siemens-vai.

com

Electrics and automation

for long rolling mills
Technology, automation solutions, electrical systems,
mechatronic packages, engineering, and services

Answers for industry.

Your challenge:
Meeting quality, flexibility, and
environmental requirements

Highest product quality

Long rolling producers are challenged to provide products
that meet ever-increasing quality standards.
Older or outdated automation systems cannot achieve the
quality control required for process production standards.
Anything less than the most modern tracking methods
and process handling equipment risks compromising productivity, metallurgical properties, cut length, packaging
quality, and overall product quality.
Maximum plant efficiency
While demands on products and processes are always increasing, steel producers are faced with limitations caused
at least in part by inadequate automation technology.
New electrical equipment can not only deliver the highest
control performance but also the best plant availability,
and reduces the risk of total shutdown resulting from unavailable spare parts.
Value
Every decision in plant operations must take into account
the return on investment because money can be expended only if a real advantage in cost savings and greater
success on the market can be accurately predicted.

Cost-efficient equipment and automation solutions from a

supplier with experience from more than one hundred
long rolling installations around the world ensure your investment and your value.
Flexibility in changing markets
Your production lines must be flexible enough to react to
market requests, and be able to produce the steel grades
your customers demand which can be ensured by the
best-quality electrical equipment and flexible production
setting and tracking systems.
Environmental care
Converting raw materials into finished steel products is
very energy-intensive. The energy consumption of electrical drives is a key cost factor that must be considered in
terms of cost saving as well as environmental conservation.
International agreements and national laws require a
reduction of pollution, energy consumption, and CO
emissions. The intelligent design and functionality of upto-date electrical and automation systems is the best way
to fulfill present requirements and anticipate those of the
future.

Fully optimized automation and electrical systems form the foundation

of reliable production processes, maximum plant performance, and
quality products that can meet all market demands. These solutions
must be ready for extensions and future upgrades, and also may need
to be compatible with existing automation environments.

You expect...
A supplier who has the right solutions for your plants needs and
experts with experience in long
rolling
A partner who is open to your
requests and has a local presence
as well as support from a global
headquarters
A company that supports you from
cradle to grave, from project
planning to realization and
throughout the entire lifecycle of
the plant
Top-shelf electrical and automation
equipment, from high-performance
drives to automation solutions that
ensure best-in-class production
Systems and solutions with high
availability, high efficiency, and
minimized operating costs
Optimized electrical equipment for
energy savings, reduction of consumption and emissions, and environmentally clean operation
Modular and open packages for
every conceivable configuration
for new installation, modernizations, extensions, upgrades, and
partial revamps
Continuous updates on your
plants production performance,
high-quality material tracking, and
plant data acquisition and reporting systems

SIROLL LR was designed in 2000 as a standardized solution that would implement the experience of many projects and extensive customer feedback.
Now it manages all long rolling mill types bar and wire rod mills as well as
medium and heavy section mills and will be continuously maintained and
upgraded to remain the state-of-the-art system worldwide. SIROLL LR provides
complete mill solutions that include modular standard packages. Additional
packages can be phased in as the mill evolves to facilitate easy modernization.

Advantages of our electric

and automation solutions
SIROLL LR:
High-performance SINAMICS AC
drives and energy-saving induction
motors
SIMATIC S7 basic automation with
modular functionality and fast
process control
Open interfaces for third-party
drives and automation equipment
WinCC HMI system with smooth
plant management and material
tracking functions
SIROLL LR Process Expert modular
process automation system across
the entire long rolling plant
SIMETAL MES with SAP integration
for plant-wide production planning
and control
Many mechatronic packages for
integration into SIROLL LR
automation or available standalone for upgrading plants in
operation
Individual designs for customerspecific requirements for new
installations, extensions, and
upgrades as well as complex modernization projects

SIROLL LR Process Expert

(process automation, L2)
ExpertManager/Roll Master
SIROLL LR
basic auto
mation (L1)
based on
SIMATIC PLCs

