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IMS Company Presentation

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INTRODUCTION

Integrated Mill Systems (IMS) provides process automation solutions for the metals industry. Our staff has a broad range of expertise in a variety of processes spanning over three decades.

Our approach has been to fully understand the customer and develop system architectures that best fit the application using standard products that seamlessly integrate with existing plant systems.

Founded to fill a need of the Metals Industry for a

source of process knowledge and experience

independent of the traditional “mill builders” and

“drive suppliers”.

This allows us the flexibility to offer our customers an

automation solution based on the automation

platform of their choosing.

Management Structure

OFFICE OF THE PRESIDENT J Zelazny Robert Urban Marius Juodisius

OPERATIONS MANAGER

GM PITTSBURGH DIV.

VP SALES & MARKETING

A MISKINIS

S HLAVACH

J MASON

SALES & PROPOSALS MGR.

ENGINEERING MGR.

MANUFACTURING MGR.

CONSTRUCTION MGR.

ACCOUNTING

R LEWICKI

D HUMMER

G PRIBICEVIC

J KOCSIS

ENGINEERS

DRAFTING

ADMIN

SHOP

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PROJECT PHILOSOPHY

Define the Project From a Total Perspective

Design for Startup

Emphasis on Integration/Factory Testing

Customer Involvement

A TOTAL PERSPECTIVE

By working with our customer to define the business goals, this understanding guides every facet of the project.

The configuration translates functions into the necessary hardware and illustrates how components interact, followed by the detailed design and system schematics.

A test plan is written to rigorously test the functionality defined at the initiation of the project.

What Separates IMS from the Rest?

By adhering to our execution principles we deliver

vertical start-ups

Risk mitigation

exceptional cost savings

schedule performance

We take pride in providing systems that do not require a system service contract

Capabilities - AGC / Elongation

Single-stand Reversing Cold Mills

Multi-stand Tandem Cold Mills

Sendzimer Cold Mills

Multi-stand Hot Finishing Mills

Steckel Mills

Plate Mills

Temper Mill Control

Capabilities

Automatic Gauge / Elongation Controls

Mill Master

Process Line Controls

Drive Design

HMI and Operator Controls

Data Collection and Reporting

Capabilities - Mill Master Control

Mill master ramp functions

Drive coordination and control

Capabilities - Process Line Controls

Line and section master control

Tension modeling and control

Accumulator control

Shear control

Catenary control

Tension leveler control

Weld Tracking

Drive Design and Integration

MG-Set Applications

AC and DC drive experience

Multi-vendor experience

HMI and Operator Controls

Experienced with most HMI packages (Citect, Intellution, Wonderware, Cimplicity, etc).

Design and fabricate main control desks and remote operator stations

Results

Our results are predictable with a focus on the system functionality through the project life.

The project’s scope is well defined leading to excellent cost performance, with our extensive testing, commissioning times are minimized.

The troubleshooting tools we build into each HMI package, enable our systems to be seamlessly turned over to and maintained by our customers.

Integration/Factory Testing

Near the completion of system coding and manufacturing phases, a detailed Factory Acceptance Test Plan is produced by our project engineers.

The test plan is then reviewed by the customer and their recommendations are incorporated.

At the completion of the coding and manufacturing phases, the system is “powered up” and tested.

System Test

Complete staging of the system with the controllers, servers, networks, HMI system and all drive controllers validation of all network interfaces to PLCs

Customer operators and the commissioning team are integrated into the factory testing for training

This capability allows the IMS team to obtain an understanding of the system prior to the commissioning, ensuring a smooth, on-time startup.

Data Collection and Reporting

Coil Quality Monitoring (CQM) system (automatic quality analysis)

Fault logging / Trending

Production Reporting

COMMISSIONING EXPERIENCE

Extensive commissioning experience in the steel industry including:

Hot Rolling Strip, Plate, and Steckel Mills

Cold Rolling Tandem, Reversing, and Sendzimir Mills

Pickling, Annealing, and Galvanizing Lines

Design Engineers provide commissioning function

Design for Startup

A-M Cleveland Hot Mill Project Execution: Phase-In Strategy

One Section at a Time

Finishing Mill Area (Best ROI)

Roughing Area (Replaced Remaining Gems)

Furnace Area (Replaces Drives)

Coilers (Replaces Obsolete PDP-11)

