Professional Documents
Culture Documents
com
Greater production.
Higher quality. Lower costs.
Factors to consider
You should expect a great deal from your solutions partner.
Reliable equipment, process consistency, production
flexibility and waste minimization. All in one package,
managed from start to finish. All of these factors have
to be taken into account in designing the optimal solutions
for your mill.
Maximizing productivity
through process optimization
How much time is needed for each process step? What
temperature profiles are required? How can transfer areas
be made more efficient? For the best answers to these
questions, your rolling mill partner should have expertise
with equipment technology and know-how to optimize
complex plant layouts.
Flexibility comes first
Short delivery times and fast production changeover
are key criteria for you to meet your customers demands.
Thats why you need to be ready to convert your rolling
stands to the next order while still processing the current
one, and change your line from one product to another
with virtually no downtime.
Quality throughout
You can achieve very high precision with rolling stands
designed to withs tand high loads and changing temper
ature r equirements. That same capability, c oupled with
sophisticated control technology, allow a wide range of
process conditions for desired product qualities.
Cost reduction
Cost optimization has many facets, including processcontrolled yield maximization, downtime reduction and
maintenance cost controls. When the entire system is
managed through one source, you benefit from a high
degree of standardization.
Environmental influences
There are sound legal and cost reasons for conservation
of resources within your plant, such as water application
for temperature control. You should also evaluate your
solutions provider by how well they support you in this
area.
For many products, steel must first be processed in a long rolling mill.
Our job is to perfectly coordinate everything to ensure steel quality
and an exceptional level of mill productivity. As the pioneers of key
technologies in long rolling, we have the knowledge and experience
to provide the best solution for your mill.
Our experience in rolling mills dates back to 1886, with the founding
of Pomini in Castellanza, Italy, and 1888, when Morgan Construction
began U. S. operations in Worcester, Massachusetts. Siemens VAI
Metals Technologies continues to innovate all elements of plant
construction: Process, engineering, manufacturing, installation and
commissioning, plus life-cycle management. No other rolling mill
manufacturer can offer a comparable range of products, solutions,
or experience.
Advantages of our
long product rolling mills:
Maximum reliability, thanks
to 250 years of combined
experience
Thousands of roll stands
commissioned
Over 1,000 rolling mills installed
or upgraded on six continents
Verifiable expertise for all
elements of plant design and
construction
Global presence and economic
strength as a part of Siemens AG
Solution providers to cover
all aspects of long rolling:
Mechanical
Electrical
Automation
Fluids
Process and plant services
Metallurgical services
Services
In-house manufacturing
and testing of proprietary
technology equipment
One contact for all questions.
SIROLL LR
basic automation
system
Mechatronical
packages
Mechatronic solutions
in long rolling mills
Shear control
Temperature control
Pinch rolls
Morgan Stelmor conveyor
Reform area
Coil handling
Compactors
Bar counting
Laying heads
Stackers
Tyers and bundlers
Fluid systems
Inline measuring systems
Non-contact measurement systems.
Further stand-alone packages:
Flat Rolling Block
Compact multi-rougher
Rail pre-cambering.
Morgan Bar Reducing/Sizing Mill:
Fully automated control of stand change and roll parting
Fully automated control of drive system clutches
Automated setup
Lubrication systems:
Monitors temperature control and oil cleanliness
Operates under a wide range of ambient conditions
Incorporates vacuum dehydration.
Water systems/product temperature control:
Designed specifically for in-line water boxes
for product controlled cooling
Incorporates specially designed water valves
for high speed operation
Balanced design avoids water hammer
Compact, maintenance-friendly valve stands
Closed loop control
Direct interface with the SIROLL LR mill control system.
9
Coil handling
Morgan Stelmor
Cooling conveyor
Coil compactor
Cooling bed
10
Bar bundling
Pouring reel
Bar sizing
11
Rolling stands
12
Convertible stand
Compact roughers
Compact roughers can be used where space is limited
or if higher reductions are required. These roughers are
equipped with special shoe plates and clamps to allow
for minimized centers. Greater reductions are possible
by using the billets own beam strength to help it enter
successive passes. When the centers are close, the stands
can be shifted in and out of the pass line to adjust or
change the guides.
Features:
Small space requirement
High reductions possible
Easy guide change.
