Hot strip from Istanbul

ÇOLAKOGLU METALURJI
Hot strip from Istanbul
SMS SIEMAG
METALLURGICAL PLANT and ROLLING MILL TECHNOLOGY
Hot rolling mills
SMS SIEMAG
Hot rolling mills
ÇOLAKOGLU METALURJI
Hot strip from Istanbul
The hot strip mill of Çolakoğlu Metalurji,
situated at the edge of the Turkish metropolis
of Istanbul, is currently the most up-to-date
hot-strip rolling mill in Turkey and has been
supplied completely by SMS Siemag. Since
we had the overall responsibility for the
mechanical equipment and the electrical and
automation package, we were able to coordinate all systems perfectly with each other.
This paid off for Çolakoğlu Metalurji already
during the commissioning phase.
Right on the Sea of Marmara: the new hot
strip mill of Çolakoğlu Metalurji.
2
Çolakoğlu Metalurji has developed from a
steel trader into a steel producer over the
last few decades. With the commissioning
of the hot strip mill in June 2010, the Turkish
family-run firm extended its portfolio from
long products to high-quality hot strip.
Contents
Compact layout, modern plant engineering
4
Electrical and automation systems
6
Top quality through in-house manufacture and Plug&Work
8
Rapid commissioning
10
Roughing mill with “camber-free rolling”
12
Mandrelless coilbox and optimized crop shear
14
Finishing mill with CVC® plus system
16
Strip cooling for optimum cooling strategies
20
Coiler with Automatic Step Control
22
3
SMS SIEMAG
Hot rolling mills
COMPACT LAYOUT,
modern PLANT ENGINEERING
The new rolling mill of Çolakoğlu Metalurji
is designed for an annual capacity of three
million tons of hot strip. The maximum
strip width is 1,650 mm and the strip
gauges between 1.2 and 25.4 mm. The
product mix includes a wide range of carbon steels including HSLA grades, tube
and pipe grades, dual-phase and TRIP
grades.
The location of the works is in Gebze,
directly on the Sea of Marmara, where
Çolakoğlu Metalurji previously operated a
wire rod and section mill. To be able to
accommodate the new mill on these
premises, it was designed as a compact
hot strip mill. The main components are
a reversing roughing stand with edger, a
mandrelless coilbox, a seven-stand finishing mill, the laminar cooling system, two
downcoilers and the pallet-type conveyor
system. Thanks to the coilbox, the distance between the reheating furnace and
the coilers is just 330 m.
TECHNICAL DATA
Commissioning
Annual production
Steel grades
June 2010
3.0 million t
Carbon steels, HSLA
grades, tube and
pipe grades, DP
steels,TRIP steels
Slab
Thickness
Width
Length
Weight
180 to 250 mm
800 to 1,650 mm
max. 12,000 mm
max. 39 t
Finished strip
Thickness
Width
1.2 to 25.4 mm
800 to 1,650 mm
Coil
Inside diameter
Outside diameter
Spec. coil weight
Weight
762 mm
max. 2,200 mm
max. 24.0 kg/mm
39 t
The rolling mill was erected on stilts in
order to avoid ground-water problems due
to its location directly on the coast. This
also has the advantage that the supply
systems located under the rolling mill,
such as those for hydraulic oil and pressure water, are accessible from floor level.
The foundation of the mill is designed as
a continuous block. This prevents the settling of individual mill areas and hence
disturbances in the rolling process.
The practice-oriented safety concept of
the hot strip mill combines maximum
occupational safety with optimum facilities
for observing the rolling process, thus
conforming to the latest EC directives.
The layout of the compact hot strip mill.
4
Wide-angle photograph of the rolling mill with
roughing stand (left), coilbox and finishing mill.
The utility supply lines under mill floor level also
have a well thought-out, clearly structured design.
