F-Manual Draft 001

Content of Manual
Auft.-Nr. / Order No. Stand / Revision ndex Blatt / Sheet

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QuaIity and Commissioning ManuaI (F)

I. GeneraI

II. Hot Commissioning Period

1. Time Schedule Rev.: --
2. Performing 1
st
Coil Rev.: --
2.1. Product and Process data
2.2. Pre-settings Mill
3. Hot Commissioning Rev.: --
3.1. General
3.2. Hot Commissioning Program

III. Acceptance Tests (AT)

1. General Rev.: --
2. Performance Test Coordination Team Rev.: --
3. Procedure of Performing the Tests Rev.: --
4. Preconditions Rev.: --
5. AT-Program Rev.: --
6. AT-Schedule Rev.: --
7. Evaluation of Performance Guarantees Rev.: --
8. Certificates Rev.: --

Content of Manual

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IV. Product QuaIity

1. General Rev.: --
2. Personnel Requirements Rev.: --
3. Conditions to ensure the Product Quality Rev.: --
4. Operation and maintenance Rev.: --

QuaIity and Commissioning ManuaI

. General

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I. GeneraI

The Quality and Commissioning Manual (QCM) is intended as a guideline for the Buyer to achieve
excellent product quality over a long period of time.

t is divided according to the three main phases:

1) The period of time between end of the functional test and the first product
2) The period of time between first product and Acceptance Certificate
3) The time after Acceptance Certificate

The manual can also be considered as a guideline proving the performance of the contract equip-
ment quickly and effectively. The requirements for a successful start-up are included as well as the
preconditions to be maintained in order to secure the product quality over a long period of time.

Beside the Quality and Commissioning Manual (F), the following manuals are also relevant:

- Operating Manual (A)
- Equipment Manual (B)
- Sub suppliers' Components Manual (C)
- Erection Manual (D)
- Electric and Automation Manual (E)

The Quality and Commissioning Manual gives an overview of the hot commissioning period and
the preconditions refer to contract chapter 5 which must be fulfilled in order to achieve the product
quality and the performance of the plant.

Hot Commissioning Period (Chapter II)

The Hot Commissioning Period starts with the 1
st
Product after successful completion of the func-
tional tests according to the Erection Manual. This Chapter shall help to get a general understand-
ing of the complex procedure of the start-up and hot commissioning processes. n order to achieve
a smooth start-up and successful hot commissioning, some important factors need to be consid-
ered which will decisively influence the rate of progress.

Successful commissioning demands high standards of:

2 Planning and organization before and during hot commissioning among all parties involved
2 Personnel (qualified skilled operators and supervisors)
2 Knowledge of equipment and understanding of the process combined with discipline, aware-
ness and satisfactory coordination
2 Communication between all operators and supervisors
2 Correct operation of all components of the plant and correct state of the equipment
2 Required quality of the pre-material for every stage of the process

The application of such a general understanding will ensure that the planned schedule can be fol-
lowed in a correct and successful manner.


. General

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Acceptance Tests (Chapter III)

This chapter contains the stipulated Acceptance Tests (AT) with regard to the terms of the con-
tract. According to contract chapter 5 the material grades for the AT should be tested during com-
missioning in corresponding quantity and quality. The suppositions are the sufficient process stabil-
ity and the fulfilment of the preconditions listed in the contract chapter 5 and in the manual chapter
. The quality tests shall be performed during running production.

Product QuaIity (Chapter IV)

Chapter V lists the most important preconditions which have to be fulfilled to achieve the pro-
cessing stability and the required product quality. The entire production process and product quali-
ty have to be continuously monitored. Any deviation needs to be corrected immediately. This calls
for a good organization of the production as well as management regarding the personnel and
production facilities.


. Hot Commissioning Period

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II. Hot Commissioning Period
1. Time ScheduIe

The QCM describes the main activities and requirements during the commissioning period from the
1
st
coil to the Acceptance Certificate (AC). The Hot Commissioning starts with the successful com-
pletion of the No Load Tests according to the Contract and Erection Manual.

