EXTRACTS
FROM VARIOUS NEWSLETTERS
MODERNIZATION
OF COLD ROLLING MILLS
SMS group Extracts from various newsletters
CONTENTS
Contents
SMS Siemag is the right
partner for modernizations of cold rolling
mills. This has been
proved by numerous
references during the
last few years, some of
which are shown in this
magazine.
4
Intelligent solutions
for cold rolling mills
14Bilstein
Four-stand tandem mill
modernized
6CARBON STEEL
8
OAO Severstal
Higher yield and better
quality
10Ruukki
Tandem mill to receive
upgrade
11ArcelorMittal
Brasil
Expansion of cold strip
capacity
12Bilstein
Smart upgrade concept
16Rasselstein
Tailor-made modernization
17Rasselstein,
Andernach
Modernization of tandem mill
18Ilva, Cornigliano
Continuous exit section
installed
19Ilva, Novi Ligure
21Rasselstein,
Andernach
Relocation and revamp
21ArcelorMittal, Genk
Revamping of reversing mill
22Wickeder
Westfalenstahl
ire damage remedied as fast
F
as possible
24International
Steels Limited
Increasing annual
capacity by 40 percent
Higher drive power
20TKS, Dortmund
Modernization of PL-TCM
25KYCR
Coil Industries
Expansion of reversing
cold mill
2
CONTENTS
26STAINLESS STEEL
28Outokumpu
Prepared for new
33ThyssenKrupp
Nirosta Düsseldorf
For quality and stainlesssteel strip
requirements
29 VDM Werdohl
Large product unit
30Revamps in
Torshälla, Terni
and Krefeld
Experience that counts
32ThyssenKrupp
Nirosta Düsseldorf
Smooth modernization
34ArcelorMittal, Genk
Revamp of “CRM 4” completed
Digital reading
Order PDF version under
coldrollingmills@
sms-siemag.com
36Theis
Kaltwalzwerke
A world’s first: CVC plus
®
in multi-roll stands
37ThyssenKrupp
Nirosta Dillenburg
Higher productivity
IMPRINT
Publisher SMS group
38Register
Corporate Communications
Eduard-Schloemann-Straße 4
40237 Düsseldorf, Germany
www.sms-group.com
Cover photo Bilstein GmbH & Co KG,
Germany. Operator controls mill
operation of the comprehensively
modernized tandem cold mill.
3
COLD ROLLING MILLS
SMS group Extracts from various newsletters
Automatic work roll change device.
“Rotary Inspect“ inline inspection station.
4
Bending and shifting systems.
COLD ROLLING MILLS
INTELLIGENT SOLUTIONS
FOR COLD ROLLING MILLS
After the global steel boom of recent years, the market is going through
a phase of consolidation. Now is the right time to bring old plants
up to the state of the art to prepare for future tasks and challenges.
As a supplier of plant and equipment,
SMS Siemag offers its customers not
only integrated and new plants, but of
course also intelligent solutions for
the modernization of existing works.
For this, our portfolio includes extensive technology packages as well as
extra facilities for mechanical equipment, utilities, electrics and automation – all from a single source. With
Hydraulic valve stand module.
reference to some recent examples,
we would like to present various solutions for different types of plants.
The modernization of cold rolling
mills necessitates concepts that are
exactly tailored to the plant and to the
needs and requirements of the customer. Therefore, we team up with our
customers to develop modernization
solutions. Not only do our activities account for the technological and design
requirements, but as early as in the
project planning phase we draw up
and implement exact and detailed
schedules for manufacture, erection
and commissioning.
Our customers benefit from our
long-standing experience in the various fields of cold rolling mill equipment and technology. Besides a large
number of new plants built worldwide,
we have modernized over 40 cold rolling mills in a whole range of different
designs since 1995. Here are some examples.
i
SMS SIEMAG
the right partner for
modernizations:
reparation of tailor-made
P
modernization concepts
Competent project teams
Decades of experience in the construction and modernization of cold
rolling mills
Exact planning over the entire
project handling time
Extensive pre-assembly plus testing in our shops
Assignment of experienced erection
and commissioning teams
5
CARBON STEEL
SMS Siemag’s portfolio for carbon steel rolling comprises reversing
cold mills, compact cold mills and tandem cold mills, as well as
skin pass mills for tempering. Customers can rely on high quality equipment
and tailor-made solutions.
6
7
The four-stand tandem cold mill at
OAO Severstal gets an all-around revamp.
HIGHER YIELD
AND LESS OPERATION COSTS
SMS Siemag modernizes 4-stand tandem cold mill 1700 at OAO Severstal in Russia.
This will enlarge the product range, improve quality and increase the annual production.
Russian steel producer OAO Severstal
placed an order with SMS Siemag in
February 2014 for modernization of the
4-stand tandem cold mill 1700 at
Cherepovets works in northwest Russia. With replacement of the tandem
cold mill in 4-high design, operating
since 1963, annual production will be
increased by 200,000 t up to 1,300,000 t.
The modernization includes the opportunity of later coupling of the tandem
cold mill with a new pickling line.
Thereby OAO Severstal will be prepared
8
for increasing material requirements
of the customers, especially of the automotive industry.
SMS Siemag has supported numerous customers in adopting tandem
cold mills technologically to current
and future market demands. This experience combined with the expertise
as system supplier of mechanical,
electrical and automation systems has
essentially contributed to OAO Severstal choosing SMS Siemag as supplier.
SMS Siemag is going to replace the
four mill stands and the entry section
completely. On the entry side, a double
expansion head pay-off reel with strip
centering device and equipment for
strip head end preparation as well as a
roller press are installed. The roller
press helps to increase strip tension
prior to the first mill stand, especially
when rolling thicker strips, which is
beneficial to rolling of high strength
grades. The entry side coil car will be
additionally equipped with new hydraulic controls.
PRECISE AND EFFICIENT ROLLING
The core of the tandem cold mill is built
by four new mill stands in 4-high design,
providing the latest rolling technology by
SMS Siemag for precise and efficient
rolling. The technical configuration
comprises hydraulic gap and wedge adjustment, CVC® plus as well as positive
and negative work roll bending. In the
last stand strip, quality is optimized by
multizone cooling and DS system. SMS
Siemag has optimized the roll and interstand cooling according to up-to-date
findings, allowing high reductions.
Automatic work roll change devices
enable fast work roll change, whereby
idle times will be reduced. Especially
when looking on the intended later
coupling of the TCM to a pickling line,
realizing continuous operation, it is
important to keep production on a high
level. The back-up roll change will be
assisted by a new semi-automatic
change device.
NEW AUTOMATION SYSTEM
The first mill stand drive will be completely modernized with drive system,
motor and feeding by a medium voltage electronic frequency converter.
The remaining stands will be equipped
with new drive spindles. The existing
Leonard-converter as the gear of mill
stands 2 up to 4 as well as of the tension reel will be provided with a new
field weakening by SMS Siemag.
The tandem cold mill gets the latest
generation X-Pact® level 1 and level 2
automation. In addition, the technological measuring systems for strip
thickness, strip tension and rolling
speed will be exchanged. This complete solution provides for significantly
reduced thickness tolerances and offgauge lengths at the strip head and
tail ends, by setup value calculation on
the basis of the process model and the
mass flow control, both developed by
SMS Siemag.
Together with OAO Severstal a tailored operating concept was realized.
The electric lines will be supplied in
dust-proof containers. This simplifies
the integration into the existing surroundings and reduces efforts for the
customer.
Apart from the existing tension reel,
the exit section of the tandem cold mill
will be exchanged. To fulfill challenging demands on strip flatness, behind
stands one and four highly precise XShape flatness measuring systems
are to be installed.
REDUCED EMISSIONS
The tandem cold mill will receive a
modern mill stand cladding with a
most efficient fume exhaust system,
keeping the environment for the mill
operators free from emission. The mill
stand platform with hydraulic valve
stands allows good accessibility for
maintenance. Further, SMS Siemag is
going to install new high- and lowpressure hydraulic systems and to
modernize the existing emulsion plant.
New feed line filters and chain-type
magnetic separators clean the emulsion in an efficient way from the contamination of the rolling process. By
this emulsion consumption and operational costs are reduced.
