precise cold rolling electrics and automationsms-group.us/files/a-315e_precise cold...

PRECISE COLD ROLLINGPRECISE COLD ROLLING Electrics and Automation

FLAT ROLLING MILLS

SMS SIEMAG

CONTENTS

X-Pact® Electrics and Automation 4

Modern hardware solutions 6

Energy distribution and drive systems 8

Level 1 automation 10

Level 2 automation 12

Level 3 production planning systems 14

Safety strategy 16

Plug & Work 18

Modernization strategies 20

Services 22

3

Electrics and AutomationSMS SIEMAG

2

ELECTRICS AND AUTOMATIONELECTRICS AND AUTOMATION for cold rolling mills

This kind of growth comes not only from the latest engineering solutions, but also requires integratedautomation to reap the full benefit for your end products.SMS Siemag supplies seamless revamps so you benefitfrom technological improvement of your productionacross the board.

PROFESSIONAL PARTNER

FOR COLD ROLLING MILLS

SMS Siemag supplies cold rolling mills for almost all products and capacities. Included here are reversingstands, continuous tandem mills, skin-pass mills, and cluster stands. They cover a range of products from carbon steels, silicon steels, tinplate, stainless steels, to copper.

Our experts in electrical, automation, technological, andmechanical systems work together to ensure the plantsyou get are perfectly coordinated in all aspects. That’show you can rely on intelligent, market-driven solutionswith high productivity for top-quality cold strip.

HOLISTIC SYSTEM EXPERTISE

Now, more than ever, the market for metallurgical plantautomation demands high plant availability and quality ofthe end products. To meet these requirements, SMSSiemag many years ago launched its policy of supplyingnot only engineering, technological controls and processmodels, but also the entire electrics, automation, anddrive technology for its plants. That makes us a one-stop-shop for all aspects of engineering, construction, and commissioning.

Acutely aware of our responsibility to you, we ensure allsystem components mesh perfectly. Short paths, directcommunication, and the common interests of everybodyinvolved add up to the best conditions for just that.

EXTENSIVE MODERNIZATION

STRATEGIES

As an operator of metallurgical plants, you know how crucial it is to constantly add to and renew your productionequipment so you retain your market standing with excel-lent product quality.

5


4

X-PACT®X-PACT®

Electrics and Automation

The entire spectrum of automation technology fromSMS Siemag is available to you under the X-Pact®

brand name. That applies to all plant types, whethersteelmaking or casting plants, rolling mills or stripprocessing lines. Central to X-Pact® for cold rollingmills are high cost-efficiency and transparency of ourcontrol technology. X-Pact® encompasses all levels ofautomation from Level 0 to Level 3. There has beenextensive standardization of our products whichmeans we were able to vastly improve the competi-tiveness of our Electrics and Automation solutions.

X-Pact® for cold rolling mills pools our special processknow-how in a system oriented toward the distinctprocess technology required here. Additionally,because X-Pact® focuses on the cold rolling processand associated controls and regulations, we wereable to simplify the application software. Thatenabled us to fine tune the application software at a lower outlay. What’s in it for you? The solutioncomes with a leaner system structure, making itmuch more straightforward to use.

MULTI-STEP STRATEGY

All the systems are based on uniform platforms within a modular structure. We apply the latest hard-ware and software developments here. Everything is broken down into separate levels (base modules,technological modules, plant-specific modules), so elements only have to be customized where necessary.

If the IT environment changes, for instance due tonew hardware only the base modules need to bemodified. Similarly, when new technologies comeinto play, only the technology modules are affected.The plant-specific modules contain project-specificfunctions and routines.

Plan of the various module levels.

You benefit from this structure because it improvesboth the effectiveness and lifetime of the technologymodules. What you can also count on is the stabilityof the plant-specific modules, even if you replaceyour IT infrastructure or change certain equipment.

HOMOGENEOUS SYSTEM

ENVIRONMENT

Generally, when it comes to the automation of rollingmills, a distinction is made between operation andsequence controls, and fast technological processcontrols. Included here are not only material-trackingsequence control systems, but also controls for auxil-iary machine groups, for instance hydraulic stations,cooling and lubricating systems, rolling oil and emul-sion plants.

So, in X-pact® for cold rolling mills, all regulation andcontrol functions are preferably embedded in a hard-ware platform (X-Pact Embedded) and a joint pro-gramming environment (LogiCAD).