5
SMS SIEMAG
Hot rolling mills
ELECTRICAL and
AUTOMATION SYSTEMS
The entire hot strip mill operates with
SMS Siemag's X-Pact® electrical and
automation package. The supply scope
of this package included the Level-1 and
Level-2 systems with process models,
technological measuring systems, instrumentation, sensors as well as a common
HMI for both automation levels. Also
the drive systems with their converters
and all motors, including roller table distribution boxes, main and mill pinion
gear units, and the drive spindles for
Çolakoğlu Metalurji's compact hot strip
mill, were all included in the SMS
Siemag supply scope.
Of great importance for the product quality are the technological process models:
pass schedule calculation (PSC), profile
and flatness control (PCFC) and the
cooling model (CSC, Cooling Section
Control). They are based on mathematical-physical models which provide the
settings for the various equipment items
of the rolling mill under consideration of
the material properties.
Perfectly coordinated with each other: mechanical
equipment and electrical und automation systems.
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The target values calculated by the
process models are set to precise times
by the highly dynamic technological control systems and are controlled during the
rolling in such a way that they observe
the product parameters in accordance
with the boundary conditions. Furthermore, a clearly structured HMI and
ergonomically arranged control elements
make it easier for the operating personnel to monitor the rolling process.
Process visualization in the
HMI systems.
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SMS SIEMAG
Hot rolling mills
TOP QUALITY
through in-house manufacture
and advance commissioning
When a new plant is started up, it is
essential to ensure problem-free commissioning, a rapid run-up and good plant
performance right from the first day. We
have achieved this with the Çolakoğlu
Metalurji hot strip mill thanks to the well
thought-out and proven design of all
components, manufacture according to
the highest quality standards and the preliminary tests performed on the mechanical equipment and automation systems.
The core components of the mill such
as the millstand chocks, gear units and
drive spindles, coilers and hydraulic rollgap adjustment systems have all been
fabricated in our Hilchenbach workshops.
These workshops include a powerful
machine pool that incorporates more
than 70 state-of-the-art machine tools.
The automation system of the hot strip
mill was tested by SMS Siemag before
delivery, using the tried-and-tested
Plug&Work method: The complete mill
automation, including all control desks
and local operator stations, were set up
in the test field and connected to a simulation system.
The test field for the
Plug&Work tests.
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The simulation depicted the mechanics,
sensors, drive engineering and rolling
process in real time. The entire mill thus
became available in our test field for the
testing and optimization of the kinematic
sequences, dynamic behavior and operating procedures.
Plug&Work was also used to extensively
prepare Çolakoğlu Metalurji's operators
for their future job in the mill. The personnel learned the plant functions and
the handling of these under realistic
operating situations in virtual productive
operation.
Gearwheel
production.
Pre-assembly and function
testing of mill stands.
Operator training.
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SMS SIEMAG
Hot rolling mills
RAPID COMMISSIONING
and excellent rolling results
The first strip was rolled by Çolakoğlu
Metalurji on the new hot strip mill on
June 15, 2010. This had been originally
scheduled for the end of June but due to
the good preparations the cold commissioning was brought forward by around
two weeks.
Already in the second month after commissioning, the hot strip mill had attained
about a third of its nominal production
thanks to the pre-optimization and precommissioning of the mill with the aid of
Plug&Work. The mill demonstrated its full
potential just four months after commissioning, when the rated capacity was
exceeded in several production shifts.
Also with regard to the strip quality, the
benefits of SMS Siemag supplying the
entire mechanical equipment and automation systems became evident right from
the start. Already after three weeks, 99 %
of all strip produced was within the agreed
tolerances not only for strip gauge and
width but also for strip profile and flatness.
The first coil with a final gauge of 1.2 mm.
A mere seven weeks after the start of
production, Çolakoğlu Metalurji was
rolling strip with the aimed-at minimum
final gauge of 1.2 mm. In this rolling
operation too, the gauge, width and
final rolling temperature remained within a narrow tolerance window over the
whole length of the strip. Around three
months after commissioning, Çolakoğlu
Metalurji reduced the final strip gauge
even further, producing strips with a
gauge of 1.1 mm.