SIROLL LR HMI
based on
SIMATIC
WinCC

SINAMICS main and

auxiliary drives

Standard products plus engineering

experience: SIROLL LR is the standard
solution for long rolling

Our motivation
As a full-line supplier, we try to understand complex market requirements and we need to react to diverse requirements from the smallest upgrade solution (such as a
shear drive upgrade) to complete turnkey solutions (for example, L2 and L1 drives and energy-saving equipment) to
the highest technical demands for high-speed and special
steel grade production.
From products to solutions
There is a core concept at the heart of every product. It
consists of standardized components and services for customer requirements that occur repeatedly even across
industry lines. With specific adaptations or additional features, the core concept can then be transformed into a
customized solution.
Product lines generate cross-industry synergies through
the common use of components, systems (hardware and
software), platforms, services, and tools. Product line
synergies are then realized in products, solutions, and services for the customer.
Success from a single source
Our solutions ensure that all aspects of a mills design,
manufacture, installation, and start-up are managed with
careful coordination and expertise. This comprehensive
Yesterday

approach is unique. As the only supplier with an extensive

knowledge of electrical systems (more than 150 years)
and mechanical expertise (acquisition of Morgan, Pomini,
Ashlow, and VAI/GM from 20052008), Siemens alone can
claim 250 years of mechatronic expertise.
Automation from the global market leader
As the manufacturer and designer of SIMATIC hardware
and software, Siemens is the trendsetter in industrial automation systems. Siemens is able to supply custom-made
solutions for a variety of industries: from single machine
tools to complete factories containing basic automation,
process automation, and MES solutions.
Wheres the proof?
With our SIROLL LR concept, our world-class electrical
equipment, our unmatched mechanical expertise, and our
process and design tools, we set benchmarks for the long
rolling market. We are successful in delivering complete
new mills as well as a wide variety of upgrade projects.
The numbers demonstrate the success of our concept.
More than 100 rod, bar, and billet mills around the world
have set new standards for technological leadership, reliability, and performance and have captured the greatest
market share in long rolling equipment.

Today

Automation and drives

Plant engineering

Digital plant engineering

Siemens is the worlds leading supplier

of electrotechnical and automation solutions as well as drive technologies for
the steel industry and OEMs

End-to-end supplier of metallurgical

plants

Simulation of the entire production chain

Mechatronics
Integration of automation, drive technology, and power generation and distribution
Integration of electrical and mechanical
elements to produce mechatronic
solutions
Product Lifecycle Management
Faster project integration through software-based design, development, and
engineering
Support over the entire lifecycle

Tomorrow

New production standards

Billet welding
Spooling
Heat2power: new method for storing heat
More sustainable production
Energy-efficient processes
CO reduction
Flexible use of raw materials
Flexible supply- and demand-oriented
production

SIROLL LR standardized electrical

and automation topology for complete
or partial mill solutions

SIROLL LR is part of our commitment to deliver comprehensive, totally

integrated solutions from a single source. Our process knowledge combined
with Siemens state-of-the-art automation components and software that
runs on user-friendly human-machine interfaces provides operators with
simple and efficient tools to master their processes.

Drives
Selected high-performance AC drives to meet all your
needs, designed with our special expertise with CAD engineering tools, offering optimized models for lower investment and lifecycle costs.
Automation
Open communications, standard hardware, modular software our Totally Integrated Automation means lower
costs and greater flexibility.
Production monitoring system
Fully scalable, from basic information to a full-featured
control panel (Level 2 and higher) for all your production
processes.
Human-machine interface
Focus on the essentials: optimal working conditions
for the operator, in the pulpit, or elsewhere in the plant.

Technological tools and control system

Rolling speed, minimum material tension, and fine-cutting
position controlled according to your process requirements and plant specifications.
Diagnostics
An integral element of our automation systems
with the goal of minimizing plant downtimes.

Lifecycle
Our services extend from maintenance to expert
consulting to customized modernization concepts.