That ensures maximum availability of all system variables. Interfaces between different system plat-forms are no longer necessary because the reflectivememory (RFM) architecture supplies all process datato all the sub-systems immediately and simultane-ously. This is also how a PDA system can be inte-grated into the overall array using RFM.

It’s one of our principles to react flexibly to customerstandards or special requirements, especially forrevamps. That’s why our solutions easily integrateyour existing control systems, as well as otheroptions such as programmable logic control (PLC).

SIMPLE SYSTEM MANAGEMENT

The open architecture of X-Pact® makes it independentof proprietary solutions. That means the automationsystems are entirely implemented under LogiCAD on the basis of international standard IEC61131-3. This is important for international projects and ensuresour systems can be updated, maintained, and furtherdeveloped by all our customers.

Using logi.CAD is the easiest thing in the world for system engineers and programmers familiar with PLC programming. The FBD (Function BlockDiagram) technology in LogiCAD features the same structure and procedures as the CFC-Technik (Continuous Flow Chart) used in a PLC program -ming environment.

FBD Function Block Diagram.

7


6

MODERN HARDWARE SOLUTIONSMODERN HARDWARE SOLUTIONS

HARDWARE AND SOFTWARE

PLATFORM

We use state-of-the-art computer technologies forour Level 1 process control in real-time. Equallyadvanced, ProBAS software takes care of graphicprogramming and diagnosis. A typical configurationconsists of:

One or more engineering stations (MS Windows)An X-Pact® ProBAS development serverOne or more X-Pact® embedded automation systems

X-PACT® EMBEDDED

AUTOMATION PC

X-Pact® Embedded is the SMS Siemag hardware platform for modern, sophisticated control and tech-nological regulation systems in cold rolling. X-Pact®

Embedded is based on modern Core™ 2-Duo technology from Intel® and provides the maximumcomputing power to all 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 rely on 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).

Typical X-Pact® embeddedconfiguration.

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 process controlExtensive diagnosis optionsWide scale use with increasing acceptanceInterfaces to classic bus systems

Furthermore, using this technology drastically cutshardware engineering requirements because for the first time signals for the highly dynamic actors/sensors can be picked up close to the mill by thenon-central periphery devices. That eliminates masses of cable as well as the associated adaptationof process signals.

The technological regulation systems from SMS 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.

X-Pact® Embedded

E-room

CPU

Pro�

bus

Realtime EthernetPro�bus

Remote I/O Boxes

Valve Cylinder Sensor Drives & I/O

Field

DE-CENTRALIZED SYSTEM

ARCHITECTURE:

Single CPU-systems (CPCI)Only power supply and networkconnected to the field area Real-time Ethernet as fast field-busReduced signal- and HW-engineering Highly reduced complexity

An increasing number of supplierssupport devices with fast Ethernet interface, e.g. new valve series fromMOOG, position transducers by Heidenhain


8

ENERGY DISTRIBUTION and DRIVE SYSTEMSENERGY DISTRIBUTION and DRIVE SYSTEMS

Our Electrics and Automation Division also suppliesthe equipment for energy distribution and drive tech-nology in cold rolling 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,emergency power generators, USV plants as well as low-voltage main distributors and the associatedEmergency Off strategies.

SCOPE OF SUPPLY

FOR DRIVE SYSTEMS

Here, we supply all variable drives for cold rollingmills. Added to this are constant drives of all powerclasses. The bottom line for you? Low investmentand operating costs due to reduced power dissipa-tion, a smaller footprint, and low maintenance areserious advantages of our energy distribution anddrive systems.

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.

Mill stand entry area.

9

Drive side of a cold rolling mill.

Our in-depth process know-how means we canexactly determine the diversity factors and evaluatepass schedule data. As a result, we can optimallydimension all components, from overhead line feedsto mechanical control elements.

RELIABLE DRIVE SYSTEMS

There are a large number of parameters that influ-ence the design of rolling mill drives, especially in the megawatt power range. Together with renownedsuppliers, we devised and optimized new founda-tions for these medium-voltage drives over recentyears.

Intelligent switching systems are able to reduce theharmonic wave strain on the network side to such an

extent that no filters are necessary on this terminalserver. These power trains (medium voltage switch,converter transformer, voltage converter, motor) aredimensioned according to the actual process require-ments, which can be seen from the pass scheduleplans included in our scope of supply. Using an optimized transmission of the drives, we ensure youget a plant with maximum flexibility in the design ofyour production processes. Included in the X-Pact®

process control package are the technological drivefunctions. They keep the interface to the drives leanand standardized.

