveled.

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COLD AREA

The Level 1 system consists of various automationfunctions. Each function works independently and islinked with the corresponding sensors and actors.These are the main functions:Area Control / Machine Control SystemsSupport Control SystemsDrive systems

Area Control / Machine Control System

The individual sections in the cold area are designedspecifically for the plate production process. Includedhere apart from the cooling and inspection beds arethe shear line with machines such as crop shear, double side trimming shear, slitting shear, dividingshear, sample shear, and the finishing line equipment.There’s an Area Control System for each section thatcoordinates communication with the systems involvedin the process. These can be Level 2 systems, theautomation systems of the adjacent sections, the HMI,or the safety system. Due to this modular design, it’seasy to put together different levels of complexity.

Support Control System

This controls the media systems, among them hydraulic stations, oil lubrication systems, and grease systems.

Drive systems

Drives for the shears and the cooling bed/finishingline equipment as well as the roller table drives fallinto this category.

Leveler.

Level 2 - Automation HMI

MaschineControlFunctions

Level 1-Automation

Drive Systems

Area ControlSystem

SupportControlSystems

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Our HMI systems link the plant and the operator. Theymap the production process including everything to dowith materials and technology. Armed with the infor-mation from the process observation, the operatoruses the latest graphical methods to manually influ-ence sequences and control the machine groups, e.g.media units.

In line with our operator-centered approach, ouremployees work closely with your operating person-nel. Involving your team in the Plug & Work tests isanother effective way to prepare them for their newtasks.

HUMAN MACHINE INTERFACE (HMI)HUMAN MACHINE INTERFACE (HMI)

NEW OPERATING PHILOSOPHY FOR

MORE QUALITY IN THE PRODUCTION

PROCESS

Your operating personnel will appreciate clear andsimple functions that make their job so much easier.They can benefit directly from no-nonsense controlsthat minimize operating errors.

That’s because SMS Siemag has developed a new,production-driven operating philosophy and a novelcontrol desk design for your operating staff.Already, our innovative desks have been installed in anumber of heavy plate mills and have proved a hugesuccess. Central to the design is the operator’s viewof the entire production process. To ensure this com-prehensive overview, we tailor the automation struc-tures to your plants.

HMI process data.

Ergonomic control desks. Ergonomically designedoperator chair.

Electrics und Automation

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TECHNOLOGICAL PROCESS

MODELS

MILL STAND

PSC® Pass Schedule Calculation

PFC® Profile and Flatness Control

To ensure an optimum rolling process, it takes a gooddefault setting. Our technological process models cal-culate, for every pass, the relevant parameters suchas plate thickness, roll bending, roll shifting, speedand the rolling force to be expected. They also speci-fy the associated rolling speed. The calculation alwaysaims at maximum production throughput while com-plying with the required product quality. This involvesallowing for the limits of the plant as well as the cur-rent plant situation, the material properties, productdimensions and the temperature.

Our calculations for profile and flatness as well as forthe pass schedule are based on mathematical-physi-cal models. That ensures we can calculate good set-points for new products – from the very start – wherethe material properties are known. Special to our lineis that the Level 2 system uses short and long-termadaption functions to gradually equalize any differ-ences between the calculated default values and thevalues measured during the rolling process.

SMS SIEMAG


HIGH PRODUCTIVITY

The X-Pact® Level 2-systems are key to increasingthe productivity of modern plate rolling mills. Improv-ing product quality as well as increasing productionvolume and flexibility are the main tasks of the Level 2-systems, which are based on mathematicaland physical process models.To fulfill their role in quality assurance, process con-trol systems must not only optimize processes, butalso ensure efficient product and production datacapture.

Just like the elements of the other automation levels, SMS Siemag Level 2-solutions are indepen-dent of the hardware structure. They provide for distribution of the individual functions over severalcomputers.Communication with the external systems, for exam-ple a production planning system spanning severalplants, is implemented as a separate function tomaintain high flexibility with regard to different con-nections.