11

Years of SIROLL LR
a long rolling success story

Compare with production worldwide

process automation from a single source

SIROLL LR
a standardized solution for long rolling
Technological packages

2008
WALSIN LIHWA, (Taiwan), installation of
modernization packages in modular
design for basic automation, process
automation, and drive solutions
1999
Pilot plant at STELCO
MC MASTER (Canada),
SIROLL LR for bar mill

Compactor 1
COMP1
OS1

2010
HANDAN, (China),
mechatronic packages
fully integrated into
SIROLL LR solution
for both wire rod and
bar applications

2008
Morgan integration,
process expertise for
high-speed long rolling
applications

2000
Pilot plant at ANYANG,
(China), SIROLL LR for
wire rod mill

PA
client

Label
printer

BA HMI
client

BA (L1) HMI
basic automation

PA (L2)
Process automation

SYSTEM BUS

Switch

Compactor (COMPn)

Coil Handl.H (COILH)

Compactor control
Media system control

Coil handling control

Sequencing horizontal
Interface wire tiers
Media system control

S7-300
(one per compactor)

Switch

Rolling Mill (MILL)

S7-400

Coil Handl.V (COILV)

Rod Outlet (ROD)

Coil forming control

Coil handling control
Sequencing vertical
Media system control

Central switching
(main drives and media)
Mode of operation
S7-400
Cascade
Water box control
Loop control
Shear control
Stelmor control
Reducing sizing mill
Stelmor blowers
Intelligent pinch roll
Laying head FEO

S7-400

Rolling Mill (CTRL)

Central switching main drives

and media system
Mode of operation
Furnace interface
Entry area charging
and transport operations
Roll change functions
Mill offline functions
Transport to mill
Descaling
Weighing system
Media system control

S7-400

Central switching main drives

Mode of operation
Schedule handling
Cascade control
Minimum tension control
Loop control
Self-adaptation

Example Level 1 automation package

Stand control and complementary machines
in an existing plant
Control
Tension-free rolling
Speed master
Shear control

2001

2002

2003

2004

2005

2006

2007

2009

2010

Central switching drives

and media system
Layer forming
S7-400
Carriage control
(one per stacker)
Rotating arms enhanced position
Media system control

2011

Charging Grit
Monitor

Furnace Tracking
Monitor

Continuous Mill
Monitor

Heats

Billets

Billets

Coils

Billet Yard
Module

Melt Shop Initial

Inventory Module

Online System Help

Module

Heats

Heats

System messages

Roll wear detection

MES server
melt shop

Process monitoring guide

Process data
acquisition

BA (L1) HMI
basic automation

PA (L2)
process automation

Plausibility
Module
Info messages
Basic modules

Plant Maintenance
Tracking and Guide
Module
Maint. messages

Rolling Mill and

Delay Configuration
Module

MES Synchronizing
Module
Billets/coils

Tracking function

Coil Weight and Tag

Monitor

Quality Online
Monitor Module

Coils

Coils

Analysis and
Reports

Coil Yard Inventory

Module

Heats/billets/coils

Coils

Level 2
Management
Module
Performance reports

Product Genealogy
Module
Billets/coils/bars

Offline Sample
and Laboratory
Module
Product reports

Extension modules

SIROLL LRPX
laboratory

Roll shop manager

SIROLL LR Process Expert functions and features

Bar counter contact and non-contact

Stelmor package
Coil plate control

The basic technological functions, based on extensive

experience in the long rolling industry, include:

Special feature

Production sequencing

Interface to SIMETAL MES Manufacturing Execution

System (L3) and other IT systems

Radio-controlled operator station option

Heat data management

Production program optimization

Raw material assignment

Quality online monitor

Automatic mill setup data management and control

Roll and guide management

Material tracking

Melt shop interface

Data processing/archiving

Maintenance tracking and guide manager

Plant monitor
Weighing and tagging

Offline sample & laboratory interface generation

of QA certificates

Analysis and report manager

Coil yard inventory

HMI (WinCC) stand-alone

BAR PULPIT

MES server
long rolling plant

Production
Sequence Module

Laying head pipe wear detection

S7-400

Minimum tension control

Central switching drives

Mode of operation
Process handling layer collection
S7-400
Roller table sequence
Fixed-speed cold shear control
Cut-to-length positioning
Short layer handling
Process quenching
Layer transport and forming Shear control
Interface strapping/binding Cut optimization
Weighing system
Tilting aprons
Media system control
Magnetic brakes

Bar Handl. (BARH)

Central switching drives
Mode of operation
Proccess handling layer collection
S7-400
Roller table sequence
Fixed-speed cold shear control
Cut-to-length positioning
Short layer handling
Layer transport and forming Straightening
Interface strapping/binding Saw control
Cold shear control
Weighing system
Rotating arms
Media system control

Production
Program Module

Rolls and Guides

Management
System module
rolls/calibers

Operation

The future
The advantages of SIROLL LR are unlimited. With a modular architecture specifically designed to accommodate extensions using the most modern control systems, drives,
technical assemblies, and software available, SIROLL LR
allows continuous improvement to plant capabilities,
ensuring the highest-quality products and processes.