No Load Test - 31.05. - 31.08.2013
1
st
coil - 31.08.2013
Hot Commissioning - 01.09. - 30.11.2013
Performance Tests (AT) - 01.10. - 30.11.2013
FAC - 01.01.2014

The Buyer has to ensure while the Seller will assist the Buyer that the determined preconditions
and the required production guidelines will be fulfilled in accordance with the requirements of the
QCM and the Contract respectively.

The Acceptance Tests (AT) shall start after the 1
st
coil if the preconditions (Chapter .) for the re-
spective tests are fulfilled and sufficient process stability is reached.

2. Performing 1
st
CoiI

The functional tests will be completed with Buyer's participation before performing 1
st
coil. The cor-
responding tests to be performed before performing 1
st
coil can start are stipulated in the Erection
Manual Chapter 3 (single functional tests).

The 1
st
coil can be performed, if the preconditions for the 1
st
product are fulfilled and the cold com-
missioning is finished or is sufficiently advanced.

There are some important factors for the commissioning period which influence the rate of pro-
gress. Some of the main factors are communication, knowledge of the equipment and an under-
standing of the process. These factors - combined with discipline, awareness, co-ordination and
supervision ensure that the planned schedule can be followed in a correct manner.

Further important factors concern the state, operation and maintenance of the equipment as well
as continuous quality checking of the product and equipment.

All safety/emergency procedures must be observed at all times and have absolute priority.

The Cold Strip Mill line is erected and will be maintained by the Buyer's personnel according to the
Seller's instructions.

t is understood that all necessary systems of the mill are function-tested and basically adjusted.
Material tracking, models and associated measuring equipment are deemed to be calibrated at a
certain level.



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The general preconditions (for details see SMS-SEMAG contract chapter 5.3, erection manual) for
the whole plant are:

1 The mechanical equipment (including hydraulics, pneumatics, etc.) is in operation and
properly maintained.
1 The drives, control and regulating systems are in automatic mode within their normal oper-
ating ranges.
1 The measurement devices are well maintained and properly calibrated. The measurement
environment is established in accordance with the specification of the manufacturers.
1 All automation control systems are in full operation.

The tolerance guarantees given are only valid if the Level computers are in operation.

Equipment supplied by the Buyer must be available and operational in terms of time, quality and
function as required.

1 All necessary tools are available to perform tasks (e.g. for cobble removal).
1 The consumables provided such as water, energy, lubricants, spares, wearing parts, etc.
are available in sufficient quantity and required quality. The tanks are filled, the accumula-
tors are filled and under corresponding pressure.
1 The Buyer has to ensure that the operational spares such as work rolls, back-up rolls,
shear knives, etc. are available.
1 Level or the PD computer should to be installed at least for thin gauge rolling in order to
achieve the contract guarantees (primary data sets must be available).

During the test the Buyer as well as the Seller shall be responsible for the recording and proof of all
relevant operating data, test parameters as well as all test results. Before starting any performance
test the procedure for recording, extracting and evaluating of the relevant data should be estab-
lished.



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2.1. Product and Process Data
1
st
CoiI

For the 1
st
coil the Seller suggests the following data for the incoming slab and the final parame-
ters:

Material AA 3104
Entry - Thickness 2.50 mm
Width 1750 mm

Exit - Thickness approximately 0.3 mm

The conditions of the strip (chemical composition, temperature, etc.) shall correspond to the re-
quirements of e.g. Annex 7-1.2.4.

2.2. Pre-setting 1
st
CoiI

Refer to 2.1 "Product and Process data"

The pre-setting has to be done according to the requirements of the Technological Commissioning
Engineer of the Seller.

Pass scheduIe, CVC adjustment range and CVC work roII and backup roII grind

See Attachments.

For further notes, refer also to the "Coiler Master Control.
Setting of the side guides for the 1
st
coiI

Settings
(DS + OS) strip width plus 160 mm (80 mm on both sides)



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3. Hot Commissioning
3.1. GeneraI

At the beginning of the production the operators get familiar with the equipment under supervision
of the Seller. Then extension is possible to 24 h production if the operators are familiarized with the
equipment. After that time production will be extend to 24 h a day and the Buyer personnel will
operate the Plant under their own responsibility.