Report system HMI

Data transfer

Perfo

rmance evalu

ation

Internal material tracking

Coordination

(event handling) Process

dataStrategie

Technologicalprocess models Archive

database

Process model Shell

Sequence of pass schedule and set value calculation.

Modules of theLevel 2 system.

Longitudinal rolling

Slab

90° turn

Finish rolling

Broadsiderolling

Thickness profile afterlongitudinal rolling

Head and foot shape inconventional rolling

Shorter head and tailends due to ASC

90° turn

Mother plate afterfinish rolling

Thickness profile afterbroadside rolling

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9 or 5-roll modes of thecold plate leveler.

The ASC strategy.

PLATE COOLING

SMS Siemag implements physical and mathematicalprocess models that precisely control the coolingstrategies. This is essential for setting the desiredgrain structures and mechanical properties of theplates.

According to the product requirements two coolingtypes are available: laminar cooling, or the spray cool-ing system developed by SMS Siemag. Characteristicof laminar cooling are a wide application range withlow operating and maintenance costs. Spray coolingunits feature powerful high-pressure stations andpinch rolls between the cooling beams. That ensuresfast cooling and good flatness even of very thin plates.

LEVELERS

It’s the precise interaction of the mechanical equip-ment and the X-Pact® automation that produces reallyoutstanding leveling results. The leveling model devel-oped by SMS Siemag controls the process and calcu-lates exactly how to adjust the straightening rolls andthe torques.

The key parameters for these calculations are thematerial properties at the current plate temperatureand the plate dimensions. Of course, the levelingprocess also takes into account any flatness detectedby the operating personnel.

This is where unflatness and residual stress areremoved from the plate. The cold plate leveler can beoperated in 9 or 5-roll mode. That extends the levelingrange without any need to change the rolls.

ASC Automatic Shape Control

To minimize the scrap generated by cutting off thehead and tail ends of the plates, they must be rolledas closely as possible to a perfect rectangular shape.

That’s where our shape control system comes in. Itworks by adjusting the rolls at the beginning and endof each pass so that the plate edges are thicker thanthe middle. After turning, the extra material at theedges means the plate is rolled in the subsequentpasses into an almost rectangular shape.

The ASC model calculates the length and height ofthe positive wedges according to the material anddimensions.

Influencing factors inPFC model calculation.

Thermal camber Roll wear

Roll bending

Roll flattening dueto the plate

Roll flatteningbetween the rolls

Force distribution

Material flow

Plate flatness

Roll grinding/roll shifting


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SUPERORDINATE MATERIAL TRACKING

Our Level 2 material tracking system is responsiblefor allocating piece information to production planningdata. Applying this data, the Level 2 system supportsa production-oriented overview of the material in theplant. Furthermore, Level 2 initiates set value calcula-tions depending on the material position. These arethe main functions:

Primary data entry for specifying information onmaterial flow and slab and plate processing in thevarious machinesSequence control for controlling the material flowof slabs and plates in the various machines Material tracking modules for controlling and moni-toring position and condition of the various materi-als such as mother and daughter plates Communication modules for data exchange withvarious automation systems, from the slab furnaces to the piler equipment.Automatic set value generation for all machines inthe plantMeasured value capturing, filtering, and concentra-tion for reporting and quality controlProduction monitoring and reporting Production of plate groups for multi-plate rolling instatic and continuous batch mode.


CUTTING OPTIMIZATION

Another intelligent solution is our cutting optimizationsystem. It takes the measured geometry of themother plate, then alters the planned cutting patternto ensure the best cut for production of the finishedplate. Apart from the required geometry and qualityof the finished plates, this system also takes intoaccount the performance of the various shears.

To minimize scrap, the finished plates are positionedoptimally within the measured contour of the motherplate. Included in the calculation data is the maxi-mum throughput rate of the shear line.

If the measured geometry does not match theplanned cutting pattern, the cutting optimization func-tion calculates dividing cuts at the cropping shear andfits the finished plates into the new contour.All this happens fully automatically.

Roughing standwith edger

Finishingstand

Platecooling

Hot plate leveller

Cooling andinspection beds

Screen shot of a cuttingspecification.