“Bottom-Up” Approach

1. Drives

2. Masters & Sub-Masters

3. Operator Desks

4. Level 2

REFERENCES

ACME

US

COLD MILL

1992

Main Drives, Mill Master, AGC, Screws, Coiler Control, Thickness

LTV

OH

77” Cold Mill

1992

New MG Set Control, AGC, Mill Master, New Screwdowns, Interstand Tension

LTV

OH

84” Cold Mill

1993

Drives, AGC, HMI, Spray control, Interstand tension, Coiler control, Level 1

Worthington

OH

Skin Pass Mill

1993

Drives, Mill Master, HGG, AGC, Roll Bending, Elongation, Control Desk, HMI

Timet

PA

Z Mill

1994

Main Drives MG Replacment,Mill Master, AGC, HGC, Shape & Thickness Control, Gauges, Setup Model, Pulpit

Washington Steel

PA

Z Mill

1994

Main Drive MG Set Control, Mill Master, AGC, HGC, Shape & Thickness Control, Gauges, Setup Model, Pulpit

ATI

PA

Plate Mill

1995

Mill Master, Screwdowns, PLC, HMI, Table drives ,Pass Schedule calc’s. Furnace control,

REFERENCES

Rajinder

India

HSM

1995

Mill Master stand control, 6 Stand Roll force cylinders, AGC, HGC, HMI, DEC Alpha L2

USS Irvin

PA

84” HSM

1996

Main MG Set Control, Mill Master, New Rougher & Edger Drives, New Coilers & Table drives,

LTV

OH

80” HSM

1997

MG Set Upgrade, Level 1 & 2, Stand control, Models, Pulpit

LTV

OH

84” PL

1998

Drives , Level 1, HMI, PLC, OCS, L2 Interface, MCC

USS

PA

Rougher

1998

Mill Master, Level 1, Side Guides Drives upgrade

WPI

OH

48” Galv. Line

1998

New PCR, New Drives, PLC, HMI, Sub-Stations, SWG,

USS

PA

Coiler

1999

Level 1, HMI, PLC, Pulpit, Automax SW upgrade,

REFERENCES

LTV

OH

Roughing Mill

2000

Replace GE Directomatic stand controller with Automax Mill Master, Level 1, PLC, Remote I/O , Slab Tracking, Edger control, Screw Pos., Reg. Spray Control

USS ET

PA

Skip Hoist

2001

New Drives, Redundant PLC, HMI, New feedback & position devices.

LTV

OH

Caster

2001

Drives, PLC, HMI, mold level control, Operator control

USS

PA

Pickle Line

2002

Level 1&2 ,New Drives,PLC, HMI, Operator control, MCC

USS

PA

Galv. Line Temper Mill

2003

New PCR, Level 1, HMI, Drives, AGC, Tension Control, Elongation RECO

ISG

OH

HSM

2004

MG Set Upgrade, Level 1 & 2 Mill Master stand control, Mill Models, New Pulpit

ATI

PA

Plate Mill

2005

Mill Master, MG Set Main Drives Control, Table drives PLC, HMI, Screwdowns

REFERENCES

USS

PA

84” PL

2006

Drives, Level 1, PLC, HMI, Operator control, MCC

IPSCO

KY

Pipe Mill

2006

New Drives, Flying cutoff control, PLC, HMI, OCS, Level 1 Remote I/O MCC

USS

PA

HSM

2006

Drives upgrade, Level 1&2, PLC, HMI, Down Coilers, screws,

AK Steel

PA

HSM

2007

MG Set Upgrade, Mill master, PLC, HMI, MCC, Pulpit

ATI

MA

Z Mill

2007

Drives, AGC, PLC, HMI, Coilers

Arcelor Mittal

OH

HSM

2007

Drives upgrade, level 1&2 , PLC, HMI, Screws, loopers, Coilers New Pulpit

AK Steel

PA

TCM

2008

MG Set upgrade, Screws, HMI, PLC, OCS

REFERENCES

USS

PA

Coke Works

2010

TK Uhde OEM TURNKEY Automation

Arcelor Mittal

OH

TCM

2010

Drives, Mill Master PLC , HMI, Level 1&2

Shape control, AGC

USS

OH

Q&T Finishing

Line

2011

Level 1 mill auxiliaries, PLC, HMI, OCS, Material tracking, Robot integration