1
st
- 7
th
/8
th
week 1-shift operation (but at least two shift crews available)
7
th
/8
th
- 16
th
week 2-shift operation
from 16
th
week 3-shift operation

According to the contract the hot commissioning period of the Plant will start after the no-load test
has been completed. That means when the 1
st
coil has been made, the hot commissioning period
starts. At the end of the hot commissioning period the Acceptance Tests (AT) will be completed
and the Final Acceptance Certificate (FAC) will be signed (12 months after Last Major Delivery).

Frequent days for maintenance and analysis of operational results are required to train the person-
al and to keep the equipment in good condition in order to optimise the Plant. The weekly shut-
down should be a minimum of one day at least for the first two months.

The main purposes of the first two months of full operation are:

1 Stabilization of basic mill operation
1 Familiarization of personnel with equipment.
1 Testing and optimization of rolling parameters (width, speed, thickness, chemistry, tem-
perature)
1 Mill operators to get their levelling practices finely tuned in preparation for light gauge
rolling
1 Establishment of all preconditions required for thin gauge rolling

The main purposes for the period from the 3
rd
to the 8
th
month after start-up of hot commissioning
are:

1 Functional guarantees test for mill: preparation time, etc.
1 Rolling guaranteed material grades.
1 Optimisation of rolling performance, minimising of thickness.
1 Quality guarantees tests and production test. These tests mark the end of the commis-
sioning phase if they are fulfilled.

Stable rolling conditions are required to achieve the minimal strip thickness. The thickness of the
slab to be used depends on the final strip gauge according to pass schedule.



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3.2. Hot Commissioning Program

The Hot Commissioning Program is a proposal which describes a possible start-up of the plant in
the period of time between the first product and the issuing of the AC. This proposal was devel-
oped by the Seller based on the knowledge and experiences of similar projects. t considers the
special requirements during the entire hot commissioning period regarding the material quality,
quantity, slab and strip dimensions, etc.

The Buyer shall review the proposed schedule in due time prior to commencing the hot commis-
sioning. n case the Buyer has deviating customer orders, the schedule can be adapted according-
ly. Nevertheless the Buyer has to consider that the commissioning/testing time is limited and fol-
lowing the time couldn't be sufficient to test all guarantee values according to contract chapter 5.

The Hot Commissioning Program shall be mutually agreed between the Buyer and the Seller be-
fore starting the hot commissioning. The mutually agreed Hot Commissioning Program shall also
be considered as the time schedule for processing of the AT activities.

n the case of any changes to the Hot Commissioning Schedule a joint agreement has to be found
between the parties involved.

Before commissioning the tests a team shall be formed which is in charge of coordination and fol-
low-up of all the AT activities. This team is the so-called Performance Test Coordination Team
consisting of team members from the Buyer as well as the Seller. The team members of both par-
ties shall be authorized to sign the Performance Test Protocols as per Annex . 8.

. Acceptance Tests (AT)

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III. Acceptance Tests (AT)
1. GeneraI

During the tests the Buyer as well as the Seller shall be responsible for the recording and proving
all relevant operating data, test parameters and all test results. Before starting any performance
test the procedure for recording, extracting and evaluating the relevant data should be established.

2. Performance Test Coordination Team

Before commissioning the tests a team shall be formed which is in charge of coordinating
all ATactivities. This team is the so-called Performance Test Coordination Team con-
sisting of team members from the Buyer as well as from the Seller.

The main tasks of the team is to coordinate and to follow-up the AT-activities. The team
members of both parties shall be authorized to sign the Performance Test Protocols as per
Annex 8.Certificates.

The target is to perform all tests in the period of time as scheduled. The Performance
Tests shall have the priority over the normal production.

ResponsibIe personneI

1. n this subchapter those persons are mentioned who are nominated to accept and
sign the test certificates.