For the challenging modernization
there is only one main shutdown of two
and a half month being scheduled. By
this revamp, OAO Severstal gets a
state-of-the art tandem cold mill, able
to meet given targets to the full extent
and being characterized by low maintenance, resource saving and efficient
operation. (Newsletter 1/15)
i
FACTS &
FIGURES
Year of commissioning Annual production Strip thickness 2016
1,300,000 t
5.5 – 1.5 mm (entry)
3.2 – 0.4 mm (exit)
Rolling speed max. 1,500 m/min.
Material grades carbon steel and
high-strength,
micro alloyed Si-steel
9
SMS group Extracts from various newsletters
COLD ROLLING MILLS
TANDEM MILL AT RUUKKI
TO RECEIVE UPGRADE
Tailored modernization concept
SMS Siemag is modernizing the tandem mill of the Finnish
steelmaker Ruukki at its Haemeelinna location. The cold
rolling mill is being equipped with high-precision adjustment systems.
The four-stand quarto tandem mill has been in operation
since 1972 and is the central facility for cold strip production at Ruukki. Here, carbon steel strips with widths ranging from 540 to 1,575 mm and maximum entry gages of
up to 6.30 mm are rolled down to final gages as thin as
0.30 mm. The annual capacity amounts to 1,250,000 t.
Before the contract was awarded, investigations were
performed by SMS Siemag with the aim of defining measures by means of which the quality level, productivity and
economic efficiency of the plant can be increased step by
step. In addition, Ruukki wanted to enlarge the portion of
high-strength grades in the product mix. On this basis, a
modernization concept was prepared in cooperation with
the customer.
In 1998, SMS Siemag had already equipped mill stands 1
and 2 with state-of-the-art hydraulic adjustment systems.
Within the scope of the current order, mill stands 3 and 4
are now being provided with hydraulic adjustment systems
which are characterized by high positioning accuracy, precise roll gap adjustment and good accessibility as well as
serviceability. Thus, performance and reliability of the tandem mill are again significantly improved.
All quality-relevant components are manufactured and
subjected to extensive tests in the SMS Siemag workshop
in Hilchenbach. This ensures smooth installation at Ruukki,
so that after just one short revamping shutdown period, the
plant can resume operation at the end of July 2013. (Newsletter 1/13)
i
EXPERIENCE
COUNTS
Sophisticated modernization concepts
by SMS Siemag help the customer
attain maximum improvement of the
plant performance at minimum effort
and costs. The experience of numerous business departments of SMS
Siemag have been incorporated in the
customized concept for modernization
of Ruukki’s tandem mill. Another
essential factor is the close cooperation and coordination with the customer throughout all project phases.
10
Cold-strip complex of ArcelorMittal
Brasil S.A., São Francisco do Sul.
Four-stand tandem mill before extension (entry side).
THE SUCCESS STORY
CONTINUES
ArcelorMittal Brasil extends cold-strip capacity to 1.4 million tons per year
ArcelorMittal Brasil contracted SMS Siemag to extend the
cold rolling mill in São Francisco do Sul in the state of Santa Caterina, Brazil, so as to be able to boost the annual capacity of the PL-TCM to 1.4 million t. Situated on an island,
the complete cold strip complex was built by SMS Siemag
in 2003, under the name of Vega do Sul, responding to an
order by Usinor (now ArcelorMittal) and CST, Brazil.
The Vega plant had originally been designed so as to permit capacity to be increased after successful placement of
the products on the Brazilian market. Today, the former
Vega do Sul ranks among Brazil’s leading producers of
high-quality hot strip. With the contract now awarded to
SMS Siemag, ArcelorMittal Brasil is implementing the original plan for mill extension. In keeping with the order, the
four-stand pickling line/tandem cold mill (PL-TCM), which
currently operates in semi-continuous mode, will be
equipped for fully continuous rolling. With this measure,
ArcelorMittal wants to boost annual production from currently 900,000 t to some 1.4 million t.
and the coil handling systems will be modified accordingly.
The side trimmer in the pickling line will be extended by two
knife heads and two scrap choppers. In addition, the emulsion system and the acid regeneration plant will be adapted
to the new situation.
REVAMPING IN JUST TWO WEEKS
All revamping work will be completed during a two-week
main shutdown of the mill. Then, in October 2010, the mill
will produce the first strip in fully continuous operation.
(Newsletter 2/09)
The four-stand tandem cold rolling mill in figures
Production data
Material
Strip width
deep-drawing steels, higher-strength steels
750 to 1,875 mm
Strip thickness
ingoing
1.2 to 4.8 mm
outgoing
0.4 to 2.0 mm
SHEAR, EXTENSION OF SIDE TRIMMER, MORE DRIVE POWER
Coil weight
max. 40,000 kg
For fully continuous operation, we will supply and install a
second tension reel, a drum-type shear and pinch roll units.
The new reel will be identical in design to the existing tension reel. The drive rating of the first stand of the tandem
mill will be doubled by the provision of a second motor. In
the exit section, the baseframes, the fume exhaust system
Technical data
SECOND REEL, NEW PINCH ROLL UNITS AND DRUM-TYPE
Stand type
Rolling speed
Rolling force
Capacity
four-high stands with CVC® plus
max. 850 m/min
30,000 kN adjusting force per stand
1,400,000 tpy
11
COLD ROLLING MILLS
SMS group Extracts from various newsletters
REVAMP OF BILSTEIN’S
TANDEM COLD ROLLING MILL
Smart upgrade concept for minimum production losses
SMS Siemag has developed a new revamp and modernization concept which, unlike conventional procedures, guarantees plant users significantly less production losses,
shorter commissioning, steeper ramp-up curves and thus
faster Return-on-Investment. For modernizing the fourstand tandem cold rolling mill of Bilstein GmbH & Co. KG,
Germany, SMS Siemag is implementing this concept in a
way that is tailored to the specific needs of the customer.
The essential steps of the concept are: inventory of the actual situation, engineering, installation of a process-IO
server (PIOS), integration test, revamp and optimization.
670 mm and thicknesses of 7.5 to 0.3 mm. The starting material is slit hot strip which, owing to different wedge profiles, poses high demands on the cold rolling process. The
modernization mainly aims at enhancing the plant’s availability, boosting production by 60,000 tpy, improving product quality and increasing the degree of automation.
The revamp activities are to be carried out during regular shutdowns. Three standstill periods of five weeks in total are available.
SMART UPGRADE CONCEPT
FOR MINIMUM PRODUCTION LOSSES
Supplied by SMS Siemag in 1969, the four-stand tandem
cold rolling mill to be modernized has meanwhile undergone several expansions. It rolls a wide spectrum of 400,000 t
of cold-strip products per year in widths between 320 and
Inventory of the actual situation. All mechanical and electrical components, all functions, processes and sequences
as well as the operating philosophy of the mill will be
checked and documented in the customer’s works.
Engineering. The engineering and subsequent manufac-
Plug&Work test.
The tandem cold rolling mill at Bilstein.
STARTING SITUATION
12
Old
New
PPS / L3
Process models / L2
Process control / L1
Process control / L1
Remote IO´s
PIOS
PIOS
(Process IO Server) =
“electronic terminal board”
M
Process-IO server.
Time
Modernization steps
at
SMS Demag
in the plant
Process models / L2
Production, %
Mechanically caused conversion times
115
100
Inventory
of situation
Electronic terminal
board “PIOS“.
Monitoring on old plant
Conversion and
optimizing phases
(stepwise)
Operation with
new plant
Integration
test
Engineering
Time
Modernization time schedule.
ture will be based on the exact data provided by the inventory and a description coordinated with the customer of
new functions, modified process sequences and the new
operating philosophy.
PIOS, the “electronic terminal board”. Almost simultaneously with the preparation of the engineering, a processIO server (PIOS) will be installed in the customer’s existing
plant during scheduled maintenance shutdowns. Representing the “heart” of an automation system – a kind of
electronic terminal board with software switch – it permits
to run the system in the shadow mode and to implement
step-by-step changeover to the new signal paths and/or the
new automation system. Operation in parallel with the old
automation system allows switchback to the old automation in case of deficiencies or problems. In this way, production is safeguarded!