Reversing 2-high stands
A group of two stands can roll cast or forged billets in
horizontal-vertical arrangement. Every two passes, the roll
gap is adjusted and rolling direction changes. Reversing
roughers increase the process flexibility. Electrical equipment may be simplified by the use of asynchronous
low-voltage motors with multi-stage reduction units.
Sliding stands
Modern 2-high sliding stands, reversible and fully automated, represent an innovative solution for roughing and
intermediate trains. The rolling line remains fixed, while
pass is changed by the stand sliding movement. The roller
tables and bar manipulating systems are simplified.
The automated change of stand permits the use of off-line
prepared stands, which reduces down-times:
Sliding rougher
Features:
Fast stand and roll change
Simple foundations
Convertible stands
Todays mills can be used in a wide range of configurations
in order to provide an unlimited selection of products
from a single mill layout. Convertible stands allow either
horizontal or vertical positioning, with quick and automatic
selection, and are mainly used in the intermediate and
finishing trains, in accordance with production
requirements.
Features:
Less than two minutes to change position
Features:
Three possible arrangements for twist-free rolling:
horizontal, vertical and 45 (X)
Most compact stand design available on the market
13
14
Mechatronic solution
Fully featured mechatronic packages provide complete
and effective control of Siemens VAI Metals Technologies
bar sizing technologies to ensure guaranteed performance.
Features:
Higher mill utilization with multi-groove rolls
Features:
Full local and remote control options
Fully automated control of stand change and roll gap
Automatic setup
Other solutions
The Cantilever Sizing Stand is the simple solution for
a quick and economical project, to improve the size
tolerance at 90 to the last finishing stand.
Features:
Easy and economical installation in existing mills
15
Continuous finishing mill for rails and sections with Red Ring stands
Features:
Rails hydraulically clamped and lifted
Stacking systems
The layers of sections arriving from the straightening
and cold-cutting area are properly braked and buffered
onto the first transfer table of the stacking area.
16
Features:
Rigid frame contains two sets of double-supported
horizontal rollers
4-slit rolling
Slitting systems
Siemens VAI Metals Technologies powered slitters provide
highly accurate and consistent dividing. They allow rebars
to be rolled in multiple strands, significantly improving
the productivity of small size rebars, without increasing
their finishing speeds. Slitting rolls have ten times the
life of slitting guides, while offering higher speeds and
better accuracy. Divided strands may be finished in the
same rolling stands or individually, for better product
quality and tolerance.
Benefits:
Bar maximum delivery speed: 50m/s
Benefits:
Reheating furnace and rolling mill can also be operated
to full design capacity for small size rebars, which
become less costly to produce
Benefits:
Bar maximum delivery speed: 28m/s
18
Cooling beds
Cooling beds
Siemens VAI Metals Technologies cooling beds are
designed using standard elements that can be combined
in accordance with plant product mix requirements
and production capacity. Full mechanical component
standardization assures constant equipment quality,
as well as high performance levels.
Features:
Perfect repeatability of braking cycle, at any speed
19
Features:
All major drive components are below floor level,
thus reducing noise, improving visibility and providing
convenience for mill crews
New entry end drive arrangement allows easier access
to the motor and no restriction on motor size
Entry end drive enables disconnection of finishing line
shafts when not in use to minimize wear on high-speed
components
High-quality sealed roll housings provide reduced
maintenance and long life
Roll housings are easily lifted out for quick change times
Designed for thermomechanical rolling, with capacity
for low rolling temperatures
Capable of rolling to tight tolerances
Tungsten carbide rolls give better rod quality and longer
roll life.
Morgan Modular Vee No-Twist Mill
This patented new design enables the changing of pairs
of roll stands in a few minutes, so that size changes can
occur very quickly.
Stands not used on larger sizes are disconnected, thereby
extending the overall life of the equipment and reducing
maintenance costs. This design also minimizes power
consumption and thereby reduces operating costs.
Used in conjunction with a Morgan Reducing/Sizing Mill
and single family rolling, the Morgan Modular No-Twist
Mill maximizes utilization in the rolling mill.
Mini-blocks
Mechatronic solutions
The performance and reliability of the Morgan Vee
No-Twist Mill and Morgan Mini-Blocks can be enhanced
with the application of specialized mechatronics
packages, including:
Bearing temperature monitoring:
Provides temperature status for bearings in the block
Issues warnings of high temperatures that can be
caused by bearing wear or lubrication problems
Constant monitoring improves performance and
prevents system downtime
Fully integrated into standard SIROLL solution.