Database transfer tables (TCP/IP, FTP)

Front-end orientation

Bar in Coil (BIC)

Central switching main drives
and media systems
Mode of operation
Coil transfer
Coil cooling
BRSM offline functions
Media system control

2008

Function overview

Cut length optimization

Stacker (STCn)

2000

SIROLL LR Process Expert Level 2 automation

Production orders

Replacement

S7-400

Bar Outl. (COOL SLOW)

1999

Technological packages are electrical packages that include the latest technology to enhance the operation and
performance of long rolling mills. These packages implement
the advanced Siemens control concept into existing
long rolling mills. Whether to enhance production, ease
operation, or provide a better understanding of specific mill
operations, these systems are fully flexible and seamlessly
integrated into a new system as integrated solutions or in an
existing system as a stand-alone solution. When supplied
as part of a full mill control system, the technological
packages are embedded into the SIROLL LR solution.

MAIN PULPIT
Process data
acquisition

TERMINAL BUS

2005
Siemens Metals
Technologies IT,
process expertise
for bar and section
rolling

2003
Pilot plant at
PANZHIHUA, (China),
SIROLL LR for
H-beam and rail mill

COIL HANDLING PULPIT

Compactor n

A real mill managers process expert system

A process automation system that allows mill management to monitor the performance of their facility based
on either actual operating data or world standards.

STEP 7
S7-300/S7-400

Control

Interface to mill control

(Ethernet/PROFIBUS/hardwired)

Downtime management

PROFIBUS
ET200

Online system help

Field
Switch

User-friendly integrated HMI

HMDs,
sensors

Stand-alone solution

Optional modules of Process Expert:

Servo
drive/motor

Definition of KPIs (Key performance indicators and

powerful Condition Monitoring)

Main
drive/motor

Genealogy module

10

Drives solutions for long rolling

SINAMICS drive panel

Long rolling is one of the fastest and most complex

processes in the iron and steel industry, and it relies on
appropriate drive technologies. A wide range of steel
grades, shapes, and dimensions must be produced
within tight delivery deadlines. Siemens Metals
Technologies provides the right drives, ensuring product quality, stable production, high flexibility, and
shorter downtimes for product changes. SIROLL LR increases plant performance through low-maintenance
and dynamic AC drive systems for every power range.
Highly flexible drive solutions and power demands
The main and auxiliary mill drives in combination with the
mill stand main motors are crucial elements. The mill drive
and motor technology must therefore be highly dynamic,
with an extremely accurate response and a stable control
system. In addition, the drive technology should feature
high overload capability, smooth running, maximum availability, service-friendliness, and seamless integration into
automation systems.
The SINAMICS family provides functions like drive control,
operator control, diagnostics, and standardized communication across the entire SINAMICS family.

Air-cooled AC induction motor

Low-voltage: SINAMICS S120

The modular SINAMICS S120 drive system is suited for
rolling in a power range up to approximately 2,000 kW.
The SINAMICS S120 system is based on two-level voltage
source converter topology with IGBT transistors on the
motor side and separate rectifiers on the line side. The
motor-side inverters are typically connected to a common
DC bus fed by a common infeed.
Medium-voltage: SINAMICS SM150
The SINAMICS SM150 medium-voltage drive is used for
sophisticated single- and multi-motor drive applications,
combining high dynamic performance with maximum
control precision. Supporting a drive output range extending from approximately 2.5 to 30 MW, the SINAMICS
SM150 system is based on water-cooled three-level converters designed around integrated gate-commutated
thyristors (IGCT) with a voltage source link and active
front end (AFE).
DC drives: SINAMICS DCM
The SINAMICS DCM DC drive offers many advantages:
flexibility, dynamic performance, ruggedness, reliability,
and operational characteristics that can be expanded in a
modular fashion. The SINAMIC DCM system can be optimally adapted for use in modernizations, because it is supplied with rated DC currents from 15 to 3,000 A in a twoor four-quadrant configuration. A key benefit is that
existing DC motors in good condition can be reused with
advanced SINAMICS technology.

