Modernising the coupled pickle line/tandem mill at TKS Dortmund

With minimum downtime, Siemens modernised ThyssenKrupp Stahls coupled pickle line/tandem mill in Dortmund Germany, enabling the 30-year-old plant to rival the production quality of todays most advanced facilities.

AUTHOR: Peter Hopf Siemens AG

hyssenKrupp Stahl AG (TKS) is part of the carbon steel business unit of ThyssenKrupp Steel, which has been operating a tandem rolling mill in Dortmund, Germany since 1972. It produces quality steels primarily for the automotive industry, including an increasing proportion of the latest steel grades such as dual phase (DP) and transformation induced plasticity (TRIP) grades. Over the years, the company has been converting the mill in several stages to increase its capacity. An important step was coupling it with the pickle line in 1998. The companys next goal was to equip the mill to produce the same high-quality steel as TKSs continuous tandem mill in Duisburg, commissioned in 2000. When Siemens started the TKS modernisation project in 2001, the Dortmund plant had a mix of old and new components. The main drives were 30-year-old DC motors with analog controls. The converter-fed three-phase drive units in the coupling section dated back to 1997. Instrumentation made use of the latest 24V technology, but also included some old 220V sensors and the process peripheral equipment connected to the automation via hardware couplings and bus systems. Because of numerous minor conversions over the years, the plant was using a variety of different automation components, including automation technology from the 1990s. What is more, there was no central computer for process automation; instead, the plant relied on several computers from different vendors.

CONVERSION PLANNING
Siemens started by performing a detailed on-site review, and then worked with TKS to devise the conversion concept. As much work as possible was performed during maintenance shutdowns to keep the main shutdown time as short as possible. The hydraulic, cooling and lubrication systems were converted in stages during maintenance shutdowns before the main shutdown. Siemens also directly installed ET200 components in existing switchgear cubicles, preparing the ET200 on assembly

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panels that could then be installed in the old cubicles in a very short time during a maintenance shutdown. To minimise conversion time, the existing field bus was retained, even though it included parts from another manufacturer. Special bus connections allow the Simatic S7 to operate the Interbus. Siemens simply unplugged the bus cable from the old automation device and connected it to the new Siemens automation system during the shutdown. In the coupling section, the three-phase supply drive systems from Alstrom were also converted to the Siemens bus standard quickly and easily by exchanging the bus interface for a standardised Profibus interface. The flatness measuring system was re-used by simply replacing the interface connection with a Profibus card. To minimise costs expensive main drive power components such as motors and thyristors were re-used whenever possible. By connecting the plants 30-year-old thyristors to new digital control system, a whole series of analog cubicles were replaced by a single cubicle for dual motor control. The DC supply systems for the pickle line and the Simatic S5 automation measurement and control systems were left unchanged. Siemens linked the tandem mills reused DC roller motors, including the reused thyristors, to new all-digital Simoreg devices. The old DC reeling machine, on the other hand, was replaced completely by two new AC reeling machines with an indirect converter. Exchanging the interfaces for Siemens components allowed the reused DC and AC drive systems in the coupling section to connect to the new automation system. The conversion also involved completely replacing the basic automation system of the coupling section, tandem mill and new run-out section, including all technological control systems. This required an interface between the remaining functions of the pickle line and the new basic automation system. A new model-based SIROLL process automation system that could handle the entire plant replaced the old process computers. This resulted in a significantly simpler interface design. All converted sections now feature standard display and diagnostic systems.

FINISHING PROCESSES

r Fig.1 Main control pulpit

SINGLE-OPERATOR CONTROL OF THE MILL

All components are based on Simatic PCS 7 with WinCC as the standard control system for plant operation and fault diagnosis. The Simatic S7 provides control and regulation functions. New process peripheral equipment is connected via the ET200. The Simatic TDC automation system provides maximum computing power for technological control. Industrial PCs provide process automation. An open communications system exchanges data between the systems, using Profibus as field bus for peripheral equipment. Fast Ethernet serves as the process bus, backed by Simatic TDCs Global Data Memory for real time data exchange between the system controls. Siroll WinCC components were used for the joint display system, which features central power-up capability and a central signaling system that can be operated from any plant monitor. The plant also relies on the versatile Siemens thickness control concept, which uses the extended mass flow technique to ensure tight tolerances

under all operating conditions. The flatness control system makes use of neural networks that have a selflearning function, enabling them to adapt precisely to production requirements. Siemens paid particular attention to the design of the pickle line/tandem mills main control pulpit (see Figure 1). The high degree of automation in all operating modes allows a single operator to control the intermediate section, tandem mill and reeling machine, up to the removal of the coil from the mill. The fault diagnostic system provides the operator with relevant information in an easily understandable form, supporting fast reaction to changing situations.

INSTALLATION
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Integration tests using plant simulation are essential to success, especially in conversion projects. For the Dortmund plant, Siemens exhaustively tested the entire automation system, including all control consoles, in the test department in Erlangen before shipment. Then, the a

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FINISHING PROCESSES

q Fig.2 View along the mill stands

r Fig.3 Exit section of the modernised mill

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system was set up onsite in Dortmund two months before the main shutdown. This gave Siemens time to train TKSs operating and maintenance personnel. By carrying out ghost rolling with all production shifts, Siemens eliminated a host of problems that would otherwise have gone undetected until the plant was started up. Extensive preparation, proven systems, and expert installation management allowed the plant to start up ahead of schedule on 31 August 2003, after only a 34day production halt. After a few days, the plant exceeded the planned production figures. Analyses in October 2003 showed production quality levels comparable to those found in the most-advanced tandem mills. Figures 2 and 3 show the mill. On 26 November 2003, a major fire destroyed the entire tandem mill area, interrupting acceptance testing. The blaze affected all five rolling stands, the ventilation system, the roller installation crane, and the hall roof. Twenty different companies and 350 employees worked to repair the plant. Siemens supplied all rolling stand control

panels, plus decentralised process peripheral equipment, sensors and other components in the stand area. Renovation specialists from Siemens Industrial Services helped clean up all electrical equipment that was not directly affected. This made it possible to avoid downtime for many components. Original estimates suggested the plant would not be available for three months. However, the rolling mill started up again on 31 December, 35 days after the fire. Once production resumed in January, the acceptance tests were continued, with final acceptance in February 2004. Now that the Dortmund plant been brought up to match the state-of-the-art standards of TKSs Duisburg facility, TKS has two pickle line/tandem mills advanced enough to meet any customer requirement. MS Peter Hopf is Project Leader, Siemens AG, Industrial Solutions & Services, Erlangen, Germany CONTACT: roland.hensel@siemens.com

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