We have developed a drive media system that con-trols and monitors all the media for the motors andthe drive transformer. So, wherever you source yourdrives, they seamlessly connect with our plantautomation system.

Transformer rooms.

Low-voltage switchingplant.


10

LEVEL 1 AUTOMATIONLEVEL 1 AUTOMATION

Stability, easy maintenance, no-fuss adaptation to new environments, and top technological performance– that’s what you expect from modern automation systems. This requires a simple yet powerful basis.All X-Pact® cold rolling systems are based on our uni-form X-Pact® embedded platform with its modularstructure. As a result, they readily adapt to differentcomplexities in cold rolling.

What do our regulation systems mean for you? To begin with, you can rely on excellent technologyand functionality that ensure you achieve your targetvalues with hydraulic and electrical control elements.Other stand-out features of our Level 1 systemsinclude maximum availability plus a high degree ofprocess automation coupled with effective servicefunctions.

There is close coordination between our automationexperts and the design department to develop andthoroughly test software modules for each mechani-cal unit.

CONFIGURATION

OF THE CONTROL SYSTEM

Level 1 consists of various automation functions.Each function works independently and is linkedelectrically with the corresponding sensors andactors. Here are the main functions:

Master ControllerSequence and auxiliary controlsDrive controlsTechnological controls

Master Controller

The Master Controller coordinates the rolling processand the information exchange between the variousautomation systems involved in the process, e.g. theLevel 2 system, the safety system, and the Level 1automation functions.

Sequence and auxiliary controls

These functions ensure smooth operation in the different areas of the rolling mill. Included here arethe material flow controls in the plant feed and run-out areas of the rolling mill as well as the controls of the media systems.

Drive controls

This is a control sector that comprises all the drivesinvolved in transport, rolling, coiling and uncoiling theproduct. Essentially, they consist of the main drives,the coiler and pay-off reel drives, as well as the flat-ness measuring and deflector rollers. The „Speed-master“ coordinates all the drives involved in thematerial flow.

Technological controls

The technological controls basically comprise fastcontrol loops for the actuators, and superordinateprocess control loops. Among these process controlloops are e.g. thickness and flatness controls. Whatcounts for you is that our technological controlsensure perfect product quality in terms of thicknesstolerances, flatness, and minimized strip edge drop,as well as a stable rolling process and high plant availability.

Configuration of the control system.

11

THICKNESS CONTROL

To achieve the required thickness on the run-out side of the mill stand, the uneven thicknesses on the feed side must be eliminated. That’s the job ofthe hydraulic control element as well as the controlstrategies:

monitor thickness controlforward thickness controlvolume flow control

FLATNESS CONTROL

Tailored to the mill type and the product range to berolled, our flatness control system covers all the con-trol loops necessary for the mechanical actuators:

Work roll and intermediate roll bendingCVCplus® work roll and intermediate roll shiftingLevelingMulti-zone coolingEccentric adjustment (20-roll cold rolling mills)

Function structure of aLevel 1 system.

HMI process data.

HMI SYSTEMS

Our HMI systems link the plant and the operator.They map the production process including every-thing to do with materials and technology. Armedwith the information from the process observation,the operator uses the latest graphical methods to manually influence process control or operation of the integrated machine groups such as mediaplants.

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

This is where our technological process models setthe optimal variables (roll bending, roll shifting, andleveling) as well as the anticipated rolling force andstrip thickness. The goal is flat strip even on thread-ing into the plant.

The process models also set the necessary strip ten-sion and rolling speeds. Equally important is achiev-ing the maximum production rate coupled with thedesired product quality. Factors taken into accounthere are plant limits, current plant situation, materialproperties, product dimensions, and temperature.

The calculations for flatness as well as for the passschedule are based on mathematical-physical mod-els. Right from the start, you can also calculate use-ful values for new products if the material propertiesare known.


12

LEVEL 2 AUTOMATIONLEVEL 2 AUTOMATION

INCREASED

PERFORMANCE

Central to increasing the output ofmodern cold rolling mills is the X-Pact® Level 2 system. Specifically,it’s all about improving product qualityas well as boosting both productivityand flexibility – the main aims ofLevel 2 systems that are based onmathematical and physical processmodels.

As a vital part of quality assurance,process control systems must notonly optimize processes, but alsoensure product and production dataaggregation for the plant.