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PACING

To optimize plate processing, our pacing model mapsthe production times for each individual productionarea (rolling time, waiting time, transport time, etc.). 7It continually measures the current production time.

Applying all this data, our pacing model computes theoptimum production spacing and the ideal time to dis-charge the next slab. Everything goes into the calcula-tion: planned and unplanned delays, faulty rolling,stoppages, and more.

These are the functions included:

Pre-calculation of the time scheduleSequence monitoring from discharge out of the furnace to entry into the hot plate levelerCalculation of the furnace discharge intervals"Exit next slab" signal to the operatorMonitoring the current rolling sequence timeschedule for analysis

PRODUCTION DATA CAPTURE

AND REPORTING

Operating and product data capture is based on theprocess events of the Level 1 system. What happenshere is that the Level 2 system tracks all products inthe entry area of the rolling mill, along with their cur-rent status.

That provides data for plausibility checks for the pro-duction sequence and the calculation of product-spe-cific processing values. The relevant production andproduct data is saved in a database where it is avail-able for product evaluation as well as quality andproduct reports

Ultrasonictesting device

Crop shear Double side trimming/slitting shear

Dividing shear Inspectionbeds

Cold plateleveller

Set valuesPrimary data

Measured values

Rolling sequence control.

Level 2System


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LEVEL 3 – PRODUCTION PLANNING SYSTEMLEVEL 3 – PRODUCTION PLANNING SYSTEM

systems, Level 3 production planning offers you thesebenefits:

Maximization of overall production ratePlanning and minimization of inventories for interimproducts Analysis of energy supply conditions for reducedenergy consumptionUniform product tracking throughout the productionline Overall quality assurance up to final quality approvalIncreased compliance with delivery dates

MANUFACTURING ORDERS

You can rely on our systems to convert your ordersinto technically executable manufacturing projects.That means, according to your specifications, anextensive calculation model generates the manufac-turing data for the product.

Definition of the necessary production steps andpossible plant alternativesDefinition of the dimensions and quality of the ini-tial and intermediate productsPlanning of the output of every production stageto determine the necessary quantities of inputmaterialDefinition of sample taking and test regulations

Manu-facturing

order

Today, there is a constantly growing product variety,while customers expect ever shorter delivery timesfor top product quality. That demands meticulousplanning of your production processes. What’s more,you need close links to the production systems ofsuppliers and customers so you can react quickly tochanges. Development here focuses on “Real TimeEnterprise” (RTE), a method that checks andresponds to these changes in real time.

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

X-PACT® LEVEL 3

X-Pact® Level 3 provides you with all the tools youneed for planning and control of the productionprocesses in your metallurgical plants and rolling mill.An effective link between the commercial side of thebusiness and the technological process automation

From customer order tomanufacturing order.

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THE FACTORY MODEL

A uniform planning system covering all areas isbased on a factory model. The factory model isimplemented in the planning system in the form ofan electronic planning table.

PRODUCTION PLANNING

It’s vital to determine the doable delivery dates for allmanufacturing orders in advance. That’s where ourcapacity and deadline planning comes in, examiningall the plants and plant alternatives available. As aresult, you get a sequence plan for the individualplants as well as a plan of the available input materi-als for each manufacturing order.

Material flow in a heavy plate rolling mill.

QUALITY TRACKING

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

To customer

THICK PLATE> 50 mm

To customer

PLATE< 50 mm

Heating furnaces

Descaler

Pre-leveler

Plate coolingsystem

Cooling andinspection bedsMill stand

with edger

Hot plate leveler

Ultrasonic testing device

Double side trimming/slitting shear

Dividingshear

Cold plateleveler

Cropshear


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SAFETY STRATEGYSAFETY STRATEGY

Worldwide, the importance of machine and plant safe-ty is growing. It’s not just plant operators themselves,but also laws and standards that demand personal andenvironmental protection.

Absolutely essential for safe plant operation is a coordinated approach during planning and design. The mechanical, electrical, and automation systemsare the most important elements in our safety strategy:

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

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

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

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

Together with you, we work out a practical solutionwith safety control functions that operate indepen-dently from the machine controls. This strategy alsocomplies with all safety laws and regulations. And itreduces the time and cost of testing, documentation,and commissioning. Early on – during the Plug &Work process – we extensively test the safety con-trol functions.