Historical logging
21
22
Morgan Rod Reducing/Sizing Mill in single strand high speed rod outlet
Rolling stands
Productivity features:
Single family rolling dramatically increases utilization
Mechatronic solution
The Morgan Rod Reducing/Sizing Mill mechatronics
package is a proven system on dozens of mills around
the world.
Features:
Full local and remote control options
Direct interface with mill control system
Straightforward, easy-to-navigate HMI interface
for the pulpit operator
Automated product change increases productivity
Incorporates Siemens VAI Metals Technologies
mechanical e
xpertise in gear change strategy
Electro-mechanical system fully tested prior to
shipment and commissioned on site
Fully integrated into standard SIROLL solution.
Features:
Grain refinement possible with thermomechanical
rolling results in improved properties
Unique oval-round-round-round pass sequence
delivers high-reduction rolling for internal quality while
enhancing surface quality and extending roll life.
23
Morgan High Speed Laying Head with patented tail end control
Mechatronic solution:
Laying head and intelligent pinch roll mechatronic
system provides:
Features:
Durable drive for reliable high speed operation
24
26
Bar in coil
Pouring reel
Pouring reels
The Siemens VAI Metals Technologies pouring reels enable
the production of bar products in coiled form, typically
for bar sizes of approximately 10mm to 60mm.
Features:
Interchangeable entry spouts accommodate a wide
product size range
Interface components:
Downenders
Multiple pinch rolls assist the bar into the tub and
control tail ends
Trimming stations
Transfer cars
Inspection stations.
The coil handling system can be shared with a rod mill
or rod outlet on a combination mill.
Process capabilities
In addition to forming a well-shaped coil with excellent
surface quality, the bar-in-coil system is designed for
optimal metallurgical and scale characteristics.
Features:
Coiling temperature can be controlled with upstream
water boxes
Blowing stations available for accelerated cooling
Insulated tunnels available for slow cooling of
critical grades
System length and operational practice designed
to give optimal final coil temperature.
27
Features:
High productivity also for small diameters,
e.g. 75tons/hr for diameter 10 mm at 35 m/s
The innovative spooling system is a considerable technological step forward in bar-in-coil production, offering
bar producers the opportunity to be more competitive
by offering final users a reduction of post-rolling costs,
as well as a better product appearance with easier
transportation and storage.
28
Mechatronic solution
To ensure the greatest benefits from processing and
production, a mechatronic system provides for:
Roll gap control with servo motors
Mill load control using load cells
Fully automated system integrating the roll pass set up
(RollMaster) with the Level 1 control system.
29
Sawing unit
Hot shears
Siemens VAI Metals Technologies offers a full line of
hot shears for a wide variety of requirements, such as:
Cold shears
Siemens VAI Metals Technologies designs flying and
static cold shears, with direct drive or clutch and brake.
Features:
Cutting table width up to 1,800 mm
Features:
Metallic or abrasive disc technologies available
30
In addition to the wide array of rolling stands, finishing blocks and cutting-to-length systems for every
bar product, Siemens VAI Metals Technologies has an
extensive portfolio of equipment to cover the complete
range of final processing needs. From counting to
bundling and stacking, and then unloading bundles
everything can be arranged for a smooth final
production process.
Bar counting
Fully-automated counting of bars moving from the
cooling bed to the bundling station assures that customer
orders are filled accurately and completely. The system
is capable of high production rates and is accurate for all
types and sizes of bars. Current count and end-of-batch
signals can be output to downstream equipment and to
the mill tracking system for full control and information
on the process. Both contact and non-contact counting
systems are available.
Bundling system
Siemens VAI Metals Technologies provides bundlers for
round and flat bars together with bar counting for rounds
and small bundle processing systems. The packaging form
can be round, square, rectangular and hexagonal shapes.
Binding systems
Automatic binding of the packages and bundles are
available with strap or wire.
Weighing, labeling & unloading
All bundles can be automatically weighed and further
labeled for quality-assured delivery of the finished
products at the bundle unloading station. With accurate
product tracking systems provided by Siemens VAI
Metals Technologies, such as the SIROLL LR Process Xpert,
tagging accuracy and reliability of the final shipment
are assured.
31
Thermomechanical rolling
Thermomechanical Rolling (TMR) requires a combination of properly arranged rolling and cooling equipment, adequate load capacity in the rolling stands,
and intelligent rolling and cooling practices. The result
is a refined microstructure in the product that has
superior as-rolled mechanical and metallurgical
properties.