Just like other automation levels, the SMS Siemag Level 2 systems are independent of the underlyinghardware structure. It enables you to distribute the individual functionsover several computers, or to concen-trate on one powerful computer. Todo this, the system uses a CORBA-based abstraction level, the SMSSiemag CBS framework. The CBSframework features its own commu-nication function with the externalsystems, e.g. multi-plant productionplanning, to maintain high connectionflexibility.

TECHNOLOGICAL

PROCESS MODELS

Crucial for an optimal rolling processis accurate pre-setting of the roll gap.Getting this wrong can lead to pro-duction delays and longer cuttinglengths.

Modules of the Level 2 system.

13

Course of the pass scheduleand set value calculation.

Typical Level 2 report.

Differences between the pre-set values calculatedand the values measured during rolling are balancedout in stages by short and long-term adaptation func-tions in the Level 2 system.

PRODUCTION DATA AGGREGATION

AND REPORTING

Operating and product data aggregation is based onthe process events of the Level 1 system. First, theLevel 2 system tracks all products in the entry areaof the mill stand, along with their current status. Second, this data is applied in plausibility checks forthe production sequence and to generate product-specific values for the rolling and production process.Then the relevant production and product data issaved in a database where it is available for produc-tion analyses, quality and product reports.

LEVEL 3 PRODUCTIONPLANNING SYSTEMSLEVEL 3 PRODUCTIONPLANNING SYSTEMS


14

Maximization of overall production ratePlanning and minimization of inventories for interim productsUniform, multi-plant product trackingCumulative quality control up to final qualityapprovalIncrease of delivery date compliance

MANUFACTURING ORDERS

You can rely on our systems to convert customerorders into technically executable manufacturing projects. According to customer specifications, anextensive calculation model generates the manufac-turing data for the product ordered.

Definition of the necessary production steps and possible plant alternativesDefinition of the dimensions and quality of the initial and intermediate productsPlanning of the output of every production stageto determine the necessary quantities of inputmaterialDefinition of sampling and test regulations

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 Time Enter-prise” (RTE), a method that checks and responds tothese changes in real time.

The restrictive factors are the technical and techno-logical limits of the plants, which we have to takeinto account during program planning. That, in turn,creates a demand for comprehensive productionplanning systems.

BENEFITS OF X-PACT® LEVEL 3

X-Pact® Level 3 provides plant operators with all thetools necessary for planning and control of the pro-duction process in metallurgical plants and rollingmills. An effective link between the commercial side of the business and the technological processautomation systems, Level 3 production planningoffers you these advantages:

From customer order tomanufacturing order.

Picklingline

CCM cold rolling mill

Batchannealing furnace

Skin-pass mill

Coiling line

Customer

Cold rolled strip

Manual packing

Manual packing

Pickled hot strip

Customer

Customer

Skin-passed, packed

cold strip

Packing line

15

THE FACTORY MODEL

A uniform planning system covering all areas isbased on a factory model. The factory model isimplemented in the planning system as an electronicplanning 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 the coldrolling 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.

Level 1 (unsafe partof controlsystem)

17


16

SAFETY STRATEGYSAFETY STRATEGY

Improving machine and plant safety is becomingmore and more important – worldwide. Legislationand standards demand the protection of people andthe environment.

Essential for safe operation of our products is a coordinated approach during planning and design.Together, the engineering and electronic systemsform the main elements in our safety strategy:

Layout of the danger zoneRisk assessmentThe electro-mechanical function „safety“Emergency Stop

The danger zone layout divides the plant into variousdanger zones. It indicates all the plant-related safetyequipment as well as the plant limits. The riskassessment identifies and evaluates all the possiblehazards inherent in a plant, and describes the neces-sary precautions. There is also an in-depth Emer-gency Stop plan drawn up for each plant.

Together with our customers, we worked out a practical solution with the safety control functionsoperating independently from the machine controls.This strategy also complies with all safety laws andstandards. Better still, it reduces the time and cost of testing, documentation, and commissioning. The safety control functions are extensively testedearly on, during the Plug & Work process.

Danger area layout.

Monitoring a dangerarea.

Machine safety.

Separation of safety functionsand control functions.

19


18

PLUG & WORKPLUG & WORK

Setting up a Plug & Work test in the test field.

Our long-established Plug & Work service is increas-ingly popular with our customers. Central to Plug &Work are production simulations that mimic realitydown to the smallest detail. Today, due to our long-standing experience in engineering and process tech-nology, we know exactly how processes behave andwhat regulators achieve which product qualities. Oursimulation system maps this complex interplay ofvariables for exhaustive tests of your system.