On Buyer's side: ______________________________

pp.: ______________________________

On SMS SEMAG's side: ______________________________

pp.: ______________________________

2. Test Coordinator SMS SEMAG AG: ______________________________


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Communication

Commissioning teams from mechanics, automation and electric systems should always communi-
cate to harmonise the daily commissioning schedules and major changes (daily and weekly meet-
ings). Major changes should 123 be performed at the same time.

Communication between Customer and Seller is a priority. While executing his commissioning du-
ties the Seller should always consider the ever-changing conditions that occur on most sites.

All stages in the progress of the commissioning elements 4563 be documented. t is therefore rec-
ommended that a customer site meeting shall be scheduled every working day morning and after-
noon. The Seller should also have a weekly review/forward-planning meeting.

3. Procedure of Performing the Tests

PIanning

Only good organization and planning can ensure successful handling of the tests. t is required that
the procedures and duties put forward will be thoroughly discussed and settled among the parties
involved.

The Buyer 4563 be able to perform all tasks. One prerequisite is sufficiently skilled personnel. All
standard operating procedures like roll change or cobble removal are well known and trained in
them. During the period of the performance tests the Plant must be operated by the Buyer's per-
sonnel according to the Seller's reasonable instructions.

The rate of adaptation and progression rate of commissioning can only be as good as the feed-
back information. t is obvious that the information and data collection during the period of commis-
sioning is an ongoing process. A method for improving and enhancing smooth operations is to en-
sure that the information gathered is transferred to the operational groups by means of separate
training lessons. t is recommended to document procedures and set parameters internally for later
check-back reference and for any SO certificates a company wishes to apply for.

From the outset there needs to be a well-established quality control department, all formats for
investigations and defect tracking must be clear and decisive. A document and revision control
system has to be established.

Performance of tests

The tests shall be performed with all production equipment installed and documented in the pres-
ence of the Seller. The performance tests shall be initiated according to contract chapter 5 during
the commissioning period. Material grades which have not been tested before in sufficient quantity
cannot be suggested for Quality Testing. With regard to the production scheduling the shape and
grade changes are limited. During the test, the Buyer as well as the Seller shall be responsible for
recording and proving all relevant operating data, test parameters and all test results. Before start-
ing any performance test, the procedure for recording, extracting and evaluating the relevant data
must be agreed upon.

All disturbances shall be fully documented and the reason(s) for the disturbance or fault location
shall be agreed upon during the test. Where agreement cannot be reached during the actual test,
the documentation will be re-examined and analysed in detail after the event to establish the cause
of disturbance.


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All test results should be made available within five days after the end of the test. The actual meth-
od and procedures must therefore be fixed upon in advance.

4. Preconditions

This chapter indicates beside the preconditions in the contract chapter 5 those suppositions, which
have to be fulfilled by the start of the AT.
Over and above these, the preconditions of chapter V ("Product Quality) shall be fulfilled in order
to attain the complete performance and quality of the plant.

Precondition for the incoming materiaI

The incoming strip shall be in accordance with the following parameters over the full strip length of
a coil:

Item

Precondition

Thickness accuracy
with change of measured
Within 2 % of nominal thickness
Max. 0.2 % over 1 m strip length at the strip centre

Wedge shape (cross shape)
Max. 50 % of measured crown C
50

Max. 0.3 % over 10 m strip length 50 mm inside each strip edge.

Crown
Within 0.3 to 1.2 % of strip thickness
Max. 0.2 % over 10 m strip length 50 mm inside each strip related to strop
centre
Width variation Within 5 mm of nominal width
Camber Max. 15 mm over 10 m strip length
Hardness variation
Within 5 % of average hardness
Max. 1.0 % over 10 m strip length by roll force variation
FIatness Suitable for normal threading and rolling operation


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The incoming coils shall be in accordance with the following parameters:

Item

Precondition

Free of edge cracks and edge damages

Tightly wound with geometrically round inner diameter

No eccentricity or oval shape
CoiIing accuracy
between two wraps
Max. 2 mm
CoiIing accuracy
teIescope over fuII coiI
Max. 5 mm from theoretical centre
(the first 5 inner wraps and last 3 outer wraps will not be considered for
incoming coil pre-conditions and cold rolled coil performance test)
Temperature within requirements of pass schedule to avoid overheating

MiII area

At all times during the test period, four complete sets of ground work rolls will be available in front
of the mill, ready for intermediate change if and when necessary. All rolls taken out of the mill will
be removed expediently to the roll shop and new rolls returned immediately without delay to the
mill and positioned ready for the next change.

