- Improved measurement and control of strip profile and flatness
- Virtualized hardware reduces IT response time
- Updated automation hardware and software to meet current and future needs
Primetals Technologies has received the final acceptance certificate (FAC) from a Turkish steel producer after successfully completing a phased upgrade of its hot-strip mill. Phase 1 focused on upgrading the process automation system, while Phase 2 included modernizing the basic automation system and implementing advanced profile and flatness control. Primetals Technologies also installed the ALEX condition monitoring system. The mill was restarted as scheduled following installation and commissioning.
Improved Strip Profile and Flatness Quality
The Turkish steel producer selected Primetals Technologies based on several factors, including continued support from hot rolling mill automation experts, increased availability of spare parts, and improved strip profile and flatness quality.
Primetals Technologies’ extensive experience, proven automation expertise, and comprehensive support during installation and commissioning helped ensure minimal downtime and a high level of safety on site.
Phase 1: Level 2 Automation System
Primetals Technologies introduced a new Level 2 automation system, fully virtualized and integrated into the producer’s existing virtual hardware setup. This upgrade reduces IT response time and enables efficient lifecycle management.
Phase 2: Level 1 Automation
In Phase 2, Primetals Technologies replaced the basic automation hardware with a state-of-the-art solution and migrated the application software to the latest PCS7 platform. The data communication system was also updated.
A new profile and flatness system, the Contour and Flatness Optimizer, was installed. As part of both the process and basic automation systems, it enables detailed analysis of strip contour behavior throughout all mill passes. Using advanced process models and optimized control over strip profile and flatness, the system’s shadow mode supported a smooth transition by allowing models to be calibrated before startup.
During the final acceptance test, more than 2,300 items were produced, surpassing contractual requirements for in-bar control and setup for strip profile and flatness.
Key facts: Upgraded Automation Systems at Hot-Strip Mill in Türkiye
- Basic automation hardware: Simatic TDC CPU555
- Basic automation software: Simatic PCS7, D7-SYS
- Data communication system: ProfiNet ET200SP via Remote I/O
The first coil produced at the steel producer’s hot-strip mill after Primetals Technologies’ modernization of the automation system.
Primetals Technologies, Limited, headquartered in London, United Kingdom, is a pioneer and world leader in the fields of engineering, plant building, and the provision of lifecycle services for the metals industry. The company offers a complete technology, product, and services portfolio that includes integrated electrics and automation, digitalization, and environmental solutions. This covers every step of the iron and steel production chain—from the raw materials to the finished product—and includes the latest rolling solutions for the nonferrous metals sector. Primetals Technologies is a Group Company of Mitsubishi Heavy Industries, with around 7,000 employees worldwide. To learn more about Primetals Technologies, visit the company website www.primetals.com.
