
Scope of Supply
Profile Mill Fingerprint
Advanced Service Offering
Customer :
Project:
:
Product
: Profile Mill fingerprint
Customer Ref.:

Scope of Supply
Page 2 of 9
ABB ref.:
Dated.
Contents
1. Service Description ...................................................................................................... 3
1.1 Life Cycle Index .....................................................................................................3
1.2 Technical Audit ......................................................................................................4
1.3 Key Features .........................................................................................................4
2. Scope of Supply........................................................................................................... 5
2.1 Life Cycle Index .....................................................................................................5
2.2 Technical Audit ......................................................................................................5
2.3 Data Collection ......................................................................................................7
3. Deliverables - Fingerprint Report ................................................................................. 8
4. Customer Benefits ....................................................................................................... 8
5. General Conditions ...................................................................................................... 8

Customer :
Project:
:
Product
: Profile Mill fingerprint
Customer Ref.:
Scope of Supply
Page 3 of 9
ABB ref.:
Dated.
1. Service Description
Profile Mill fingerprint is an audit service for profile or long products rolling mills in metal
industries, such as bar mill, wire rod mill etc. The fingerprint service includes a complete
life cycle audit for installed equipment coupled with detailed process and control
performance audit of the mill. The audit, thus, establishes the current mill performance,
compare it with industry benchmarks and recommend the improvement plan with
associated quantitative or qualitative benefits, as applicable.
The service offering has two modules as described below
1.1 Life Cycle Index
Life Cycle Index is a very efficient method of measuring and recording the effectiveness
of the plant automation, drives, motors etc. across their entire lifecycle. Taking a lifecycle
approach to hardware or software effectiveness gives a more accurate view of total cost,
productivity and investment protection. ABB’s Lifecycle Index helps customers sustain
and in many cases increase performance of their process control systems permanently.
To achieve results like this, companies need to go beyond the regular maintenance
cycles, and keep their control system regularly optimized and adjusted to the facility it
serves. This is exactly Lifecycle Index service does. The index generates process and
equipment profiles that form the foundation for ways to optimize the productivity and
future performance of the plant. E.g., the profiles include the overall lifecycle strategy,
control level, network controller, I/O, prevention, and emergency, as depicted in Figure 1
below.
Life Cycle
Strategy
Emergency
Strategy
Preventive
Strategy
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
Functionality
Personnel
Figure 1: Life Cycle Index for Mill Automation

Customer :
Project:
:
Product
: Profile Mill fingerprint
Customer Ref.:
Scope of Supply
Page 4 of 9
ABB ref.:
Dated.
1.2 Technical Audit
The fingerprint study includes a detailed technical analysis of various section of the mill
covering from the exit of reheat furnace to the downstream equipment. The technical
analysis is done using historical process data and state-of-the-art statistical algorithms to
evaluate the current performance of the mill. The analysis evaluates the performance of
drive control, looper control, mill pacing time, shear, pinch rolls, water box control etc.
The analysis of individual sections in turn generates the Key Performance measures for
overall mill indicating current performance and the gaps to improve in terms of energy,
productivity, quality, yield and mill availability.
Figure 2: Modules covered during technical audit
1.3
Key Features
Some key features of the profile mill fingerprint service are  Life Cycle assessment of drive and automation equipment
 Detailed quantitative performance assessment for control and process variables of
different sections of the mill
 Process performance benchmarking ensures tuning of plant control system
efficiently, benchmarked to industry best practices.
 Detailed improvement plan with potential impact on mill energy consumption,
productivity, yield, and availability.
Customer :
Project:
:
Product
: Profile Mill fingerprint
Customer Ref.:

Scope of Supply
Page 5 of 9
ABB ref.:
Dated.
2. Scope of Supply
Profile Mill fingerprint is an offline audit service to assess the current life cycle status of
installed equipment and mill performance .The outputs
and recommendations from the Life Cycle Index depend on the information collected
from designated mill personnel during the visit. The output and recommendations from
the technical audit module of the service is applicable for the mill operation conditions
(production speed, mill setup and configuration, product grade) and time period for which
the historical data is collected.
2.1 Life Cycle Index
The scope of Life Cycle Index module include the following areas –
a) Motors and Drives
b) Automation
c) Level 2
d) Technology
Each of the above mentioned areas include sub-categories such as maintenance
strategy, functionality, preventive strategy etc., as depicted in figure 1. Life Cycle Index is
an on-site investigation based on a pre-defined questionnaire set asked during the
interaction with designated plant personnel.
2.2 Technical Audit
The technical audit module of the fingerprint services uses the historical mill data
collected during the site visit for a fixed production speed, mill setup and configuration
and product grade. It analyses the process data with state-of-the-art statistical algorithms
to evaluate the process and control performance of the mill. The performance is
quantified with Key Performance Indices (KPIs) for different sections of the mill, which
may include –
a) Inter-stand Control (Looper, Tension, R-factor) – It analyses Inter-stand control
parameters, as looper performance, MTC performance, R Factor variation etc.
b) Motor & Drives – this section evaluates the performance of drives on the
parameters as speed response, impact drop, torque profile etc.
c) Tracking – This section focuses on tracking performances based on HMD signals,
torque signal of nearby stands etc.
d) Water box control – This section analyses the temperature control performance of
the water box