By improving as-rolled properties and microstructures of
rod and bar products, subsequent downstream processes,
most of which are done in-house by the major steel producers, can be eliminated or significantly reduced, therefore lowering the conversion cost.
TMR in a rod mill
Although high productivity and efficiency remain the main
attraction of the Morgan Rod Reducing/Sizing Mill to most
plain-carbon unalloyed steel producers, metallurgical
processing flexibility is becoming an equally important
benefit to the specialty steel and cold heading quality
producers.
Through an engineered combination of high load design
of the patented mill and proper mill layout, thermo
mechanical rolling at low temperatures becomes a practical
production process. Siemens VAI Metals Technologies
has developed a successful combination of equipment
design and process design, demonstrated by more than
60installed and operating post-finishing mill blocks in
a variety of mill configurations, from existing two-strand
rod mills to new high speed, high production rate singlestrand rod mills.
33
MORSHOR installation
Mechatronical solution
A critical part of the accumulator is the mechatronics
system, which provides for:
Advantages:
Increases production of smaller sizes, which greatly
improves mill utilization
Optimizes product quality by allowing all products
to be rolled through a single strand horizontal-vertical
roughing and intermediate mill
Reduces by 50% roughing and intermediate mill stand
gearbox torques over two-strand rolling mills
Increases production and flexibility through multiple
outlets.
34
Environment:
Energy savings
Conventional
minimill
80%
60%
WinLinkbased
minimill
40%
20%
0%
Natural gas Manpower
Plant
consumption
footprint
Material Electricity
losses consumption
Features:
No inter-billet time
Welded joint
36
Before deburring
After deburring
Turnkey solutions
Success from a single source
37
Total engineering
Total engineering
Accurate planning that addresses everything from energy
supply and raw materials logistics to throughput targets
is a prerequisite for a successful start of your plant.
We provide all the up-front necessities to make sure
your project gets off to a safe start, including technical
consulting as well as simulation of all processes.
Automation SIROLL LR
From mill management, supervisory and control systems,
all the way to motors, drives and individual component
and sensor controls, Siemens offers a complete solution
to your rolling mill automation needs from Level 1 to
Level 3. With a full array of mechatronic packages for
equipment units throughout the process, a totally
integrated automation solution is available from the
factory floor to upper management.
Commissioning
In supervising installation and start-up of electrical
and automation, the task is to reach full production and
consistent operation in the shortest possible time.
That requires experienced automation and electrical
engineers knowledgeable in long products to support
the customer. For easier and quicker trouble-shooting,
the automation system is prepared for remote access.
38
Automation SIROLL LR
Commissioning
Our services
For the best performance of your plant throughout its lifetime
40
Equipment upgrades
Benefit from the latest design technologies, improving
overall equipment and mill performance with targeted
upgrades. Planned repair or reconditioning work is
the prime opportunity to incorporate some of the latest
designs in the mill to align with current operating
parameters and market demands.
Spare parts management
Custom spare planning allows for minimum inventory
levels to control operating cash flows. Critical spares are
readily available in stock in our warehouses around
the world to ensure key components are available when
needed most.
Guides
Backed by our comprehensive process knowledge,
Siemens VAI Metals Technologies expertise in guides
provides solutions for all long rolling applications.
A wide array of designs for mounting and ancillary guiding
equipment, is available to meet every challenge.
Training
A wide range of training programs are available for
maintenance, operations and processing. To handle
special requirements, we can develop customized
training for your people.
Life-cycle management
Partnership never ends
t
stmen
inve
w
e
N
Recycling
41
Customer:
V izag Steel, Visakhapatnam (Andra Pradesh), India, part of Rashtriya Ispat Nigam Ltd.
The task: Expand production to 6.3 million tpy, improve prductivity and optimize costs of its production line.
Our solution: A new mill with 18 Red Ring rolling stands followed by a 3-stand Pre-stressed Sizing Group, with a double
finishing area with cooling bed and three pouring reels. Initial mill capacity of 750,000 tpy.
The result:
lexible and reliable operation in expanded modern facility that profitably positions Vizag in one of the
F
worlds most rapidly developing areas.
Customer:
The task:
Expand product portfolio, increase rolling capacity and productivity, and optimize operation costs.
Our solution:
new multiline mill, including a straight bar line with 16 compact cassette rolling stands, a rod line with
A
two finishing monoblocks and a line with a flat rolling block.