Integration test. The complete hard- and software will be
installed in SMS Siemag’s test field, and will then be tested
and preset under realistic conditions by means of a simulation system. The simulation includes the existing mechanical components and those plant elements whose kinematic
behavior and dimensions were assessed in the inventory. At
the same time, Bilstein’s operating and maintenance crews
will be trained on the new system before it is started up.
Revamp and optimization. During revamping and subsequent optimization, the mechanical equipment as well as
the new functions and controls will be switched on, tested
and optimized, either completely or in part. Digital changeover at the PIOS makes it possible to restore the original
state and condition of the plant very quickly. After the new
functions have been thoroughly tested and optimized, the
“old” automation components will be removed for the new
systems to take over.
i
FACTS & FIGURES
The most important mechanical modernization
measures include:
ntry-end pinch roll set
E
Fitting all the stands with hydraulic adjusting systems
New gear wheel sets
Dry-Strip system in the exit section
Swingable bridle roll set in the exit section
A major part of the existing electrics and automation
will be replaced with new systems:
ulti-drive converter with modern synchronous motors
M
for stands and tension reels, and with asynchronous motors
for payoff reels, pinch roll units and bridle rolls
Main control pulpit, operating stations and visualization
system
Integrated automation system for sequence controls and
technological controls
Model-based level-2 system for setpoint calculation for
the entire mill
Thanks to this modernization concept, both Bilstein, the
plant user, and SMS Siemag can be absolutely sure that
revamping will go smoothly and that the goals pursued with
the modernization will be achieved within the specified
time. (Newsletter 2/07)
13
PROJECTS
SMS group newsletter 02 / 2013
HIGHER CAPACITY
SMS Siemag modernized a four-stand tandem mill for Bilstein, Germany.
Bilstein benefits from better quality and closer gage tolerances.
At Bilstein GmbH & Co. KG in Hagen-Hohenlimburg, Germany, SMS Siemag comprehensively modernized the fourstand cold rolling mill supplied by SMS Siemag in 1969. The
project involved the installation of new mechanical, electrical and automation equipment in several stages. The discontinuous rolling mill plays a key role in cold strip production at Bilstein, a company with a long-standing tradition. In
December 2010, Bilstein granted us the FAC for the complete revamp.
SMS Siemag specifically supplied the following
features from level-0 up to the level-2 system:
ulti-drive converters with modern synchronous motors
M
for the mill stands and tension reel, and with asynchronous
motors for the payoff reel, pinch roll units and bridle rolls
Main control pulpit, operation stations and visualization
system
Integrated level-1 automation system
Model-based level-2 system for setpoint calculation for
the entire mill
HIGHER CAPACITY, BETTER QUALITY
The main objective of the tandem mill modernization at Bilstein was to keep the plant at the latest state of the art and
boost annual production. Further targets were to improve
plant availability, increase the degree of automation and reduce the number of plant operators. In addition to these
aspects, the revamp was intended to safeguard and further
improve the product quality, especially in terms of gage tolerances and straight-edge coiling. A distinct improvement
was needed due to the fact that hot strip slit into two or
three bands with different taper is used as input material.
This posed a special challenge to our cold rolling experts.
The existing electrical and automation equipment was largely replaced by new systems as part of the modernization.
MODERNIZATION PROJECT IN FOUR CONSTRUCTION STAGES
SMS Siemag implemented the smart modernization project
in four stages to have only short shutdown periods. First,
the new controls for the media systems were installed.
14
During the two-week shutdown, preparatory work for the
installation of the mechanical equipment could already be
accomplished. The next phase of the project involved the
installation of new hydraulic adjusting systems and the
stand drives during a seven-day standstill.
CHANGEOVER OPERATION SAFEGUARDED PRODUCTION
A highlight of the second construction phase was the installation of the process-IO server (PIOS), which we refer to as
our “electronic terminal board”. Being the “heart” of the automation system, it permitted to run the system in the shadow mode and to change over step by step to the new automation system. The old automation system was kept live
and running in parallel. This allowed switchback to the old
system at any time. During a further regular standstill of
two weeks, the mechanical portion of the project was largely completed. It involved the installation of the entry-side
pinch roll units for stabilizing strip guiding, the exit-side
The automatic threading assistant
reduces off-size lengths.
bridle roll set and the payoff reel motors. During the last
phase, the new automation system could be completed.
Also during this phase, the operation in the changeover
mode ensured that, depending on the production requirements, it was possible to switch between the old and the
new automation system. This safeguarded production of
the four-stand tandem mill, having a key function within the
customer’s process chain, at all times, also during rampup for commissioning.
INCREASE OF ROLLING FORCE AND ROLLING SPEED
The installation of new hydraulic long-stroke cylinders
achieved a significant increase in rolling force by 30 % per
stand. The stand drives were refurbished with new gearwheel sets for raising the maximum rolling speed by 25 %.
The former DC drives have been replaced with modern AC
drive technology. This brings down the maintenance effort
significantly and improves control dynamics. In addition,
the existing operating concept based on local control stations was substituted by a central, ergonomically designed
control room.
AUTOMATIC THREADING ASSISTANT TRC®
Moreover, we developed an automatic threading assistant
TRC®, which is active during threading and unthreading. It
takes into account the wedge formation and the thickness
deviation at the strip head and tail, and ensures strip flatness and centered strip material travel. It controls the rolling force and corrects the roll-gap setting as a function of
the material properties, and helps reduce off-size strip
lengths by up to 50 %.
For improved strip drying, we installed a Dry-Strip system on the stand exit side. The stand exit area was complemented by a swingable bridle roll set for stabilizing the strip
tension there.
ECONOMIC EXPANSION OF THE PRODUCT PORTFOLIO
The new level-2 automation provides the customer with the
possibility of expanding the product range in an economic
way. As the pass schedules can be
pre-calculated with high accuracy,
rolling trials for new products can be
largely dispensed with.
TRAINING OF THE OPERATING
PERSONNEL
We instructed the operating personnel
of Bilstein during a four-week training
course on SMS Siemag’s rolling simulator to familiarize them with the new
automation. This was one reason why
the modernization measures could be
implemented so smoothly. Through
the simulation they understood how
the functions of the plant work, how to
handle them under realistic operating
conditions and how to control virtual
production processes.
i
BILSTEIN –
a name that
stands for cold
strip.
Bilstein GmbH &
Co. KG located in
Hagen-Hohenlimburg produces cold
strip in a wide range
of materials and
products. The spectrum ranges from
standard grades,
case-hardening
and special steels
SUCCESSFUL REVAMPING
through to micro-
As a result of the revamp, Bilstein has
been able to boost both production and
the yield of the plant and adjust the
product quality to specific customer
requirements. The new automation
systems in level 1 and level 2 not only
optimized threading and unthreading
performance but the entire process
control, enabling reorganization of the
shift crews. The future-oriented models in level 2 provide Bilstein the necessary basis for short-term expansion
of the product range to include new
materials. We owe the successful
completion of this modernization project not least to the excellent cooperation with the teams of Bilstein. (Newsletter 2/11)
alloyed, highstrength steels.
The company is
renowned as a
supplier of highly
specialized niche
products.
15
SMS group Extracts from various newsletters
COLD ROLLING MILLS
LONG-STANDING PARTNERSHIP WITH RASSELSTEIN
Success through tailor-made modernizations
Andernach-based Rasselstein GmbH,
a subsidiary of ThyssenKrupp Steel
Europe, is Germany’s only producer of
tinplate. Rasselstein and SMS Siemag
can look back on over 50 years of cooperation covering both the installation of new plants and the modernization of existing equipment. Since 1959,
SMS Siemag has implemented a total
of twelve successful projects with Rasselstein. In his paper, Paul Michels,
General Manager Tinning 1 at Rasselstein, reports about two demanding
revamp projects of the recent past. One
covered the two-stand DCR (Double
Cold Reduction) rolling mill and the
other one the five-stand tandem mill.
The tandem mill at Rasselstein
after modernization.
the revamped combined DCR mill was
installed and successfully put into operation in Andernach, Germany.
REVAMP OF THE DCR ROLLING MILL
Rasselstein had commissioned SMS
Siemag to relocate a DCR mill from
Dortmund to Andernach and to modernize this mill. The first step was to
dismantle the old components in Dortmund and to inspect them for their reusability. It was found that some of the
components indeed could be reused.