Monitoring of adanger zone.

Machine safety.

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Level 1 (unsafe partof controlsystem)

Separation of safety functions and control functions.

Extract from a dangerzone layout plan.


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PLUG & WORK TESTPLUG & WORK TEST

Our long-established Plug & Work service is increasing-ly popular among our customers. At the heart of Plug& Work are production simulations that mimic realitydown to the smallest detail. You benefit from our yearsof experience in engineering and process technology,because we know exactly how processes behave andwhat regulators achieve which product qualities. Thesimulation system we use in our Plug & Work strategyreflects this complex interplay of factors.

MODULE AND INTEGRATION TEST

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

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

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

Customer trainingin the test field.

Test using the originalequipment.

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Aufbau eines Plug & Work Tests.

TRAINING

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

First comes the theory in the classroom, where ourexpert employees pass on their know-how to yourteam.

We always plan an extra instruction session for themanufacturer’s experts to explain the operation andmaintenance of the measuring systems installed inour automation solutions. After this thorough ground-ing, we train your operators during the Plug & Workphase.

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

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


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SMS Siemag has developed a strategy that ensuresproduction to continue throughout alteration ormodernization work. Compared with conventionalmethods, it gives you a much higher protectionagainst failure, shorter commissioning time, steeperrun-up curves, and therefore an early return oninvestment.

REASONS FOR

MODERNIZATION PROJECTS

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

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

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

PROCEDURE

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

CURRENT-STATE ANALYSIS

The first step to successful modernization is an in-depth assessment of the current state of the automa-tion system. That includes an examination of the sen-sory systems installed to find out whether they can

be re-used. This check simultaneously determineshow new sensory and measuring systems can beinstalled. Significant here is that the current-state analysis examines all the relevant electrical and auto-mation system components as well as the completetechnological process sequence.

The second key stage is considering and selectinginterfaces to the automation systems and IT infra -structure that will stay in place. Essentially, what wefind out as a result of the current-state analysis goesinto a motor and component list, a technological process description, and a documentation of theinterfaces for each alteration phase.

HARMONIZATION OF

OPERATIONAL PROCEDURES

Over time, all plants develop their own standard ope-rational procedures. Yet it’s imperative to examinethese SOPs during the current-state analysis. Theyare drawn up and documented on site with the opera-ting and maintenance crews. Taking this as a basis,we develop and harmonize new procedures.

PLANNING THE

ALTERATION PHASES

Together with you, we plan the phases for the majorrevamp stages of mechanical, media, and electricalsystems in close cooperation with you. It all meansyou save time and money, because carrying out moreoperations in parallel before, during, and after produc-tion standstills slashes overall stoppage times. Accor-ding to pre-defined milestones, each standstill is tra-cked and if necessary re-planned by expertconstruction managers working hand in hand.

MODERNIZATION STRATEGIESMODERNIZATION STRATEGIES

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SWITCHOVER PLAN

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

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

several scheduled maintenance standstills prior tothe conversion standstill itself. Furthermore, the elec-tronic version of the switch-over plan makes monitor-ing operation possible. This is how the relevant dataand signals from the existing automation system arecaptured and analyzed by powerful monitoring sys-tems.

Plus, in highly critical cases, the switch-over technol-ogy is designed so that the entire plant can beswitched over from the old to the new automationsystem without any major production interruption.We cooperate closely with you to make sure theswitchover plan is transparent, and you make thefinal decision, taking into account all the economicand technological aspects.

RE-COMMISSIONING

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

The high point of the whole project is the plant run-up after the revamp. Yet, before this happens,we team up with you to carefully plan production ofthe material quality and dimensions you require. Thedata recorded during monitoring operation is appliedto pre-optimize our process models, clearing the wayfor immediate production start with marketable product quality.