The result:
olling capacity increase of approximately 40%, with optimized costs and an installation schedule that
R
eliminated potential impact on existing production.
Customer:
The task: Add capacity for coiled rebar and other rod products to support growing South American market on
greenfield site with the best technology for high production rates and quality.
Our solution: New single-strand rod mill with roughing and intermediate train, pre-finishing Morgan Mini-Blocks,
finishing Morgan Vee No-Twist Mill, in-line quenching, Morgan High Speed Pinch Roll and Laying Head,
Morgan Stelmor conveyor, reform and coil handling system. Provisions for future second strand.
The result:
42
igh quality rod and coiled rebar produced at finishing speeds up to 110m/s for at least 500,000 tpy on
H
single strand. Mill has rolled HYQST quenched and tempered rebar products at highest speeds in the world.
Customer:
The task:
s one of the largest steel producers in the world, Tata wanted to expand capacity in India to support growA
ing infrastructure with latest techniques for rolling rebar, and remain best-quality construction supplier.
Our solution:
ew single-strand bar mill with 16 stands for roughing and intermediate trains, two-way slitting unit, two
N
6-stand Morgan No-Twist Mills, water boxes for HYQST processing, dividing shears, patented high speed
Rotary Entry System to the cooling bed, cold shear, plus bundling and strapping equipment.
The result:
esigned to produce 600,000 tpy, mill exceeded production targets several times at commissioning.
D
One of the fastest and most efficient mills in the world for slit rolling in straight lengths, with rolling line
yields above 95%.
Customer:
Global Steel Wire, S.A., Santander, Spain, part of the Celsa Group
The task: As a renowned supplier of high quality rod products, Global Steel Wire needed to expand product size
range, increase production and improve quality for changing markets, including new bar-in-coil market.
Our solution:
Series of mill modernizations: Equipment improvements and additions to 2-strand rod mill to increase
production rate and productivity, including Morgan Mini-Blocks, Morgan No-Twist Mills, Morgan Rod
Reducing/Sizing Mills, rod outlet; bar-in-coil outlet with water cooling and Morgan Bar Reducing/Sizing
Mill for high quality bar products.
The result:
ver 10 years of mill modifications, Global Steel Wire has increased production from 570,000 tpy
O
to more than 900,000 tpy, with increases in coil weight, product size range and quality.
Customer:
The task: As part of companys overall investment program, mill revamp needed to improve Corus production
capability and cost-effectiveness.
Our solution:
new finishing mill with 7 in-line Red Ring universal stands, cooling area with rail precambering, and
A
handling equipment.
The result: The mill enables Corus to roll rail lengths up to 120 meters in an in-line continuous finishing mill.
It offers unsurpassed flexibility to process both rails and sections, with minimized change operations
and improved tolerances.
Customer:
The task:
ne of the leading players in the Middle East, Habas needed a greenfield rebar rolling mill,
O
with high productivity and equipment reliability.
Our solution:
state-of-the art fully automated multi-slitting rolling mill with 25 Red Ring stands, including a double
A
finishing train, with in-line bar quenching, multichannel braking system for high speed delivery to a 120m
cooling bed and handling areas. Bars ranging from 8 to 42mm diameter rolled in up to 4-slit process.
The result: Designed for 1,185,000 tpy, one of the most productive rebar plants in the world. Production exceeds
4,500 tons per day, equivalent to an average rebar production of 180t/h.
43
Competence Centers
Siemens Industry Inc.
50 Prescott Street
Worcester, MA 01605-2615, USA
Phone: +1 508 755-6111
Fax: +1 508 849-6678
E-mail: longrolling.metals@siemens.com
Siemens S.p.A.
Industry Sector Metals Technologies
Via Luigi Pomini, 92
21050 Marnate (VA), Italy
Phone: +39 0331 741211
Fax:
+39 0331 741386
E-mail: longrolling.metals@siemens.com
Headquarters
Siemens VAI Metals Technologies GmbH
P.O. Box 4, Turmstr. 44
4031 Linz, Austria
Phone: +43 732 6592-0
E-mail: contact.metals@siemens.com
siemens-vai.com
Order No. E10001-M3-A325-V1-7600
Dispo No.: 21661 K-No.: 20254 | Printed in Germany
GB 120208 WS 06131.0 | 06.2013, Siemens VAI Metals Technologies GmbH