But at the same time, new equipment
had to be designed and manufactured
for integration into the overall concept.
Key mechanical equipment such as
roll stands, bending systems, and work
and backup roll chocks were remachined and pre-assembled in the Hilchenbach shops of SMS. SMS Siemag
was responsible for the sophisticated
project logistics relating to both the old
and the new mill components. Finally,
16
TOP QUALITY AND REDUCED OFF-GAGE
LENGTHS
The modernized mill meets highest
quality demands in terms of strip
thickness, flatness, roughness, cleanness and surface dryness. Productivity
was improved through reduction of
off-gage lengths. Extensive online
measuring systems plus the increased
degree of automation ensure stable
and reliable process control and top
strip quality.
UPGRADE OF THE TANDEM MILL
Put on stream in 1960, the five-stand
tandem mill produces cold strip in widths
from 600 to 1,080 mm and final thicknesses ranging from 0.10 to 1.20 mm
at rolling speeds of up of 1,830 m/min.
The focus of the 2008 modernization
was on the entry area of the rolling
mill and the mill stands. The entry area received a new walking-beam system, a lowering station and a payoff
reel. The roll stands were equipped
with new hydraulic adjusting systems,
new stand platforms and a new enclosure. The SMS Siemag package also
included a new fume exhaust system
with scrubber system as well as equipment for the HP and LP hydraulic systems including associated piping.
The mill was shut down at the beginning of September 2008 and went
back into operation already four weeks
later, followed by quick ramp-up and
successful availability tests. Thanks to
the measures implemented, strip
thickness tolerances and flatness
were improved while off-gage lengths
were diminished. (Metec Newsletter
2011)
COLD ROLLING MILLS – CARBON STEEL
The site of TKS Rasselstein in Andernach.
Rasselstein’s tandem cold mill (TCM) after revamping.
Rasselstein GmbH, Andernach, Germany
Modernization of five-stand tandem mill
The scope for this modernization job comprised the entry
section of the tandem mill, new hydraulic adjusting systems, a new stand platform and stand enclosure, a fume
exhaust system as well as HP and LP hydraulic systems
including associated piping.
The new concept for the entry section was developed in
no more than two months through in-depth discussions
with the customer. Both project teams contributed their experiences to achieve an optimal configuration because the
prevailing local conditions such as foundations and bay columns, and the equipment to be newly designed had a considerable impact on the new entry section. All of these aspects could be considered as early as in the project planning
phase. Already at this point, the equipment groups to be
pre-assembled were defined, later significantly reducing
erection time during mill shutdown.
PRE-ASSEMBLY AND FUNCTION TESTS
In the course of project implementation, SMS Siemag carried out extensive pre-assembly work and function tests.
All hydraulic adjusting cylinders were completely assembled in our shops and subjected to various standard function tests on our testing stand. In addition, some of the
cylinders were tested using the original control system.
Furthermore, all new platform components including
valve stands, piping and cabling as well as parts of the interconnecting piping in the area of the platform were completely assembled in our workshops. Upon completion, all
parts were disassembled suitable for final erection and
were delivered in due time for field installation.
The re-designed entry section including walking beams, coil lowering
station, payoff reel and entry group
was likewise pre-assembled and function-tested. Being an innovation, the
lowering station was additionally
started up in the SMS workshops using the original control system.
Thanks to these measures, excellently coordinated sequences and
highly motivated project teams, the
mill could go back into production on
schedule as early as the end of September 2008, after a shutdown of four
weeks. By the end of 2008, following
specified ramp-up and successful
completion of the availability test, the
mill achieved Rasselstein’s demanded
capacity and performance. (Newsletter 2/09)
i
Benefits
of manufacture
and functiontesting by
SMS Siemag:
Components manufactured in the SMS
Siemag workshops
in Hilchenbach
are subjected to
extensive function
tests. This ensures
equipment quality
and quick start-up.
If so requested by a
customer, the scope
of function-testing
can be extended to
include testing of the
functions of complete units including
their hydraulics and
automation.
17
COLD ROLLING MILLS
SMS group Extracts from various newsletters
PREPARED
FOR THE FUTURE
SMS Siemag installed a continuous exit section of the tandem mill
at Ilva Cornigliano, Italy.
As part of the modernization of the five-stand tandem cold
rolling mill No. 1 of its Genoa Cornigliano Works, Ilva placed
an order with SMS Innse for the supply, installation and
commissioning of the new continuous exit section. This
measure is one step to allow the mill to be operated as a
PL-TCM.
After a project handling time of only 16 months, erection
of the new continuous exit section started with the shutdown of the mill in December 2008. The new carousel tension reel had been designed, manufactured and supplied in
a mere 14 months, and was pre-assembled on the new
foundation during ongoing production.
The reel is able to wind coils with a weight of 45 t and a
maximum diameter of 2.5 m. Upon completion, the coils
are transported to the downstream production facilities by
the new coil handling system.
New continuous exit section.
18
Further extensive preparation work in this area was likewise carried out while production continued. This included
foundation work, pre-cabling, pipe routing and installation
of hydraulic valve stands.
The modernization scope included the complete new
exit equipment behind stand 5 such as rotary shear, carrousel tension reel, coil car, strapping and marking machines as well as a high-speed coil car for transport of the
finished coils.
The close cooperation with the customer was the key to
the success of this project. Through this modernization step
and further revamps still pending, Ilva will receive a modern
PL-TCM and will be well prepared for the future. (Newsletter 3/09)
The new carousel tension reel.
COLD ROLLING MILLS – CARBON STEEL
HIGHER DRIVE POWER
SMS Innse modernized a five-stand tandem mill at Ilva, Novi Ligure.
Ilva now is able to roll wider strip and therefore a broader product mix.
SMS Innse recently completed modernization work on the five-stand tandem mill at Ilva’s Novi Ligure operations. The upgrade was carried out in
two steps. First, in April 2009, the second stand of the tandem mill received
a new drive. In August 2009, modernization was completed with the installation of new drives on stands No. 3
and No. 4. In addition, SMS Innse
equipped the mill with a new entry
group which is located upstream of the
PL-TCM and is connected with the entry looper via a bridge.
Today’s cold rolling mills operate
within a wide speed range and at high
rolling speeds. Increasing demands
are being made on the performance
and capacity of tandem mills and, consequently, also on the stand drives.
This was the main reason why Ilva decided to revamp the work-roll drives of
its four-high cold rolling mill.
SMS Innse’s package covered the
design, supply and installation of all
mechanical drive components for the
three central roll stands of the tandem
mill, including the pertaining central
oil lubrication system. The mechanical
drive components included:
- Sieflex motor couplings
- spur-gear mill pinion gears
- drive spindles
The Sieflex motor couplings and
spur-gear mill pinion gears were
manufactured in the Hilchenbach
workshops.
Ilva is highly satisfied with the success of this measure because mill capacity could be increased. Plus, the
higher drive power now available enables the product spectrum to be extended. In its Novi Ligure operations,
Ilva can now roll wider strip as part of
a broader product mix. (Newsletter
1/10)
Combined spur-gear mill pinion gears in Ilva’s tandem mill.
19
SMS group Extracts from various newsletters
COLD ROLLING MILLS
Dismantling of old foundations in the area
upstream of the double-reel exit section.
Modular-design double-reel exit section
in SMS Siemag’s Hilchenbach shops.
Strip turning for inspection of top surface
and underside by means of “Rotary Inspect“.
ThyssenKrupp Steel, Dortmund, Germany
Modernization of five-stand PL-TCM
ThyssenKrupp Steel in Dortmund was
keen to revamp its semi-continuous
PL-TCM to continuous operation to
boost capacity and improve product
quality.
To enable continuous operation, the
exit section was re-designed and
equipped with a double-reel unit and a
coil handing system tailored to the
situation in the works. For quality control, SMS Siemag also integrated its
innovative “Rotary Inspect” inline inspection station. This ensures reliable
strip quality control.