After roll-pass process calculations, each stand motor is selected

and optimized from standard Siemens equipment

Heavy-duty rolling motors

When it comes to overall plant operation, rolling mill motors are a crucial element. The extremely rugged synchronous and squirrel-cage induction motor technology has a
long service life and plays a decisive role in the ongoing
disturbance-free operation of the motors, which in turn
secures the availability of your entire plant. The compact
motor is designed with optimized materials and further
ensures lower lifecycle costs.

Rolling process engineering system (ROPES)

Siemens Metals Technologies in-house roll pass and process expertise has been enhanced through the incorporation of Siemens drive and motor data into ROPES. The required rolling torques/speeds are calculated from the
roll-pass information that is generated by ROPES. With this
information, engineers can design the optimal electromechanical configuration to meet process requirements utilizing standard Siemens motors and drives as well as standard gear sets.

Low-voltage
Aux drives

Medium-voltage
Stand drives
(S120 chassis)

Block drives

Grafik nachzeichnen

G120

S120

G130/S120

Book size

Book size
1.6107 kW

Chassis unit
1101,200 kW

0.37110 kW

12

...to ensure that all products manufactured conform to the

system design.

G150/S150

S120 CM

Standard cabinets Cabinet modules

751,200 kW
1104,500 kW

GM150

SM150

Cabinet modules
800 kW18 MW

Cabinet modules
2.831.5 MW

13

Level 1, HMI, and process control

Level 2 and higher-level automation

SIROLL LR Process Expert Link Bridge
ERP
Systems

Level 4: ERP, full business integration,

intelligence

MES
Supply Chain
Management

Level 3: Raw materials, inventories,

MRP, MRP II, production
cost

Historically weak manual link

Supervisory Control and
Monitoring Systems

Control Systems PLCs and Floor Level

Typical WRM overview screens

The combination of process technology, mechanical

equipment, electrical components, and automation
functions is a crucial aspect of Siemens Metals
Technologies solutions, and allows us to deliver the
highest possible performance to our customers. From
initial mill design to maintaining your plant for years
to come, Siemens Metals Technologies is unique in offering world-class solutions as a single-source supplier.
Basic automation (L1) and human-machine interface
(HMI)
Siemens Metals Technologies highly modularized technological control functions are based on extensive experience in the long rolling industry, and include:
Minimum tension control
Loop control
Cobble detection
Shear and high-speed shear control
Water box control
Intelligent pinch roll control
Coil handling system
Compactor control
Mill setup
Standard interfaces
Mechatronic packages as technological units
As an integrated and autonomous supplier, we offer a seamless array of automation functions from a single source.

Level 1: Floor control and

operations

Figure 1: The four automation levels according to ISA 95

The modular design of both hardware and software ensures flexibility for all customer requirements in upgrades,
extensions, new plants, and very complex revamps.
We achieve world records in commissioning time by customer-specific concepts, especially during upgrades and
short shutdowns.
The operator stations and HMI screens are developed
alongside experienced customers from mills worldwide,
offering a practical, user-friendly look-and-feel.
Spare-part stocks for our automation components are
available worldwide.
Experienced specialists for programming, training, and
support are available in our regional offices near you and
also at the company headquarters.
Joint mechanical and electrical teams drive our long rolling
technology forward through ongoing research and development activities and through upgrades to SIROLL LR.
Basic automation and HMI system design
Standard SIMATIC PLC S7-400 hardware components
centrally installed in the control room or as premanufactured complete container
Decentralized SIMATIC ET200 I/O modules interfaces to
plant sensors and actuators for short cable routes
PROFIBUS and SIMATIC NET standard network components ensure proven communication
MS Windows-based server-client HMI system, PCS 7, or
S7/WinCC both available
Also refer to pages 8 and 9.