A view of the coilbox and the
seven-stand finishing mill.
10
Measured data of the first
strip with a gauge of 1.2 mm.
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SMS SIEMAG
Hot rolling mills
ROUGHING MILL
with “camber-free rolling”
The production process starts with heating of the slabs in the walking beam
furnace. A high-pressure descaler then
removes the scale that has formed during
heating. The descaler operates at a maximum pressure of 200 bar and thus produces a clean surface.
The four-high reversing roughing stand
rolls the slab down to the transfer-bar
thickness calculated by the pass-schedule
model, in five to seven passes. The
roughing stand has hydraulic roll-gap
adjustment systems and a maximum roll
force of 45 MN.
The transfer bar width is preset by means
of the edger which is flanged at the entry
side. With the aid a special control of the
edging pass (“short stroke”) at the transfer-bar head and tail end, the transfer bar
geometry is optimized to the extent that
cropping losses are reduced.
“Camber-free rolling” prevents camber
from occurring in the transfer bar as a
result of thickness and temperature
wedges in the slab. It is based on the
interaction of the roll alignment control
(RAC) and the heavy, position-controlled
side guards in the entry and exit sections
of the roughing stand. The side guards
actively counteract the formation of strip
camber. RAC keeps the roll gap in the
roughing stand perfectly parallel also in
the case of slabs with temperature or
thickness wedge, thus forcing a mass
flow transverse to the rolling direction
to arise in the transfer bar. In this way,
wedges are eliminated and the formation
of a transfer bar camber is prevented.
TECHNICAL DATA
Primary descaler
Water pressure
200 bar
Edger
Roll diameter
Edging force
Width reduction
Opening dimension
Main drive
Rated torque at the rolls
1,100 to 1,000 mm
max. 6,700 kN
max. 100 mm
700 to 1,850 mm
2 x 1,500 kW
462 kNm
Four-high reversing roughing stand
WR diameter
1,250 to 1,125 mm
BUR diameter
1,500 to 1,350 mm
Barrel length
1,850 mm
Roll force
45 MN
Bearing assembly
Type KLX® Morgoil bearings
Main drive motors
Twin-drive
Rated power
2 x 7,500 kW
Rated torque
1,432.5 kNm
Technical features
Hydraulic roll-gap adjustment systems; camber-free rolling;
heavy, position-controlled side guards; Morgoil® bearings of
KLX® series; spade-end spindles
Reheating furnace and
high-pressure descaler.
12
Four-high reversing roughing stand with
edger on the entry side.
Heavy side guards actively counteract the
formation of strip camber.
Four-high mill stand with hydraulic
roll-gap adjustment systems.
Edging stand on the entry side.
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SMS SIEMAG
Hot rolling mills
MANDRELLESS COILBOX
and OPTIMIZED CROP SHEAR
The mandrelless coilbox between the
roughing and finishing mills makes the
particularly compact layout of the hot
strip mill possible. This coiling device
serves to coil the transfer bar after the
lass pass and to then uncoil it during finish-rolling. This has made it possible to
considerably reduce the distance between
the roughing and finishing mills.
TECHNICAL DATA
Temperature equalization also takes place
in the transfer bar during intermediate
storage in the mandrelless coilbox. The
strip enters the finishing mill at almost
constant temperature, thus allowing a
particularly stable rolling process. The
coil is transferred without a mandrel from
the coiling to the uncoiling station. This
avoids undercooling of the inner wraps.
Patented, width-adjustable heat-insulation hoods additionally reduce the thermal radiation from the coiled transfer bar.