As a result of these measures, production capacity rose from 165,000 t to
192,000 t per month. Another benefit
was that spare-parts stockkeeping
was facilitated because all key components of the new exit section correspond to those of the TAKO “sister
mill” which SMS Siemag had built at
ThyssenKrupp Steel’s Duisburg location in 2000.
staff involved in the project, both on the
side of the customer and of the supplier,
and active involvement of the SMS workshops, the shutdown could be reduced
from a planned four months to six
weeks. As early as December 31, 2003,
the mill was back in production, rolling
the first strip. (Newsletter 2/09)
INSTANT HELP AFTER
HEAVY FIRE IN NOVEMBER 2003
On November 26, 2003, the tandem
mill was seriously damaged by a major
fire. Thanks to the tireless efforts of all
20
The modernized tandem mill with
new double-reel exit section.
20
COLD ROLLING MILLS – CARBON STEEL
Rasselstein GmbH,
Andernach, Germany
Relocation and revamp of two-stand DCR mill
At its location in Andernach, Germany,
Rasselstein GmbH, a company belonging to ThyssenKrupp Steel, produces tinplate material for the packaging industry. Due to the shutdown of
various production units at the Dortmund location, the production capacity
in Andernach had to be increased.
Rasselstein GmbH took this step to
safeguard its market leadership in tinplate production and to cover the
packaging industry’s current and future demand for tinplate material. So
the two-stand DCR mill was relocated
from Dortmund to Andernach, and on
this occasion was extensively upgraded by SMS Siemag.
Following dismantling of the complete plant, key components such as
the mill stand, the bending system as
well as the work- and backup roll
chocks were remachined in the SMS
shops. Then, these facilities were preassembled together with newly supplied parts. Finally, the equipment was
supplied for final erection in the field.
Two-stand DCR Double Cold Reduction mills combine reduction in the
first stand with tempering (or skinpassing) in the second stand. This is
ideal for precisely setting the material
properties required for further processing. (Newsletter 2/09)
Relocated from Dortmund to Andernach:
the DCR mill No. 4.
i
CUSTOMER
BENEFITS
etaining and re-using components
R
of the old mill
Change of rolling direction
Processing of wider strips
Increase of coil weights
Short coil cycle times
ArcelorMittal Genk Stainless Europe, Belgium
Revamping of single-stand reversing mill
Back in 1988, SMS Siemag had built a
CVC® four-high reversing cold rolling
mill for the production of low-carbon
steel strip at Arbed in Dudelange, Luxembourg.
In December 2006, ArcelorMittal
Genk Stainless Europe contracted SMS
Siemag to extensively revamp the
“CRM4” cold rolling facility on the occasion of its relocation to Genk, Belgium,
and to make it fit for a new job and function, i.e. the rolling of stainless steel.
The mill in Genk made it possible for
the customer to cut production costs
and to increase the future production
capacity for stainless-steel strip.
The use of this reversing cold-rolling stand turned out to be economically very advantageous for the customer because the mill stand, major
parts of the mechanical equipment
and of the auxiliary and the secondary
facilities could be retained. ArcelorMittal Genk Stainless Europe now has a
powerful stainless-steel mill in fourhigh design. (Newsletter 2/09)
Reversing cold-rolling mill at ArcelorMittal
Genk Stainless Europe.
21
SMS group newsletter 02 / 2013
PROJECTS
Shining in new splendor:
the reversing mill after restoration.
FIRE DAMAGE REMEDIED
AS FAST AS POSSIBLE
After fire damage at the reversing cold mill of Wickeder Westfalenstahl GmbH,
SMS Siemag took on the restoration of the heavily damaged plant.
“Fortunately it happens rarely – but
sometimes it does. A seemingly unimportant mistake during ongoing production has disastrous consequences,
and a rolling mill catches fire. Keeping
the adverse effects for the plant user
as small as possible requires a lot of
experience. With its expert knowledge
and organizational skills SMS Siemag
was able to actively support Wickeder
Westfalenstahl GmbH, Germany, and
led a challenging repair to speedy success,” Klaus Grimm, the responsible
22
Project Leader Cold Rolling Mill Division, puts his experience in a nutshell.
The four-high reversing cold rolling
mill had been supplied to Wickeder
Westfalenstahl by the former SIEMAG.
It commenced operation in 1969 and
has repeatedly been modernized since
then. It is a multitalent, rolling a wide
material range from soft to higheststrength grades and clad material in
the medium strip-size area of up to
700 mm width to a minimum final
thickness of 0.15 mm.
During ongoing production, a hydraulic pipe at the coiler had been
damaged. Oil had emerged from the
pipe and caught fire. The flames had
quickly spread to the mill stand and
the drive side. The fire and fire-fighting
activities had both caused heavy damage to the vapor exhaust system including stack, mechanical and electrical equipment as well as to media and
measuring systems in the mill stand
area and on the drive side.
COLD ROLLING MILLS – CARBON STEEL
»OUR AMBITION WAS TO RESTORE THE ROLLING MILL
WITHIN A MINIMUM OF TIME:
SMS SIEMAG GAVE ITS BEST SUPPORT TO ACHIEVE THIS GOAL.«
Andreas Wellié, Manager Technical Services, Wickeder Westfalenstahl
After the loss had been verified,
Wickeder Westfalen­
stahl entrusted
SMS Siemag with the restoration of
the plant and the coordination of the
complete project which involved several suppliers. SMS Siemag supplied
the mechanical equipment and was
responsible for coordination of the
overall plant assembly.
INEVITABLE EXCHANGE
The measuring devices close to the
mill stand and the hydraulic valve
stands on the drive side had been seriously damaged by the flames and also
the extinguishing agents had partly to
be repaired or replaced. Mechanical
The four-high reversing cold mill stand
is ready to resume operation.
equipment such as the gear unit, drive
spindles, hydraulic adjustment system
and work roll bending system were inspected in the Hilchenbach workshop
of SMS Siemag. Seals and wear parts
were renewed. The complete hydraulic
piping in the mill stand area and on the
drive side had to be exchanged.
Just slightly affected by the fire
were the coil preparation station, carousel reel and recoiling line. In this
area, hydraulic valves and cylinder
seals were replaced as a preventive
measure. All components in the oil
cellar, such as the central oil lubrication system and oil-film-bearings lubrication system, were not directly
concerned, but were inspected as a
precaution and could resume operation after they had been thoroughly
cleaned.
The greatest challenge for SMS
Siemag was to meet the very tightly
calculated schedule of the project in
order to restore the operational state
of the reversing mill as early as possible. Another challenge was the existing documentation. During the many
years of its existence, the plant had
been modified several times. Some
documents had to be reconstructed in
i
FACTS &
FIGURES
MILESTONES
Order placement First coil September 1, 2012
March 18, 2013
Acceptance by Wickeder April 17, 2013
Westfalenstahl
As early as by the date of acceptance,
the mill had met the specified production data like minimum final thickness
at maximum speed for different grades.
Thus, the plant could be re-integrated
in the production process without delay.
cooperation with the project team of
Wickeder Westfalenstahl. Thanks to
an intensive and well coordinated cooperation between all participants, the
problems could be mastered in time,
and the reversing mill could resume
operation according to schedule.
(Newsletter 2/13)
[email protected]
23
SMS group Extracts from various newsletters
PROJECTS
PLUS 40 PERCENT
In February 2014, International Steels Limited (ISL), Pakistan,
selected SMS Siemag to extend its Reversing
Cold Mill (RCM). The two-stand Compact Cold Mill (CCM®)
will increase the annual capacity by 40 percent.
The four-high RCM of CVC® plus design by SMS Siemag is the first cold
rolling mill of its kind in Pakistan.
Since 2011, ISL has been producing
high-quality cold strip with widths
ranging from 700 to 1,250 mm and final thicknesses of minimum 0.25 mm
on this RCM. The annual capacity is
250,000 t. Precautions were made already in the planning phase of the
RCM to permit economical extension
of the plant to a two-stand CCM® later
on. These concerned primarily the layout of the foundations and media systems. ISL recently exercized its option
and awarded SMS Siemag the order
for an extension which will increase
the annual capacity by 40 percent.
NO CAPACITY ADAPTATIONS
SMS Siemag will supply the second
mill stand which is of identical design
to the existing one, as four-high stand
with hydraulic adjustment, CVC® plus
and work roll bending system. The
supply package of the second stand
furthermore includes the X-Shape
flatness measuring system. As the
capacity of the emulsion system has
been designed for two-stand operation right from the beginning, capacity
adaptation is not required. The only
thing to do is replace the exit-side
equipment such as tension reel and
coil car to permit installation of the
second mill stand. Torsten Seeger,
24
The RCM at ISL will be supplemented by a second mill stand to come
as CCM®. The second mill stand will be installed on the left side.