14

Level 2: Monitoring, production sequence,

recipes, and settings

Process automation (L2) SIROLL LR Process Expert

Consolidation in the global steel industry is bringing new
challenges to the task of managing several plants in different locations and countries. Overall business performance
is controlled by business management, but plant performance is achieved at the mill floor operations level. Due
to constraints in technology and cultural limitations, there
has historically been a weak link between business management and production management in long product
rolling mills and also between the companys different
work centers (mill to mill).
A bridge to the future topology of mill production
control
In accordance with ISA 95, there are four levels where all
business performance and plant data is collated and reviewed. The four levels are shown in Figure 1, which also
shows the levels that are typically driven and managed by
the business side and those that are driven by the production or work centers.
With the technological evolution of PLC control, data collection, and production monitoring devices as well as the
development of fully integrated ERP systems, we can now
integrate and bridge the four levels. This bridge has been
missing in the past, and it is the critical advantage of the
SIROLL LR Process Expert system.
The SIROLL LR Process Expert solution domain extends
from the Level 1 basic automation system that provides all
basic rolling data and information to the MES level with its
product genealogy relationships and production planning
and reporting.

SIROLL LR Process Expert reporting module

The SIROLL LR Process Expert collates the data from Level

1 with all management data and presents the resulting information in a standardized format to meet all specific mill
or company requirements, including reporting, operations, and mill operation tracking. Complex KPIs from the
operational perspective are prepared and displayed and
tools are provided to analyze and locate areas of opportunity as well as drive continuous improvement.
SIROLL LR Roll Master
SIROLL LR Roll Master is an extension that provides the following functions:
Easy computer-aided creation of pass schedule
Calculation of material spread, mill load, and bar temperature on the basis of more than 200 steel grades and
special alloys
Accurate settings of mill guides for product dimension
changes
Mill setup that generates the components actual
condition
Simple management of all key data related to mill
grooves, guides, and rolls; available for high-production
mills and special-steel-grade mills rolling only a few billets per lot
The process automation consists of MS Windows servers
with Oracle database applications
Also refer to page 10.

15

Mechatronic solutions
in long rolling mills

Water box control system (mill floor)

High-speed shear

Rod reducing/sizing mills with offline units

High-speed intelligent pinch roll and laying head

Mechatronics merges mechanical, electrical and control

systems as well as software as an intelligent approach
to the design of electromechanical systems. At Siemens
Metals Technologies, we use this technology to integrate our process expertise along with our advanced
equipment to offer you enhanced products that provide
functionality, flexibility, and ease of use.

Our portfolio includes the following standard packages:

Wire rod mills

Enhanced temperature control

Tiers

Coil storage system MORSHOR

Inline measurement systems

Intelligent pinch roll

Non-contact measurement systems

Modular no-twist mill

You can obtain these robust and proven systems to help

your operation run smoothly, all from a single-source
supplier.

Stacking and bundling machines

Automation topology
Technological and mechatronic packages are an intelligent
approach to merging mechanical systems, electrical systems, control systems, and software with a single global
source for technical support.

Technological packages are electrical packages that include

the latest technology for enhancing the operation and performance of long rolling mills. Whether to increase production, ease operations, or afford a better understanding of
specific mill operations, these systems are fully flexible
and seamlessly integrated into new or existing systems.
Mechatronic packages are mill solutions provided with
mechanical equipment. Combining mechanical and electrical components designed to be used together, mechatronic packages are standard, proven modules that offer
value-added solutions to any long rolling mill.
When supplying a full rolling mill solution, these systems
are integrated into the mill control SIROLL LR. For modernization solutions, they can be delivered as stand-alone systems and interfaced with the existing mill control.

Bar and section mills

Rotary shear control
Reducing/sizing mills
Cooling bed entry systems
Contact and non-contact bar counting solutions

Fluid systems

High-speed shear control

Rotary shear control
High-speed finishing blocks

Tiers

Reducing/sizing mills

Fluid systems

This technology integrates Siemens long-rolling process

expertise with advanced equipment to produce proven
products that provide advanced functionality, flexibility,
and ease of use. Whether supplied as full rolling mill solutions or as modernization solutions, they can all be easily
upgraded.