Plug & Work starts with module tests that put theindividual hardware and software componentsthrough isolated function checks. Next, integrationtests examine the fault-free interaction of the mod-ules. Unlike other suppliers who usually wrap up thepre-testing and resume only after the entire plant is finished, we use this valuable time to the benefitof our customers. Here’s how: We install the entireautomation system in one of our test fields and con-nect it up to a simulation system. Finally, all that’sleft to be done is to set up the customer-specificconstruction models of the plant including the kine-matic and dynamic parameters of the plant behaviorand the sensors. This is how we build a computer-aided simulation model to test the operating andprocess behavior of your plant.

The result: The operator feels he is working on theactual plant – all the operational procedures andprocesses are visualized in real-time. He can controlproduction virtually, but also learn maintenance rou-tines. Using this hands-on method, we fine-tune theautomation system in advance so you benefit fromsmooth running and perfect operability.

The solution palpably reduces commissioning times,as well as on-site corrections. Your operators appreci-ate the real-life training opportunity provided duringtesting because it’s an ideal way for them to preparefor their future work on the plant.

TRAINING

Intensive training of your personnel on new, complexsystems is a priority for us.

First comes the theory in the classroom, where ourexpert employees pass on their know-how to yourpersonnel. Also available for them is detailed trainingmaterial, so if necessary they can look things uplater.

We always organize an extra instruction session forthe operation and maintenance of the measuring systems installed in our automation solutions. Thatmakes sure each manufacturer’s specialists knowthe ropes. Second, after the basics, operator trainingcontinues during our Plug & Work process.

Only then do we follow up with on-site training atthe construction location. It’s standard procedure forus to include your employees in plant commission-ing, and as a result they get to know the systemsand processes on the ground.

Each training module builds on the last so that by the end of commissioning your staff will be able tooperate the plant reliably and independently. If faultsoccur, they will know how to pinpoint the cause andwhat to do about it.

Operator training.


20

MODERNIZATIONSTRATEGIESMODERNIZATIONSTRATEGIES

SMS Siemag has developed a strategy that ensuresproduction continues throughout alteration or mod-ernization work. Compared with conventional meth-ods, it gives you a much higher protection againstfailure, shorter commissioning time, steeper run-upcurves, and therefore an early return on investment.

REASONS FOR REVAMPS

Improved product propertiesBetter production/productivityReduced production costsIncreased availability

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 tech-nological values in the entire process

PROCEDURE

These are the main steps in a revamp project: Current state analysis, adaptation to plant operatingprocedures, conversion work planning, plant test,switch-over plan, re-commissioning, and optimi -zation.

CURRENT-STATE ANALYSIS

The first step to successful modernization is an in-depth assessment of the current state of theautomation system. Included is an examination ofthe sensory systems installed, to find out whetherthey can be re-used.

This check simultaneously determines how newsensory and measuring systems can be installed.Significant here is that the current state analysisexamines all the relevant electrical and automationsystem components as well as the complete tech-nological process sequence.

The second key stage is considering and selectinginterfaces to the automation systems and IT infra-structure that are to stay in place. Essentially, theknowledge gained here goes into a motor and com-ponent list, a technological process description, anda documentation of the interfaces for each conver-sion phase.

ADAPTATION TO THE

OPERATIONAL PROCEDURES

It’s quite normal that, over time, all plants developtheir own standard operational procedures. TheseSOP need to be carefully examined during the cur-rent-state analysis. They are identified and docu-mented on site in cooperation with the operatingand maintenance crew. Taking this as a basis, SMS Siemag and the people who work on the plantdevelop and agree on the new procedures.

PLANNING THE

CONVERSION PHASES

Together with you, we plan the phases for the majorconversion stages of mechanical, media, and electri-cal systems. These plans are mapped out in detailprior to the individual conversion steps.

Here again you benefit because maximization ofoperations carried out in parallel before, during, andafter production standstills minimizes overall stop-page times. Then, according to pre-defined mile-stones, each standstill is tracked and if necessaryre-planned by expert construction managers workinghand-in-hand.

21

SWITCH-OVER PLAN

Simply switching the signals at the interfaces is theeasiest way of changing plant operations over fromold to new automation systems. That’s what we doduring the modernization standstill – we shift thefield signals from the old to the new automation sys-tem. Invaluable here is that, in the course of mainte-nance standstills before the conversion, individualfunctions can be tested in advance. However,changeovers during standstills have a certain finality.It’s almost impossible to change back to the oldplant.