Project Manager of SMS Siemag,
comments: “The plant extension
schedule was made to keep the downtime as short as possible. ISL will be
able to start production on the CCM®
in mid 2015.”
Due to the geographical proximity
to ISL in Pakistan, Esmech Equipment
Pvt. Ltd., SMS Siemag’s Indian jointventure partner, will supply further
plant components, including equipment for roll changing, the interstand
area, enlargement of the mill stand
platform and stand enclosures as well
as valve stands for the LP hydraulic
system. (Newsletter 2/14)
i
CCM®
Compact Cold Mills
(CCM®) efficiently
close the capacity
gap between singlestand reversing mills
and tandem cold
mills. In the range
up to 800,000 t per
year, they optimize
investment and
operational costs.
www.sms-siemag.com/
cold-rolling-mills
PROJECTS
EXPANSION CONCEPT
KYCR, Bangladesh, enlarges its cold rolling mill, which SMS Siemag
supplied in 2002. Annual production is increased to 170,000 t.
KYCR Coil Industries Ltd., Bangladesh, placed an order with
SMS Siemag for the expansion of their existing CVC® plus
six-high reversing cold mill to become a compact cold mill
(CCM®). Since 2002, the single-stand reversing cold mill
(RCM), which had been supplied by SMS Siemag to KYCR
Coil Industries Ltd. in Chittagong, has been producing cold
strip with widths between 600 and 1,050 mm and final thicknesses of minimum 0.9 mm. Accordingly, this plant with
CVC® plus technology had been specifically designed to roll
thin strip which includes operation with thin work rolls having a minimum diameter of 200 mm for high reduction. The
existing RCM will be expanded to a two-stand CCM® with
CVC® plus in both mill stands. Thus, KYCR will increase its
annual production capacity to approx. 170,000 t. (Newsletter
2/14)
www.sms-siemag.com/cold-rolling-mills
KYCR will expand its RCM to a compact cold mill.
25
STAINLESS STEEL
The portfolio of SMS Siemag for stainless steel rolling comprises single-stand
20-roll mills in mono block and split block design. The CVC® plus 18 HS design
can be applied in single-stand mills as well as in tandem cold mills.
26
27
SMS group Extracts from various newsletters
COLD ROLLING MILLS
The “SG3” 20-roll cold mill of Outokumpu Nirosta in Krefeld is being revamped.
Modernization at Outokumpu Nirosta
A sprightly 45 - ready for new challenges. SMS Siemag revamps 20-roll cold mill.
Outokumpu Nirosta in Krefeld, Germany, has awarded to SMS Siemag,
Germany, an order to modernize the
20-roll cold mill “SG3” of type MB
21BB-61“. The order was placed at the
beginning of September 2014, with the
aim of technically updating the
45-year-old cold rolling stand and preparing it to deal with demanding new
rolling tasks.
The 20-roll cold rolling mill of stand
type Monoblock MB 21BB-61“ had
been supplied in 1969 by SMS Siemag
(previously Demag). It was modernized
in 1991. Following the closure of the
Outokumpu works at the DüsseldorfBenrath location, the production previously carried out there, for example
thin mirror-finish material, is being
transferred to the Krefeld works.
REVAMP OF THE COLD ROLLING MILL
The “SG3” 20-roll cold mill, with a
strip width of 1,570 millimeters, and
strip gages of max. 10.00 millimeters
in the entry section and min. 0.50 millimeters in the exit section, will continue to be used for the production of
high-grade special-steel strips made
of austenitic, ferritic and martensitic
28
materials. The mill’s future rolling
tasks will include, in particular, thingage ferritic strips in high-gloss quality (2R bright-annealed). The cold
rolling mill needs to undergo a certain amount of conversion work in order to satisfy the preconditions for
manufacturing mirror-finish material. The SMS Siemag supply scope
comprises changes to the entry and
exit sides and on the millstand itself.
To achieve the desired strip surface
quality, the existing squeezer system
is to be converted to a dual-cassette
wiper system, including changing device, which can be operated with various types of coated wiper rolls. One of
the aims of the conversion work is to
enable the entire thickness range to
be rolled at maximum rolling speed.
The existing strip cooling system will
be equipped with a volume control so
as to allow pre-setting of different
rolling-oil quantities, depending on
the pass schedule. The axial shifting
system of the first intermediate rolls
is to be renewed in the millstand. The
plant is also to be provided with a new
millstand door and new exhaust
hoods. The pinch roll situated at the
entry end will be replaced by an adjustable, swiveling pinch roll. This will
make it easier for the strip to be
threaded into the stand. The exit end
too will be provided with a bending
and pinch roll. Furthermore, new carry-over tables will ensure that the
strip head end can be inserted directly into the reel slot. The above work
will help to achieve safe, gentle and
Still in good shape after 45 years: the mill
stand door. But it’ll be also renewed.
28
rapid threading and tailing-out of the
strip and thus ensure the efficient operation of the rolling mill also in the
future.
Besides the equipment described
above, the SMS Siemag supply scope
also comprises the dismantling of the
components to be replaced, the performance and supervision of erection
of the new equipment items, and the
commissioning of these items. A tight
time schedule has to be observed
here, since the commissioning of the
modernized mill is to take place already in July 2015, following a revamp
shutdown of 21 days.
This is already the fourth order
within a period of a few years for the
revamping of a 20-roll cold mill,
awarded to SMS Siemag by customers in Germany, and is powerful proof
of the confidence in the ability of SMS
Siemag to carry out modernization
work. (Newsletter 1/15)
Facts + Figures
Mill stand type
MB 21BB-61“
Material
Martensites, austenites,
ferrites
Strip width
1,570 mm
Strip thicknessMax. 10.00 mm (ingoing)
Min. 0.50 mm (outgoing)
Coil weight
Max. 26 t
Rolling speed
Max. 500 m/min.
Revamp of 20-roll cold mill
VDM Metals, Germany
In April 2014, VDM Metals GmbH, Germany, commissioned SMS Siemag to
upgrade its 20-roll cold mill for highperformance materials. The splitblock rolling mill of size SB 33-30” was
supplied by SMS Siemag and has been
in operation since 2002. On this mill,
VDM Metals rolls a broad material
spectrum of nickel-based and high-alloy special stainless steels from a
width range between 350 and 750 millimeters down to foil thickness with a
minimum final gage of 0.02 millimeters. The revamp will include modifications in the entry and exit sections and
in the flatness control system area.
The split-block 20-roll cold mill of VDM Metals will undergo slight modification.
29
COLD ROLLING MILLS
EXPERT SINCE 1950
SMS Siemag has more than 50 years in experience
of installing 20-high cold rolling mills.
Three modernization examples prove the know-how.
30
20-high cold rolling mills have been part of SMS Siemag’s product portfolio since the 1950s. Right from the beginning,
SMS Siemag has constantly optimized many of the technical details of these rolling mills to better measure up to the
needs and requirements of cold-strip producers. The achieved key developments contribute to higher productivity and
significantly improved product quality.
These developments are not only suited for new plants, but are also used to modernize existing facilities. The installation of individual systems, for example new rolling-oil wipers, is just one of many modernization solutions. As can be seen
from the following examples. (Newsletter 2/09)
Example 1:
Example 2:
Revamp of MB23-56“ mill
at Outokumpu Nyby
ThyssenKrupp Acciai Speciali Terni
MB22-49“
The 20-high cold rolling mill at Outokumpu Nyby in Torshälla, Sweden, was modernized to give it more reliability in
meeting the thickness tolerances and to improve the strip
flatness. Supplied by SMS Siemag back in 1956, the rolling
mill rolls stainless-steel hot and cold strip of the AISI 300
and AISI 400 series in widths between 700 and 1,400 mm
and a final gage of minimum 0.2 mm.
Mill modernization was implemented in several steps.
First, the stand was dismantled in just three days. On this, it
was mechanically overhauled and equipped with modern
actuators for roll and crown adjustment in our workshops.