With regard to all media spray applications such as cooling, cross-spraying, and lubrication; the
following is required in general:
1 Defined position and alignment of headers and nozzles according to the specification
1 Lubricant and water in sufficient quality (cleanliness, temperature, chemistry), quantity and
pressure
1 Flow without clogging

OperationaI pre-conditions

1 The eccentricity of the work and back-up rolls will be maintained within 0.007 mm for the
BUR and 0.005 mm for the WR. These values will be measured on the grinding machine.
The overall roll stack eccentricity must not exceed 25 m, measured from tip to tip in the
roll gap.
1 The spool eccentricity must not exceed 0.5 mm, the maximum oval shape must not exceed
1 mm.
1 Uniform and appropriate roll roughness all around the circumference. The roughness and
surface of the rolls are suitable to produce the required strip qualities at assumed rolling
speeds.
1 The rolling oil is suitable to produce the required strip qualities at assumed rolling speeds.
1 All actuators, measuring instruments and control circuits are active and work proper and
perform repeatable within their nominal operating ranges and limits.
1 Operation is in automatic mode without operating errors due to manual intervention
1 Rolling schedule for normal production on a warmed-up mill stand shall be used, utilizing
the optimum control mode. A warmed-up mill is defined as having the rolls, coolant and lu-
brication system at stabilized temperature under rolling conditions.

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1 Strip head end to be prepared to facilitate easy threading
1 Change parts and commissioning spares shall be made available by the Buyer at side to
ensure smooth commissioning, production and tests.
1 The mill will be maintained by the Buyer accordingly to Sellers instructions and manuals
during commissioning phase and performance test period.
1 The coil centering accuracy onto the pallet after loading via bay crane is in the range of
25 mm.
1 Thickness gauge capability has been mutually agreed prior to start of the performance
tests. This could include also offline measurement methods for verification.

Alle Rechte vorbehalten / All rights reserved


. Performance Guarantee Tests (PGT)

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6. PG ScheduIe

The following table contains the guarantee tests according to Appendix 5.

Table 6.1a): Schedule for PGT

Item-No. Designation Week after first CoiI
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
5.3.3 (1) Thickness accuracy
Nominal Exit Thickness : > 0.600 mm

Nominal Exit Thickness : 0.351 mm - 0.600 mm




5.3.4 (1) Flatness performance
Nominal Exit Thickness : > 0.600 mm





5.3.5 (1) Work roll changing time for one stand

Alle Rechte vorbehalten / All rights reserved



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Item-No. Designation Week after first CoiI
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
5.3.5 (2) Work roll changing time for any stands simulta-
neously

5.3.5 (3) Additional mill calibration time after roll change

5.3.6 Centring accuracy of the coil at pay-off reel

5.3.7 (1) Coiling accuracy at tension reel. Edge variation
between two adjacent wraps

5.3.7 (2) Coiling accuracy at tension reel. Telescopic over
full coil (from theoretical centre)

5.3.8 Strip surface quality

5.3.9 (1) Availability of Electrics and Automation

5.3.9 (2) Availability of mechanical equipment and fluid
systems


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7. EvaIuation of Performance Guarantee

The following overview contains a selection of cases which can lead to an exclusion from the tests.
For other exclusions refer to the contract.

No. Operation / Deviation Annex
01 f any deviations from the preconditions as specified will occur during the per-
formance tests, the strips or periods of time affected by said deviations may
be excluded from the evaluation.

02 Operator interventions (other than vernier adjustments provided) may cause
the strip to be excluded from the evaluation.