Drum-type crop shear
Strip cross-section
max. 50 x 1,650 mm
Shear force
max. 13,000 kN
Transfer bar speed
during cutting
0.5 to 2.0 m/s
Shear knives per drum
2, offset by 180°
Mandrelless coilbox
Transfer bar thickness
Transfer bar width
Coiling temperature
Entry speed
Coiling speed
Uncoiling speed
The transfer bar is cropped at its head
and tail ends by the drum shear before
it runs into the finishing mill. Both cuts
are made using a separate pair of knives,
thus giving the head and tail end of the
transfer bar the shape that is needed
for reliable threading and tailing-out. Our
crop optimization system makes use of
the measuring systems for strip-shape
detection and strip speed to reduce the
cropping losses to a minimum.
Start of uncoiling.
14
25 to 40 mm
800 to 1,650 mm
900 to 1,100 °C
max. 4.0 m/s
max. 5.0 m/s
max. 2.0 m/s
Entry side of the finishing mill with coilbox,
crop shear and descaler.
Drum shear.
The crop ends are proof of the low
loss of material due to cropping.
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SMS SIEMAG
Hot rolling mills
FINISHING MILL
with CVC® plus system
The seven-stand finishing mill rolls down
the transfer bar to the required final gauge
between 1.1 and 25.4 mm. Before this,
the secondary descaler removes the scale
that has formed during roughing down.
For gauge control all stands are equipped
with hydraulic roll-gap adjustment systems. The strip profile, flatness and contour are set in the finishing mill by the
CVC® plus system in combination with the
work-roll bending system. Using the roll
force, elastic deformation, thermal crown,
wear on the work rolls and further parameters, the pertaining technological
process model PCFC® (profile, contour
and flatness control) calculates for each
strip the correct shifting position for
the work rolls equipped with the special
CVC® plus roll-barrel finish, as well as
the setting values for work roll bending.
In this way, the roll gap for each strip is
adjusted to the changing conditions.
TECHNICAL DATA
Roll force
F1 to F4
F5 to F7
Work rolls
Barrel length
Diameters F1 to F4
Diameters F5 to F7
Back-up rolls
Barrel length
Diameters F1 to F7
Bearing assembly
42 MN
36 MN
1,850 mm
820/720 mm
700/630 mm
1,850 mm
1,500/1,350 mm
MORGOIL®
bearings
Main drive motors
Rated power
7 x 8,000 kW
Technical features
Hydraulic roll-gap adjustment systems;
work roll bending; CVC® plus; hydraulic
loopers (F1 to F6); anti-peeling device
(F1 to F4); roll-gap lubrication (F2 to F6);
work-roll quick changing system (F1 to F7)
Work rolls are changed fully automatically,
which takes just a few minutes. A rollchanging car transports the work rolls
back and forth between the roll bay and
roll workshop.
The seven-stand finishing mill.
16
Control room of the finishing mill.
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SMS SIEMAG
Hot rolling mills
FINISHING MILL
with CVC® plus system
Hydraulic loopers are installed between
the stands and ensure stable strip travel.
The stands F1-F4 are equipped with an
anti-peeling device. This device lowers
the surface temperature of the strip by
spraying on water directly in front of the
roll gap, thus reducing the thermal load
on the work rolls.
The roll-gap lubrication system in stands
F2 to F6 reduces the friction in the roll
gap by spraying an oil-water mixture
onto the work rolls. The roll force is thus
reduced by around 15 to 20 %.
The finishing stands are characterized
by their compact and low-maintenance
design. This ensures that each hydraulic
actuator is controlled by its own module.
The individual modules are combined on
the mill stand platform to form compact
columns. There they are protected and at
the same time they are easily accessible
for maintenance purposes. The pipes
between the control modules and the
actuators run along the side walls of
the finishing stands, providing optimum
protection from damage. All equipment
arranged below the mill floor, e.g. for
supplying the mill stands with hydraulic
oil, water or electricity, are also optimized for easy maintenance.
The finishing stands are driven by threephase AC motors, which are fed by directcurrent intermediate circuit converters.
The drive power is transmitted in stands
F1 to F4 via main gear units, mill pinion
gears and Sieflex® spade-end spindles,
while stands F5 to F7 are directly driven.
Fully automated changing of the work rolls.