Finally, it was re-installed and put back into service. Thanks
to our tailor-made revamping schedule, production losses
could be minimized. While the stand was being modernized
in our shops, the entry and exit areas were revamped in the
customer’s works so as to enable the handling of coils with
larger diameters. In addition, a new hydraulic station was
provided. Due to the narrow space conditions, it had to be
located on top of a steel structure.
In the second revamping phase, SMS Siemag modernized the axial shifting system of the inner intermediate rolls.
The new hydraulic adjusting system featuring automatic
coupling of the rolls is ideally suited for highly dynamic influencing of the strip flatness.
This mill, originally built in 1957, was installed in Terni in
1974. For modernization, SMS Siemag made provisions
to enable the handling of larger coils (higher coil weight,
larger coil diameter), and equipped the rolling mill with a
new rolling-oil filtering system and modern strip-thickness control systems. The electrical equipment was upgraded while retaining the main drive ratings. Today, this
rolling mill produces stainless-steel cold strip and, due
to its modular design and drive rating, is particularly
suited for the rolling of titanium strips.
Example 3:
Revamp of MB22-52“ mill (SG 2)
at ThyssenKrupp Nirosta, Krefeld
The size MB22-52“ (Mono-Block) mill built by SMS Siemag in
1963 was originally equipped with all then-modern adjusting
or control elements. Our key revamping measures included
the provision of a new hydraulic adjusting system, a crown
adjusting system, an axial shifting system in push-push design, a new media platform with hydraulic controls, new rolling-oil wipers as well as thickness and flatness measuring
systems including control. The goal was to bring productivity
and especially product quality up to current standards.
31
COLD ROLLING MILLS – STAINLESS STEEL
Just 18-day downtime – Smooth
modernization at ThyssenKrupp Nirosta
SMS Siemag extensively modernized the 20-roll cold mill,
size MB21BB-64”, which had been erected in the Düsseldorf-Benrath works of ThyssenKrupp Nirosta in 1976.
The modernization focused on the area of the mill stand
which was equipped with a hydraulic roll adjusting system,
an axial shifting system for the inner intermediate rolls,
and a new media platform.
Advantages of the high-tech components. The hydraulic
roll adjusting system permits closest strip thickness tolerances to be met. The crown adjusting system serves to
adapt the roll gap to the entering strip and thus attain top
strip flatness. The axial shifting system of the inner intermediate rolls helps perfect the rolling result right up to the
strip edges and facilitates roll changes. The all-in-one media platform is characterized by easy maintenance.
The new stand components were completely manufactured, pre-assembled, and tested in the SMS Siemag workshop in Hilchenbach. Thus, final installation could be accomplished within a single plant downtime of just 18 days.
Commissioning progressed as scheduled and was completed 17 days ahead of the contract deadline by granting
the FAC on February 6, 2012. (Newsletter 3/12)
“FITTED WITH THE NEW HIGH-TECH COMPONENTS BY SMS SIEMAG, THE
20-ROLL COLD MILL IS PERFECTLY PREPARED TO MEET THE RISING DEMANDS
OF OUR CUSTOMERS, ESPECIALLY IN RESPECT OF THE STRIP QUALITY.”
Peter Großmann, Manager Production at ThyssenKrupp.
First strip rolled on January 7, 2012, after a conversion period of just 18 days.
32
High-tech stand
components for
ThyssenKrupp
Nirosta, Düsseldorf
For quality and stainless-steel strip
Pre-assembled mill stand in the Hilchenbach
shops of SMS Siemag.
ThyssenKrupp Nirosta GmbH, Germany, contracted SMS Siemag in February 2011 for the upgrade of the 20-roll
cold rolling mill “SZ 1600” of its Düsseldorf-Benrath works.
Once again, TKN counts on SMS
Siemag competence in the modernization of this type of mill. The SMS
Siemag Mono-Block of size MB21BB64“ has been in operation since 1976.
Modernization of the stand area.
The upgrade measures will focus on
the mill stand which will receive a hydraulic roll adjusting system for closest strip thickness tolerances, a hydraulic crown adjusting system and a
hydraulic axial shifting system for the
inner intermediate rolls.
Crown control. Hydraulic crown adjustment is implemented through servo-controlled adjusting cylinders ensuring good flatness and optimal
adaptation of the roll gap to the material profile.
Axial shifting of the inner intermediate rolls. Hydraulic axial shifting of
the inner intermediate rolls allows to
achieve a perfect rolling result right up
to the strip edges. Axial shifting of the
inner intermediate rolls is accomplished by means of a push-pull system. This facilitates roll changing because the inner intermediate rolls no
longer have to be uncoupled by hand.
New media platform. The “SZ 1600”
will also receive a new media platform
in All-In-One design. Our media platform is characterized by a compact
modular design and maintenance
ease. The valve units for control of the
hydraulic functions will be integrated
together with the piping.
Manufacture with pre-assembly plus
testing. All new components of the
stand will be manufactured in the Hilchenbach workshops, and pre-assembled and tested including their piping.
Thanks to pre-assembly and testing in
our shops, the time and work needed
for final installation and commissioning
in ThyssenKrupp’s Benrath works will
be reduced to an absolute minimum. As
a result, TKN will be able to roll the first
strip already at the beginning of January 2012 after a mill stoppage of just
17 days. (Newsletter 3/11)
Technical data
Stand type
Size MB21BB-64“
Material Austenitic, ferritic, martensitic strip
Strip width 650 to 1,650 mm
Strip thickness
Ingoing
2.0 to 8.0 mm
Outgoing 0.5 to 6.0 mm
i
ADVANTAGES
of our stand components
etter dynamics of the actuators
B
and adjusting elements
Improved positioning accuracy,
hence better reproducibility of
product quality
Greater adjusting precision
Less wear
Closest strip thickness tolerances
and minimum off-gage lengths
Closest strip flatness tolerances
Easier roll changing
33
Relocated and modified
RCM.
Device for automatic and
fast work roll change.
34
COLD ROLLING MILLS – STAINLESS STEEL
REVAMP OF “CRM 4”
IN GENK COMPLETED
ArcelorMittal Genk Stainless Europe issues PAC
On September 19, 2008, Arce­lor­Mittal
Genk Stainless Europe granted SMS
Siemag the PAC for the revamping of
the “Cold Reversing Mill CRM 4” at its
location in Genk, Belgium. The project
is now in its final stage. The first coil
had already been rolled in April 2008
after a short erection time.
REVAMP WITH A MOVING HISTORY
The mill stand now revamped had
been in operation at ArcelorMittal
(previously Arbed) in Dudelange, Luxemburg, since 1988. Supplied by SMS
Siemag, it originally was a CVC® fourhigh reversing cold rolling mill for the
rolling of low-carbon steel strip. ArcelorMittal then decided to relocate this
mill stand to its operations in Genk. In
December 2008, ArcelorMittal Genk
Stainless Europe (formerly Ugine &
ALZ) contracted us to extensively revamp the “CRM 4” reversing mill and
to make it fit for a new job and function, i.e. the rolling of stainless steels.
COSTS DOWN, CAPACITY UP
The facility in Genk makes it possible
for ArcelorMittal Genk Stainless Europe to cut production costs and increase the future output of stainless
steel strip which is used, for instance,
in industrial applications, for the manufacture of household goods and in the
automotive industry.
THE REVAMPING MEASURES
For the revamp, the existing CVC® plus
shifting systems were modified to
make them more compact. On the
stand entry and exit sides, we provided
holddown rolls, pinch rolls, leveling
and bending rolls as well as an oil wiper unit. In addition, the mill received
new reversing coilers, two coil cars
and two coil deposits.
MODIFIED ROLL CHANGING EQUIPMENT
Normally, stainless steel strips are
rolled in multi-roll cold mills. The use
of a four-high reversing mill for this
task necessitates a suitable rollchanging system. That’s why the roll
changing facilities had to be modified
so as to enable automatic roll changing. The roll changing car now has two
cassettes which can accommodate a
total of four roll pairs. The number of
rolls on the car was thus doubled
compared to the conventional design.
