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 hot-strip 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
