As part of the project, a new F7 finishing mill stand was integrated into the line, while the hardware and software of the existing X-Pact® automation systems were completely upgraded. These improvements have enabled the plant to produce strip in thinner gauges and at higher quality standards, once again demonstrating SMS group’s collaborative approach throughout the entire plant life cycle.
Originally commissioned by SMS group in 2011, the CSP® strip plant has an annual capacity of approximately 2.5 million tons and produces hot-rolled strip in widths from 900 to 1,680 millimeters and thicknesses ranging from 16 millimeters down to 1 millimeter. With the addition of the F7 mill stand, the existing coil changing equipment was also adapted, optimizing rolling force distribution, particularly for harder grades, wider strip widths, and thinner gauges. The new stand reduced bottlenecks in the finishing mill section, enabled increased output for specific product groups, and allowed the continuous casting thickness to be maintained at more efficient levels.
Within the scope of the project, the mill stands from F1 to F5 were also upgraded, and a new hydraulically controlled pass line adjustment system was commissioned. Five laminar cooling zones were replaced with four reinforced cooling units featuring edge masking capabilities. The entire exit area was renewed, a new measuring house was installed, and the infrastructure was prepared for the future integration of a second multifunctional measuring system.
As part of the technical upgrades, SIEFLEX® gear-type spindles with an internal oil return line were integrated into the system. Thanks to advanced hardening technology, optimized tooth geometry, and a dedicated tribological system, these spindles can transmit up to twice the torque compared to conventional designs. The continuous lubrication system ensures effective cooling, eliminates the need for grease maintenance, extends equipment service life, and reduces downtime.
During the modernization, SMS group migrated the level 1 and level 2 automation systems to the powerful X-Pact® ProBAS platform based on X-Pact® Embedded controllers, and the existing human-machine interface was updated. Advanced process models within the level 2 automation system were implemented to maximize production efficiency and product quality. The X-Pact® Pass Schedule Calculation (PSC®) model generates precise rolling schedules aligned with production requirements, while the X-Pact® Cooling Section Control model provides fully automatic cooling, ensuring consistent material temperature throughout the process. In addition, the X-Pact® Profile, Contour, and Flatness model enhances process stability by enabling precise control of thickness and flatness tolerances.
From the first day after the revamp, 14 coils were rolled without any strip breaks, and by the sixth day the plant successfully achieved production of strip as thin as 1.2 millimeters. These early results, achieved despite a challenging shutdown period, highlight the success of thorough preparation and pre-commissioning tests.
Hendrik Trimborn, project manager at SMS group, stated that the close cooperation established with Tata Steel during the implementation, shutdown, and commissioning phases was decisive for the project’s success. He emphasized that open and trust-based communication enabled early identification of issues and the development of joint solutions. Trimborn also emphasized that the short and efficient commissioning phase exceeded the expectations of all parties, clearly demonstrating the value of a strong partnership.
The integration of the new F7 stand and the advanced X-Pact® automation solutions stands as a clear example of SMS group’s commitment to supporting its customers throughout the entire life cycle of their equipment and creating long-term added value.
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