What we usually suggest, especially in the case ofcomplex interfaces and production-critical plant parts,is a switching plan. It allows testing of partial func-tions of the new automation system over severalplanned maintenance standstills prior to the conver-sion standstill itself.

Furthermore, the electronic version of the switch-over plan makes monitoring operation possible. Thisis how the relevant data and signals from the exist-ing automation system are aggregated and evaluatedby powerful monitoring systems. In highly criticalcases, the switch-over technology is designed sothat the entire plant can be switched over from theold to the new automation system without any majorproduction 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 conversions. You can rest assured that,due to our long-standing experience in commission-ing metallurgical plants, we can get your plant up andrunning again within a minimum timeframe.

The high point of the whole project is the plant run-up after the revamp. Yet, before this happens, weteam up with you to carefully plan production of thematerial quality and dimensions you require. The datarecorded during monitoring operation is applied topre-optimize our process models, clearing the wayfor immediate production start with saleable productquality.

What’s more, 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 further development and sign acooperation agreement that might even lead to excit-ing innovations! Many successful projects confirmthe effectiveness of our revamp strategies.

Old

PPS/L3

Process models / L2

Process control / L1

Remote IO’s

Remote IO’sPIOS

Process models / L2

Process control / L1

New

PIOS (Process IO Server)

Switch-over plan between oldand new automation.

23


22

SERVICESSERVICES

COMMISSIONING

Right from the start of the Plug & Work tests,our experienced engineers are on the spot inthe test field. As the final stage of the Plug &Work test, when the scope of supply and functioning has been confirmed, they test theautomation to make sure it’s perfectly ready for commissioning.

Essentially, commissioning on site consists ofthe following stages:

Cold commissioningHot commissioningSystem optimization during productionPerformance tests

Cold commissioning

Included in cold commissioning are all the activitiesnecessary for rolling the first strip. It concludes withthe first strip.

Hot commissioning

This starts with rolling the first strip. It’s the phasewhen all the mechanical and electrical functions aretested under load to check that the open and closed-loop controls are working properly.

Optimization of the systems

during production

This is when the parameters of all the systems areadjusted to ensure the new facility achieves therequired performance.

Performance tests

Finally, a test program we run through together withthe customer demonstrates that the plant meets thecontract specifications.

AFTER SALES SERVICE

Whenever you need us, we are always there to help – and it shows: in the form of our after salesservice. This keeps you in touch with our expertknow-how. Specially developed for X-Pact® Electricsand Automation, the ServicePortal SP/1 from SMS Siemag gives you special access to fast faultremedy.

Right from the start of commissioning, we set up a service portal for optimal plant support. It ensuresstable, protected communication between your andour own networks. Via this portal, the SMS Siemagexperts access your plant’s automation system togive you immediate support in the form of remotediagnosis and maintenance – worldwide and fromday 1.

Advantages of the service portal

Some 70 percent of faults can be corrected imme -diately. Alternatively, faults are isolated. Take forinstance faulty parts. Our experts can usually identifythem online, possibly deactivate them, and send aservice technician to replace them on site.

DOCUMENTATION

Central, continuous administration

of project documentation

We manage the entire order documentation in an MS Excel-based spreadsheet. It comes completewith a table of contents that gives you an easy andimmediate overview of the complete documentation.All the necessary documents, such as functiondescriptions, circuit diagrams, and operating instruc-tions are saved in this list at one central, structuredlocation. Also integrated are all the documents generated throughout the project. That means everydocumentation transfer gives you the full current status in electronic form.

The spreadsheet itself contains all the necessaryinformation on each document, e.g. file format, printformat, language, version, and life cycle. All you haveto do is to go straight to the center of the program,and you’ll find the document you want very quickly,then simply click on a link to open it. This is how the operator finds his operating manuals, the mainte-nance employee the data sheet for a sensor, and theprogrammer the software details for the automation.

Furthermore, once the project is completed, you cancontinue the documentation yourself and administernew documents or document versions.

Spreadsheet-based documentmanagement.

The service portal makes fast and secureremote maintenance possible.

A/3

15E

1500

/04/

11 .

Ky

. Prin

ted

in G

erm

any

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 EXPECTATIONS

“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.”

precise cold rolling electrics and automationsms-group.us/files/a-315e_precise cold...

Documents