The gear units are equipped with casehardened gearwheels and teeth to
ensure the transmission of extremely
high drive torques. The drive spindles
are lubricated by an integrated oil recirculation system. This system enhances
the reliability of the spindle and the
accessibility at the drive side of the
stand.
Finishing stands with CVC® plus, work roll bending
and hydraulic roll-gap adjustment systems.
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SMS SIEMAG
Hot rolling mills
STRIP COOLING for implementing
the optimum cooling strategy
The cooling section uses selective cooling to produce the exact material properties for the rolled stock. Intelligent
cooling strategies make it possible for
Çolakoğlu Metalurji to produce strips
with cost-effective alloying concepts.
The laminar cooling section is around
80 meters long and divided into 17 individually controlled groups. The last two
groups are so-called trimming zones in
which a particularly precisely controlled
admission of water is possible in order
to attain the coiling temperature.
The optimum cooling strategy for each
strip is preset by our X-Pact® cooling
model. It is based on the implementation
of the essential physical operations such
as the thermal conductivity in strip gauge
direction, the transfer of heat in air and
water zones, as well as the transformation behavior of the material during the
cooling process. The model calculates
the relevant cooling curve for each strip
on the basis of these values.
The upper cooling headers of the laminar
cooling section can be swiveled through
almost 90°, thus making the roller table
accessible for maintenance also by a
crane. The rollers form a unit with the
motor and, being designed as quickchange units, can be replaced within a
very short time.
TECHNICAL DATA
Laminar cooling section
Total volumetric flowrate
Length
Cooling groups
with micro zones
with trimming zones
20
12,700 m³/h
80.5 m
15
2
The 80 m long laminar cooling section
for flexible cooling patterns.
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SMS SIEMAG
Hot rolling mills
COILER with Automatic Step Control
and gentle coil transfer
The rolled strips are coiled by two fully
hydraulic downcoilers. The coilers are
optimized for straight-sided, closely
wound coils for all steel grades and strip
dimensions. They ensure safe coiling and
quick discharging.
The incoming strip is picked up by the
pinch roll unit and reliably routed in the
entry gate to the coiler mandrel. Throughout the coiling process, hydraulic side
guards center the strip and thus ensure
straight-sided wound coils.
While the first few wraps are being
wound, the wrapper rolls of the coiler
are lifted off the strip surface for a short
moment before the strip head end is
coiled round. This patented automatic
step control system prevents marks on
the inner wraps and protects the coiler's
mechanical equipment.
TECHNICAL DATA
Coiler
Strip gauge
Coil weight
Outside diameter
Mandrel diameter
1.2 to 25.4 mm
max. 39 t
min. 1,160 mm,
max. 2,200 mm
762 mm (expanded)
Coil conveyor system
Type
Pallet-type conveyor system
Coil conveyor
with horizontal coil eye
Coil weight
max. 39 t
Coil temperature
max. 700 °C
Throughput
60 coils/h
The wound coils are transferred to the
pallet-type conveyor system and taken to
the coil storage yard with horizontal coil
eye. The novel pallet-type conveyor system is characterized by a safe and gentle
transport of the coils at low investment,
maintenance and operating costs.
The downcoiler unit.
With the pallets being controlled individually, the operations in the coil storage yard
are made independent of the production
in the hot strip mill. This makes it possible
to form buffers and thus enables the optimum utilization of the shop crane. Empty
pallets are returned simultaneously with
the loaded pallets.
Control room in front of the
downcoiler unit.
22
Pallet-type conveyor system.
The coils are conveyed into the coil
storage yard on the pallets.
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MEETING your EXPECTATIONS
Hot Rolling Mills Division
Wiesenstrasse 30
57271 Hilchenbach, Germany
Phone: +49 (0) 2733 29-1616
Fax:
+49 (0) 2733 29-2832
E-mail: hot.mills@sms-siemag.com
Internet: www.sms-siemag.com
W4/311D
1000/09/11 . Ky . 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.”