Furthermore, you can rely on comprehensive sup-port, starting with continuous assistance during run-up, through to technology support from our develop-ment departments. Sometimes both sides recognizethe potential for joint improvements and sign a coop-eration agreement that might even lead to excitinginnovations! There are a large number of successfulprojects we have carried out that confirm the effec-tiveness of our revamp strategies.

Old

PPS/I 3

Process models / L2

Process control / L1

Remote IOs

Remote IOsPIOS

Process models / L2

Process control / L1

New

Switchover plan between oldand new automation systems.

PIOS = process IO server“electronic terminalstrip”


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SERVICESSERVICES

COMMISSIONING

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

Essentially, commissioning on site consists of thesestages:

Cold commissioningHot commissioningSystem optimization during productionPerformance tests

Cold commissioning

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

Hot commissioning

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

System optimization during production

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

Performance tests

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

AFTER SALES SERVICE

There is even more we can do for you in the form ofour after sales service. This gives you continuedaccess to our expert know-how.

Specifically for X-Pact® electrics and automation, theSP/1 service portal from SMS Siemag offers you theoption of rapid support in troubleshooting – 24/7.

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

THE ADVANTAGES OF THE SERVICE

PORTAL

Some 70 percent of faults can be corrected immedi-ately. Alternatively, we isolate any faults that occur.Take for instance defective parts. Our experts canusually identify them online, possibly deactivatethem, and send a service technician to replace themon site.

The service portal is ideal for fast and secure remote maintenance.

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DOCUMENTATION

We manage the entire order documentation in anExcel-based spreadsheet. It comes complete with atable of contents that gives you an easy and immedi-ate overview of the complete documentation. All thenecessary documents, such as function descriptions,circuit diagrams, and operating instructions are savedin this list at one central, structured location. Equallyuseful, the solution integrates all the documents gen-erated throughout the project. Every documentationtransfer gives you the full current status in electronicform.

The spreadsheet itself contains all the necessary infor-mation on each document, e.g. file format, print for-mat, language, version, and life cycle. From a centralmenu, you go straight to the heart of the program, soyou find the document you want very quickly, andsimply click on a link to open it. This is how the opera-tor finds his operating manuals, the maintenanceemployee the data sheet for a sensor, and the pro-grammer the software details for the automation.Once the project is completed, you can continue thedocumentation yourself and administer new docu-ments or document versions.

Document managementusing spreadsheets.


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ELECTRICS AND AUTOMATION FOR ALL SYSTEM VARIATIONSELECTRICS AND AUTOMATIONFOR ALL SYSTEM VARIATIONS

HEAVY PLATE MILL

WITH ONE MILL STAND

HEAVY PLATE MILL

WITH TWO MILL STANDS

STECKEL / PLATE COMBINATION

FOR MANUFACTURING STRIPS

AND PLATES

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Our X-Pact® automation systems use state-of-the-artcomputer technologies on the basis of ultra-modernreal-time-capable field bus systems.

They offer you not only high availability, but also anergonomically designed work environment that helpsyou improve the quality in your production process.

Furthermore, we supply the energy and drive sys-tems for all SMS Siemag products. Equally favorableis the link-up between our mechanical and electricaldesign departments. That helps you optimize thedrive concepts for our rolling mills – from the roll gapand the transmission design right up to the design ofthe frequency converters and motors.

Here is how you benefit from automation systemsfrom SMS Siemag: they improve your product quali-ty and result in a higher yield while also loweringyour energy and personnel costs. As part of our Plug& Work concept, we perform comprehensive inte-gration tests. This ensures fast run-up times.

SMS SIEMAG AG

Electrical and Automation Systems Division

Wiesenstrasse 3057271 Hilchenbach, Germany

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

Ivo-Beucker-Strasse 4340237 Düsseldorf, Germany

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

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

MEETING your EXPECTATIONSA/319E

1000/05/11 .Ky . Printed in Germany

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

Documents

FASCINATING HEAVY PLATE - SMSgroupIncsms-group.us/files/A-319E.pdf · FASCINATING HEAVY PLATE Electrics and Automation ELECTRICS and AUTOMATION Heavy Plate Mills SMS SIEMAG. ... ty