03 nadmissible manual interventions by the Buyer's personnel will result in ex-
clusion of those strips from the evaluation of performance guarantee and
shall not be taken into consideration as production loss.

04 All cobbled pieces, first strips behind cobbled pieces and the rejected pieces
will be excluded from performance evaluation.

05 Errors in performance that are found to be attributable to chemistry errors for
a given steel grade will be omitted from evaluation.

06 Slabs cast with deviations from the specified parameters (for example chem-
istry, temperature, casting powder etc.) are excluded from the guarantee.

07 Slabs exceeding the maximum dwell time in the furnace can be excluded
from the performance trials.

08 All cobbled or ripped strips will not be used as test samples and will be ex-
cluded from the performance evaluation.

09 Delays caused by failure not due to the Seller's reasons or lack of external
services will not be under the Seller's responsibility and may not influence
commissioning, function tests and performance tests.

10 All strips with change in thickness and with change in speed are excluded
from temperature tolerances.

11 The hot strip head ends and tail ends will not been taken as test samples.
12 Process limits: Operation in a control limit, as detected by the automation
system or observation, may disqualify the piece.


V. Product Quality

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IV. Product QuaIity
1. GeneraI

The following statements summarise the conditions to be met and maintained for achieving good
quality results during the operation of the Plant. Basic and detailed conditions are outlined in the
production and operating manuals.
Coils rolled from slabs not within the specified requirements may not fulfil the requested quality
results.
Any disturbances of the Plant shall be fully documented.
Data collection of the process parameters shall be made available as soon as possible or at least
within a few days after the end of the data collection and measurement period.
All plant drives, controls and regulating systems have to be in automatic operating mode and
within their normal operating range. No limits shall be exceeded.
Plant operators and personnel have received training and education and are skilled in for
executing their tasks.

2. PersonneI Requirements

All senior mill operators must be proficient in their respective positions and carry out their
corresponding responsibilities. The Buyer's supervisor(s) are to be in full control of all shift
personnel and responsible for the communication between the Buyer's personnel.
The composition of the shift personnel performing the tests should be balanced so as to ensure
the best possible results.
The suggestion by the Seller for personnel requirement is minimum one person on each control
stand and an adequate number of maintenance personal and for the computer system. The
personal requirement should be discussed before the Hot Commissioning starts.
Number of staff is based on normal production and on 3 (three) shifts with 8 (eight) hours each.


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3. Conditions to ensure the product quaIity
This chapter indicates those preconditions which shall be fulfilled in order to
achieve the complete performance and quality of the plant.

MiII and CoiIer area

With regard to all media spray applications such as cooling, cross-spraying, descaling and
lubrication; the following is required in general:
- Defined position and alignment of headers and nozzles according to the specification
- Lubricant / water in sufficient quality (cleanliness, temperature, chemistry), quantity and
pressure
- Flow without clogging

Item Precondition Remark
RoIIer tabIes,
roIIs (generaI) All rolls must be rotating and free of any defects
that would contribute to bottom surface scratches.
Adjustment of roller drives as required (strip
tension).
General
Side guides All side guides are to be clean and free from any
remnant material.

Measuring
gauges and
transducers
All measuring gauges (speed control, thickness
control, flatness control) in specified measuring
range.

Finishing miII Cooling and cross-spraying - see above-
mentioned general explanations.


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Running-in of
the miII
To achieve the necessary warm-up of the rolls and
levelling of the mill, enough strips are to be rolled.
The quantity of the corresponding strips depends
on e.g.:
- actual levelling state of the mill
- length of the interruption since the last rolling
(e.g. cobble, start-up of a sequence)
- temperature of the rolls (roll change, cooling
conditions during the interruption)
- thickness of the last strip and of the strip
currently rolled
- experiences, practice and confidence of the
operator
Recommendation
(Absolute minimum)
under normal conditions
(after roll change, break
< 40 min.):
HGC, CVC,
BUR
baIancing,
thrust pIates
Pressure and position transducers in functional
condition.

CVC
PIus
and
WR bending
WR bending and CVC
Plus
in operation and
adjustable.

