50-paper-Tommaso di Paolo-Modernizing Automation a

1-7(2K_K_F_11.DOT01/2006I&SDAC)•D:\temp\1651488887363.doc/1-7/MeMeXModernizingAutomationandDrivesoftheBaoshanTandemColdMillNo.1TommasodiPaolo,RainerPolster,AlfredDümmlerABSTRACTInJanuary2004,BaosteelawardedSiemenswithacontracttomodernizetheelectricalequipmentandautomationofitsContinuousTandemColdMillNo.1.Thetandemcoldmill,whichcanberuninboth,batchandcontinuousmode,hasbeenoperationalsince1989.Forthismill,SiemensissupplyingnewSimoreg-typedigitalcontrolsystemsfortheexistingDCdrivesandanewbasicandprocessautomationsystem,includingtheassociatedtechnologicalcontrollers.Reintegrationoftheexistingprocessmodels,whichalsocameoriginallyfromSiemensandhavebeenadaptedovertheyearstotheproductionprocessbythecustomeritsself,aretobecarriedoutbyBaosteel.Themodernizedmillwentintooperationinautumn2005.Thearticleexplainstheprojectindetail,therevampstrategyandtheresultsfromthestart-upphase.KEYWORDS：TANDEMCOLDMILL,AUTOMATION,MODERNIZATION0INTRODUCTIONOntime,therevampedBaosteelcontinuoustandemcoldmillNo.1locatedinBaoshan,ChinawentbackintooperationinNovember2005.ThemostproductiveColdrollingmillwithinBaosteelGroupwasreadytoberevampedafternear15yearsinoperation.TheprojectwasstartedtokeepBaosteelsflatsteelproductsonaworld-classlevelandgettingthebasisforfutureproductrequirements.ThechallengeTheBaosteelGroupislocatedinBaoshan,northofShanghaiontheJangtzeRiver.Baosteelisoneoftheleadingmanufacturersofsteelstripproductse.g.fortheautomotiveindustries,etc.inChina.Themodernizationisaimedatimprovingthethicknessandflatnesstolerancesandensuringhighproductquality,especiallyforbuyersintheautomotiveindustry.Asecondobjectiveistoincreaseproductivityintheplantandtoinstallmoderndigitalautomationequipment.2-7(2K_K_F_11.DOT01/2006I&SDAC)•D:\temp\1651488887363.doc/2-7/MeMeXFigure1:CTCMviewtothedriveside,upsideleftthemainpulpit3-7(2K_K_F_11.DOT01/2006I&SDAC)•D:\temp\1651488887363.doc/3-7/MeMeXTheBaosteelfive-standtandemcoldrollingmillisoneofthelargestofitskindanywhere.-itwasoriginallybuiltinthelate1980sbyaconsortiumofSiemensandSchloemann–Siemag–waspartofthefirstexpansionstateofBaosteelflatsteelproductioninBaoshan.Atthattime,the5-stand,4-highmillrepresentedthestateoftheart,featuringhydraulicgapcontrol,workrollbending,aprocesscomputerwithSiemensTypeR30,set-upmodels,andfullyautomaticoperation.Themillwasbuiltfordiscontinuousandmainlycontinuousoperation.Establishedduringtheinitialproject,thecordialrelationshipbetweenSiemensandBaosteelwasneverinterruptedovertheyearsandsucceededbymanyotherprojects.Besidetheinvestmentinnewcapacitiesandtheextensionsoftheamountofproduction,BaosteelisinvestingincontinuousimprovementoftheirexistingplantsinordertofollowthemarketrequirementsandtostrengthentheircostpositionintheChinesemarket.KeyMillDataEntryThickness:1.8–6.3mmExitThickness0.3-3.5mmStripWidth(max):1890mmCapacity:2.400.000tpyCoilWeight(max):max.45tExitSpeed(max):1900m/minAutomationupgradeimprovesproductqualityandproductivityTheSiemensautomationupgradeconceptfocusedprimarilyonimprovingproductqualityatthemill.Togetherwiththecustomerfollowingmodernizationscopewereelaborated:BetterdynamicresponseandbettersupportofthemassflowthicknesscontrolthroughdigitalizationifthedrivespeedcontrolAddinganewlaser-basedspeedmeasurement.ReplacementofexistingCPC’sbystateoftheartequipmentAdditionaltensionmeasurementbeforestandNo.1forSIEMENSadvancedMassflowcontrol(optionaldancerrollcontrol)Replacementofthe15-yearoldbasicautomation,includingtheoperatorpulpits.NewprocessautomationInterfacetoexistingtechnologicalmeasurement,e.g.Thicknessgauges,tensionmeasure-ment,IntegrationoftheexistingSIEMENSVAIflatnesscontrolInterfacetoandintegrationofthenewMiebachLaserweldingmachine.4-7(2K_K_F_11.DOT01/2006I&SDAC)•D:\temp\1651488887363.doc/4-7/MeMeXTheprojectphasesSIROLLCMforColdMillsfromSiemens,whichincludesthedigitaldrivecontrolsforhighestaccuracyformedthecoreoftheautomationconcept.ThemechanicalmodificationswerecarriedoutbyBaosteel.TheorderforthenewweldingmachinewereplaceddirectlytoMiebachbyBaosteel.20072004200520062003OrderPlacementManufacturingandEngineeringSystemTestinErlangenInstallationAutomationColdCommissioningStart-up/FineTuningWarrantyperiod30.01.2004ShutdownMaintenanceshutdowns21/28daysOnSiteSystemTestFigure2:ProjectscheduleProjectmanagementandengineeringweredonebySiemensI&SinErlangenandbyBaosightinBaoshan,withsignificantparticipationbythecustomer.TrainedonSIMATICautomationsystems,customerpersonnelwereresponsiblefortherealizationofimportantfunctions,suchaspartsoftheHMI,basicautomation,andprocessautomation.Anintensivesystemtestonsitelastingoversixweeksbeforethemainshutdownconcludedtheengineeringphase.Duringthistest,allimportantfunctionsweresimulated,includingtheHMIandalloperationmodeandsequences.Theoperatorsweretrainedonthenewsystemaswell.Beforethemainshutdown,thecontrol-andthyristorpowerunitsforallthesmallerstriptransportingdriveswerereplacedandcommissionedduringregularmaintenanceshutdownsusingtheexistingcubiclesandwiring.Alsothetestofthefiringpulsesforthemaindrivesandlargerstripdrivestotheremai