Customer :
Project:
:
Product
: Profile Mill fingerprint
Customer Ref.:
Scope of Supply
Page 6 of 9
ABB ref.:
Dated.
e) Shear performance – This section analyses includes cut cycle and tracking
repeatability of the shear
f)
Pinch roll – This section analyses torque and speed profile of the pinch roll during
the rolling to find out whether it grips the material properly
g) Input Billet Temperature Profile – It analyses the temperature profile of the billets
coming out of reheat furnace, and evaluate potential for thermal energy savings.
h) Mill Pace time analysis – Furnace pace time, mill pace time, downstream
equipment pace time analysis is done to reveal the potential (based on bottleneck
analysis) for improving the productivity by operating close to optimal pace time.
i)
Mill Speed Analysis – Mill speed analysis can be done to identify the potential of
increasing the production speed by utilizing the design capacity of motors with
same R-factor for each stand.
j)
Quantitative Assessment of overall mill performance – This section relates the
sectional KPIs calculated in modules above and calculates the overall mill
performance measures such as rolling energy consumption, productivity, yield
and quality impact, wherever applicable.
Figure 3: Snapshot for torque analysis summary for all stands

Customer :
Project:
:
Product
: Profile Mill fingerprint
Customer Ref.:
Scope of Supply
Page 7 of 9
ABB ref.:
Dated.
Figure 4: Illustration for shear performance analysis
Each of the sections, mentioned above, for technical audit quantifies the performance by
calculating pre-defined sectional KPIs. E.g. torque data analysis is done for large number
of billets for every rolling stand, the output of which is presented in the plot depicted in
figure 3. Figure 3 allows us to get the entire mill snapshot w.r.t. torque performance for all
stands. Figure 3 shows high number of peaks for stand 7 which can further be analysed
for possible reasons. Apart from such mill snapshots, histograms indicating the statistical
performance for a KPI are also included in the report as illustrated in figure 4.
2.3 Data Collection
The technical audit needs collection of pre-defined set of data. IBA data or any other
reliable data logger output in ‘text’ or ‘excel’ format can be used for the technical analysis.
Besides IBA data, the technical audit requires other mill information and data such as, but
not limited to –
a) Mill configuration – Number of stands, number of loopers, number of HMDs,
number of loopers and their distance relative to the reheat furnace outlet.
b) Furnace discharge pace time and downstream equipment productivity
c) Furnace energy rate
d) Motor and Roll Data – maximum rpm, gear ratio and roll diameter for each stand
e) Shear related data – shear blade diameter, gear ratio for shear motor etc
Customer :
Project:
:
Product
: Profile Mill fingerprint
Customer Ref.:
f)

Scope of Supply
Page 8 of 9
ABB ref.:
Dated.
Other set points, mill set up data or threshold values either from level -1, level-2 or
manual interaction
3. Deliverables - Fingerprint Report
The deliverable of the fingerprint is a report which contains the following information –
a) Life cycle index and recommendations for life cycle management. Figure 1 shows
the results of one such life cycle index which will further be appended with
recommendations with relevant implications of the proposed life cycle
implementation plan by the expert.
b) The report for technical audit module includes calculated process and control
performance indices depicted with snapshots as in figure 3 and figure 4. The
report also includes the expert analysis by comparing and correlating different
statistical measures among sections (modules). The analysis concludes with the
potential root cause of the control or process performance issues indicated by the
audit tool, along with the quantification of potential benefits by correcting those
issues, as applicable.
4. Customer Benefits
The fingerprint study helps the customer getting better insight into control and process
performance of their mill and provides further benefits as described below.
 Improvement plan provides clear path to quickly resolve the performance gaps
highlighting potential quantitative benefits
 Facilitates management decision process by focusing on high impact opportunities
for improvement.
 Provides a solid foundation for life cycle management for various equipment &
systems in Profile Mills
5. General Conditions
a)
Under this contract ABB agrees to provide fingerprint service for the agreed bar and
rod mill line installed in customer’s plant.
Customer :
Project:
:
Product
: Profile Mill fingerprint
Customer Ref.:
b)

Scope of Supply
Page 9 of 9
ABB ref.:
Dated.
The fingerprint outputs are valid only for the mill operation conditions (production
speed, mill setup and configuration, product grade) prevalent during the time for
which historical data is collected.
c)
The historical data is collected usually for 3-4 days and the study outputs are valid
only for similar mill operation (production speed, mill setup and configuration,
product grade).
d)
Travel expenses to be borne, at actuals, by the customer. Minimum 2 site visits are
required to the site, one for data collection (2-4 days) and another for results
presentation (1-2 days)
e)
Customer has to provide all the data required by ABB to do the service. The quality
of the fingerprint output depends on the quality and amount of data provided.
However, ABB will maintain the confidentiality of the data that is provided to ABB
f)
The fingerprint is an offline service with report including recommendations as a
deliverable. No hardware or software will be delivered to the customer.
g) Implementation of the recommendations or improvement plan in the fingerprint
report is not part of this service, but to be considered outside the scope of this
service.