BUR Iocking Proper function of cylinder and limit switches is
ensured.

BUR aIigning Proper function of cylinder is ensured.
BUR
changing sIed
Step plates according to roll diameter (regrind
compensation).

Work roIIs The rolls have to cool down to ambient
temperature before grinding throughout the body
and not only on the surface.
Required grinding accuracy of the roll:
- better than 5 m related to the diameter
- radial true run: better than 5 m
- cylindricity: better than 5 m

WR cooIing
Cooling - see above-mentioned general
explanations.
Avoidance of inefficient or unnecessary cooling.


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MiII stand Undefined water on the strip surface shall be
avoided. Stripper and wiper have to be in good
condition (wear and sealing condition).

RoII Gap
Lubrication
Lubrication - see above-mentioned general
explanations. Use of suitable lubricant according to
the seller's recommendation. For operation of the
RGL the special instructions given by sellers'
personnel and manuals are to be considered.

Measuring
device
n operation, calibrated and in accordance with
operating manual.
Strip to be measured has to be dry and free of
steam (blowing-off function).
speed, profile, flatness,
thickness, temperature
CoiI
inspection
All coils should be marked and banded in
accordance with customer's requirements. Any
abnormalities seen must be reported immediately
to the test supervisor(s).
n case of surface defects due to roll marks or roll
peeling, the work rolls concerned have to be
changed immediately. f not, all following strips will
be excluded from the surface inspection test.

Storage Due storage and removal away of the coils. Proper storing and lifting
equipment available
ConsumabIes Consumables in sufficient quality and quantity


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RoII and segment shop
Item Precondition Remark
RoII shop Recommended roll grinds suitable for the
associated equipment and product

2 rolls of a set:
- shall be made by the same manufacturer
- difference of diameter shall not exceed
0,1 mm

Cooling of the rolls after use (uniform, cooling
time). All mill rolls must be completely cooled
down before regrinding. The maximum
temperature difference across the barrel length
which can be permitted at the time of regrinding is
2C.
Backup rolls - naturally cooled down for 96 hours
before grinding.
Before and during
grinding for both rolls of
a set.
Periodic hardness tests should be made on newly
ground rolls. The measured values must be in the
range of +/- 5 Shore.
Backup rolls - hardness must always be taken
before and after grinding.
The specified hardness of work rolls should be
periodically checked minimum all 10 mm of
wear.

All rolls used should have a fully documented
history.

Lubrication of Work Rolls (RM, FM) - Grease
Handling of Rolls

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4. Operation and Maintenance

The appropriate operation and maintenance of this plant is explained in details in the "Operating
Manual.