The revamping measures were
completed by the installation of an automatic oil-air coupler and a paper
winder. The hydraulic systems and the
safety equipment were adapted to the
new local conditions. All new equipment was supplied and installed within 12 months. (Newsletter 3/08)
Technical data
Material
Austenite, in the
future also ferrite
Strip width
800 to 1,600 mm
Strip thickness,
Ingoing
max. 5.0 mm
Outgoing
min. 0.6 mm
Coil weight
max. 36 t
Technical data
Stand design
Four-high CVC® 4-HS
Rolling speed
max. 800 m/min
Rolling force
22,000 kN
Drive rating
11,500 kW
Reversing coiler No. 1 1,775 kW (2x)
Reversing coiler No. 2 1,775 kW (2x)
Backup roll drive
Rolling capacity
2,200 kW (2x)
200,000 tpy
35
The tandem cold mill.
A WORLD’S FIRST: CVC® PLUS
IN MULTI-ROLL STANDS
For quality and stainless-steel strip
NEW APPLICATIONS
Theis Kaltwalzwerke GmbH in Hagen
produces cold-rolled quality and stainless-steel strip in widths of up to 650
mm on a tandem cold rolling mill
which has recently been modernized.
SMS Demag – for the first time ever –
successfully installed the CVC® plus
technology in this mill’s four-high
stands which use changeable multiroll inserts.
Work-roll diameters of 85 to 100
mm in multi-roll operation. The conventional four-high tandem mill allows
the rolling mode in mill stands 3 and 4
to be varied by adopting so-called
36
multi-roll inserts. Unlike the conventional four-high mode which uses
work rolls with diameters of 275 to 310
mm, the multi-roll mode employs
work rolls with diameters of just 85 to
100 mm which are laterally supported
by means of rollers. This allows the
spectrum of rollable final gages to be
expanded, especially for higherstrength steels.
CVC® plus technology as a flexible
control element. This necessitates a
strip-flatness control element (actuator) with a flexibility as ensured in particular by the CVC® plus technology.
For each of the two operating modes a
CVC® plus roll contour was determined
which covers the entire roll crown
range for the respective mode. While in
four-high operation the work roll is
used as CVC® plus roll, this job or function is taken over by the driven intermediate roll in the multi-roll mode.
All flatness requirements met.
wWhen using the proven CVC® plus
technology in combination with roll
bending, all flatness requirements can
now be satisfied reliably and reproducibly. This applies to soft IF grades as
well as to austenitic stainless steels
with strip widths between 320 mm and
650 mm. (Newsletter 2/07)
Separately adjustable hydrostatic support elements.
High-performance oil wiper unit
for ThyssenKrupp Nirosta Dillenburg
In cooperation with Voith GmbH, SMS
Siemag developed a new squeegeeroll system for 20-high cold rolling
mills and put it through a first series of
tests in ThyssenKrupp Nirosta’s works
in Düsseldorf-Benrath, Germany.
Won over by the excellent test results, the customer decided to have
the new Nipco™ oil wiper unit installed
in one of ThyssenKrupp’s other cold
rolling mills.
In May 2011, ThyssenKrupp Nirosta
GmbH commissioned SMS Siemag to
supply our Nipco™ unit for its German
Dillenburg works to replace the existing entry- and exit-side oil wiper systems of the 20-roll stainless-steel cold
mill. The package comprises the supply of equipment, supervision of erection, commissioning, and trial operation. The revamp will increase the
mill’s productivity significantly.
THE NIPCO™ OIL WIPER UNIT
WITH SQUEEGEE ROLLS
Our new high-performance Nipco™ oil
wiper unit perfectly adapts to any and
all boundary or operating conditions. It
ensures a uniform contact pressure
through individual hydrostatic support
elements which are exactly set to suit
the width of the strip to be rolled. This
prevents any deflection of the squeegee rolls which often occurs in conventional wiper systems.
The Nipco™ oil wiper unit ensures
a uniform wiping effect across the full
width of the strip and hence a uniform distribution of residual oil on the
strip surface. As opposed to conventional wipers, it reduces the amount
of residual oil on the strip by 30 to 60
percent. While other types of oil wipers often limit the rolling speed, the
Nipco™ oil wiper unit enables a speed
increase. (Newsletter 3/11)
i
ADVANTAGES
resulting from the Nipco™
oil wiper unit
igher rolling speed
H
Less residual oil on the strip
Less cooling lubricant being
carried along
Longer service lives of the
squeegee rolls
Short revamping time
37
COLD ROLLING MILLS – STAINLESS STEEL
Register
Revamp matter and mill feature
Actuators
Automation system
Carousel reel
Chain-type magnetic separator
Coupling of TCM with pickling line (PLTCM)
Drive system
DS System
Entry side equipment
Exit side equipment
Extension
Filter system
Fire damage
Flatness measuring system
Hydraulic adjusting system, Hydraulic gap control system
Media platform, cladding and exhaust system
Mill relocation
Mill stand replacement
Nipco™ oil wiper system
Paper winder
PIOS (Process-IOServer)
Plug & Work
Rotary Inspect
Training
TRC© threading assistance system
38
Reference
Outokumpu Nyby
Theis Hagen
TKS Nirosta Krefeld
TKS Nirosta Düsseldorf
AM Genk Stainless
Bilstein
OAO Severstal
Ilva Cornigliano
OAO Severstal
Ilva Cornigliano
OAO Severstal (preparation)
Bilstein
Ilva Novi Ligure
Bilstein
Rasselstein
Bilstein
AM Genk Stainless
OAO Severstal
Ilva Cornigliano
AM Brasil
TKS Dortmund
AM Genk Stainless
ISL Pakistan
TKS Acciai Speciali Terni
Theis Hagen
ISL Pakistan
KYCR Bangladesh
TKS Acciai Speciali Teerni (rolling oil)
Wickeder Westfalenstahl
TKS Dortmund
KS Nirosta Krefeld
Rasselstein
Ruukki
Bilstein
OAO Severstal
TKS Nirosta Krefeld
TKS Nirosta Düsseldorf
Rasselstein
OAO Severstal
TKS Nirosta Düsseldorf
Rasselstein
AM Genk Stainless
OAO Severstal
TKN Nirosta Dillenburg
AM Genk Stainless
Bilstein
Bilstein
TKS Dortmund
Bilstein (Operating personnel)
Bilstein
PUBLICATIONS
Our new brochures at a glance
W6-309E_Nipco.qxp_Neutral 14.01.14 10:48 Seite 1
W6-307E_Kaltwalzanlagen_Edelstahl.qxd_Edelstahl 18.12.13 11:46 Seite 1
Nipco®
INNOVATIVE WIPER SYSTEM
FOR COLD ROLLING MILLS
SMS SIEMAG
COLD ROLLING MILLS
FOR STAINLESS STEEL
SMS SIEMAG
METALLURGICAL PLANT and ROLLING MILL TECHNOLOGY
METALLURGICAL PLANT and ROLLING MILL TECHNOLOGY
Innovative wiper system
Cold Rolling Mills
Further
publications
are available
from our
ordering service
Modernization
concepts for a
bright future
Published in German and English
Order No.: W6/309D or E
W6-304E_Reversierwalzwerke.qxp_Reversier-Kaltwalzwerke 14.01.14 10:53 Seite 1
REVERSING COLD MILLS
References
SMS SIEMAG
Published in German and English
Order No.: W6/307D or E
W6+7-304E_Dressierwalzwerke.qxd_Referenzen 14.01.14 10:57 Seite 1
SKIN-PASS MILLS
for a perfect finish
SMS SIEMAG
FLAT ROLLING MILLS
METALLURGICAL PLANT and ROLLING MILL TECHNOLOGY
Cold mills
Flat-product rolling mills
ONLINE
All publications of
the SMS group
can be ordered via:
www.sms-group.
com/en/print_material.php
Published in German, English or Russian
Order No.: W6/304D, E or R
Published in German and English
Order No.: W6+7/304D or E
Flat Rolling Plants Division
Wiesenstrasse 30
57271 Hilchenbach, Germany
Phone: +49 2733 29-1800
Telefax:+49 2733 29-1782
E-mail: [email protected]
Internet: www.sms-siemag.com
MEETING your EXPECTATIONS
W6-312E-NL-Sonderdruck Kaltwalzwerke · Published on February, 2015 / © SMS group / Circulation in English 500 / Printed in Germany
SMS SIEMAG AG
“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 these
characteristics 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 will
not have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.”