5.3.3 Thickness
accuracy
Nominal Exit Thickness :
> 0.600 mm
The Seller will demonstrate the
capabilityof the cold rolling mill to achieve
the strip thickness tolerances according
.
< 0.50 % For the thickness performance verification the exit
thickness deviation will be measured with a fixed
sampling rate in Sellers process controller.
Thickness reduction for each rolling pass 1 20%
Rolling speed 1 80m/min
The thickness performance for both
alloys will be confirmed by measuring
samples using proven offline
measurement techniques.
5.3.3 Thickness
accuracy
0.351 mm - 0.600 mm
.
5.3.3 Thickness
accuracy
0.255 mm - 0.350 mm
.
5.3.3 Thickness
accuracy
0.201 mm - 0.254 mm
.
5.3.3 Thickness
accuracy
0.150 mm - 0.200 mm
.
5.3.4 Flatness
performance
> 0.600 mm
the strip flatness tolerances according .
5 9 I-Units The guarantee figures for flatness accuracy are defined
as statistical values (2o). The flatness accuracy test is
passed if 96% of the evaluated strip length fulfill the
guarantee values.
The flatness is measured by the exit side flatness
measuring roll. After every rotation the flatness
measuring roll furnishes a measured value for each
fully covered measuring zone.
5.3.4 Flatness
performance
0.351 mm - 0.600 mm
guarantee values.
5.3.4 Flatness
performance
0.255 mm - 0.350 mm
guarantee values.
5.3.4 Flatness
performance
0.201 mm - 0.254 mm
guarantee values.
5.3.4 Flatness
performance
0.150 mm - 0.200 mm
guarantee values.
5.3.5 Work roll change
time
Work roll changing time
for one stand
Work roll change time for one stand 1 4.5 min Stop watch The time is measured from starting of the changing car
automatic mode.
Not included in the roll changing time :
Times for maual operations
Times for crane handling
time
Work roll changing time
for any stands
simultaneously
Work roll change time for one stand 1 5.5 min Stop watch The time is measured from starting of the changing car
automatic mode.
Not included in the roll changing time :
time
Additional mill calibration
time after roll change
The time is measured from starting the
sequence "Roll Change" untill the roll gap
setting for the next ingot.
5 1.5 min Stop watch Not included in the roll changing time :
5.3.6 Centering accuracy
of the coil at pay-
off reel
Centering accuracy Centering accuracy of the coil at pay-off
reel
max. 5,0 mm The centering accuracy relates to the reference coil
diameter at coil face side for coil centering at the coil
preperation station.
The centering accuracy is related to the mill centerline. Deviation at other coil diameter areas
due to telescope or other unshaped
coil-built-up are excluded.
Measuring method Condition for measuring / test Remarks Item-No. Area / Item Function Description / definition Desired VaIue
Auf.-Nr. / Order No.
A00226.580 MAADEN TCM
Stand / Revision
2012-15-08
Blatt / Sheet
1 / 2
Measuring method Condition for measuring / test Remarks Item-No. Area / Item Function Description / definition Desired VaIue
5.3.7 Coiling accuracy at
tension reel
Edge variation
between two adjacent
wraps
max. 2,0 mm The coiling accuracy between adjacent wraps shall be
tested at 10 randomly selected coils after final cold
rolling pass.
The first 5 inner wraps and the final 3 outer wraps are
excluded from the evaluation.
The test is passed when the average
accuracy values of all measured test
coils are equal or less the guaranteed
values.
5.3.7 Coiling accuracy at
tension reel
Telescopic over full coil
(from theoretical center)
max. 5,0 mm The total telescope over the full coil shall be tested at 10
randomly selected coils after final cold rolling pass.
The first 5 inner wraps and the final 3 outer wraps are
excluded from the evaluation.
The test is passed when the average
accuracy values of all measured test
coils are equal or less the guaranteed
values.
5.3.8 Strip surface
quality
Strip surface quality The strip surface after rolling is free of
scratches and markscaused by
mechanical equipment. Additional the
surface shall be free of water or oil
stains.
Free of scratches and
marks
The roll surfaces are free of marks and skratches.
The surface of the incomming material has to be free of
scratches and marks.
The mill has to be maintained and cleaned in a propper
way.
Excluded shall be the following
partical areas:
Threading n - until target strip tension
is applied on tension reel.
Threading out - starting with tension
loss at pay-off reel.
5.3.9.1 Availibility Availability of Electrics
and Automation
2 99 % The availibility of electrics and automation shall be
verified within a period of max. 2 weeks continuous
normal operation. The latest date of starting the
availibility test is 3 months after end of performance
tests.
The equipment shall be maintained by
costumer and the maintenance
personal shall be able to correct faults
within a max. period of half an hour.
Spare parts, instructions mauals as
well as fault-finding documents shall
be stored as close as practical to the
plant site.
5.3.11 Availibility Availability of mechanical
equipment and fluid
systems
2 98 % The availibility of electrics and automation shall be
verified within a period of max. 2 weeks continuous
normal operation. The latest date of starting the
availibility test is 3 months after end of performance
tests.
The equipment shall be maintained by
costumer and the maintenance
personal shall be able to correct faults
within a max. period of half an hour.
Spare parts, instructions mauals as
well as fault-finding documents shall
be stored as close as practical to the
plant site.
Auf.-Nr. / Order No.
A00226.580 MAADEN TCM
Stand / Revision
2012-15-08
Blatt / Sheet
2 / 2

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