Laying head control

Inline measurement systems

Stelmor conveyor

Non-contact measurement systems

Reform area

Flat rolling block

Vertical and horizontal coil handling

Compact multirougher

Compactors

Rail precambering

HMI (WinCC)

Mechanical
Automation

Electrical

HMI (WinCC) stand-alone

Operation

Operation
Ethernet

Latest
technology

Technological/
mechatronic
packages

Process
expertise

416 platform
PCS 7
S7-400 SIROLL CPU

Control

STEPS7
S7-300/S7-400

Control

Interface to mill control

(Ethernet/PROFIBUS/hardwired)

PROFIBUS

PROFIBUS

ET200

ET200

Field
Process requirement

HMDs,
sensors

Integrated solution
16

Field
Servo
drive/motor

Main
drive/motor

HMDs,
sensors

Servo
drive/motor

Main
drive/motor

Stand-alone solution
17

Electrical and automation services

From planning, engineering and building to operation and modernization
solutions for the entire lifecycle

Technology-based services for a greater

competitive edge
Minimum downtime and the optimum use of staff and
resources are key to sustainable success in industry.
Siemens provides the basis for greater productivity,
flexibility, and efficiency with technology-based services
throughout the lifecycle of an industrial plant reliably,
globally, and around the clock. In-depth technology and
product knowledge as well as industry expertise within
Siemens global expert network ensure a considerable
competitive edge.
Siemens Metals Technologies offers a modular service and
maintenance portfolio that covers the complete plant lifecycle and comprises solutions suitable for multiple phases.
Individually customized service packages are combined to
assist producers in the iron and steel industry to utilize the
full potential of their production units. Throughout the
worldwide Siemens network, teams of highly skilled engineers are available to support the customers automation
staff.
Consulting and on-site surveys
Experience with more than 1,000 automation projects for
the metals industry forms the foundation of Siemens
Metals Technologies expertise. For both new and upgrading investments, technological as well as economic aspects are evaluated in close collaboration with the customer. An assessment of the projects scope followed by a
proposal of benefit-oriented solutions and a tight completion schedule ensure a successful project outcome.

18

Training packages
Qualified automation personnel is a key element in providing the highest possible plant availability, performance,
and product quality. Siemens Metals Technologies offers
customized training packages to ensure that our customers staff are fully trained and capable of operating the installed automation systems. Training packages can be prepared for production-oriented goals or for specific projects.
A relatively minor investment in well-trained personnel
cant be compared with the major benefits achieved in
overall plant performance.

Spare-part logistics
Siemens Metals Technologies spare-part services range
from providing individual spare parts to providing a single
source for the entire spare-part supply.

Technical assistance and on-site services

Dedicated engineers are available to assist plant staff
in detecting, analyzing, and solving all electrical and
automation-related problems. Our range of services can
be greatly enhanced with the installation of online data
links. These links provide the perfect way to utilize expertise from both local Siemens Metals Technologies automation specialists as well as Siemens Metals Technologies
headquarters.

Modernizations
Siemens Metals Technologies has a long tradition of providing the metallurgical industry with both integrated systems as well as individual technological and automation
packages.

Remote service capability

Remote access (cRSP = common remote service platform)
is a prerequisite for services like remote diagnosis and
remote data analysis. It allows the Siemens Metals
Technologies service specialists to provide expert support
from anywhere in the world.

System upgrades
To keep your plant at its maximum performance level and
provide the latest technology available for installed automation systems, Siemens Metals Technologies offers economical upgrade and optimization packages that reflect
state-of-the-art technologies.

Because of the SIROLL components modular design, it

is possible to install these packages either as stand-alone
versions or embedded into existing environments. In-house
experience in software and hardware engineering is the
key to achieving the fastest project implementation and
start-up.
The interfaces between mechanics, automation, and electrics are replaced by partners cooperating to share technological expertise for your benefit. The installation of
smaller packages can be performed with minimum impact
on production shutdowns.
Long-term service agreements
For a low investment outlay, Siemens Metals Technologies
offers annual service contracts that deliver economical,
fast, and nonbureaucratic support performed by our

experts to overcome bottlenecks and execute fast troubleshooting routines. Our customers benefit from the
Siemens Metals Technologies experts knowledge about
the complex functions of automation systems. Local
Siemens experts are often already integrated during the
project phase of large investments, and are therefore
highly qualified to give our customers technical support
on agreed response schedules.
Metals Service & Support Center
With the Metals Service & Support Center (MSC) service
concept, Siemens Metals Technologies offers plant operators the assistance they need, from an around-the-clock
telephone hotline and help desk to the preventive replenishment of production-critical components.
The backbone of the MSC IT landscape comprises a tracking and tracing tool and remote access to plants in order
to guarantee that the relevant information is quickly available for any service request that needs to be managed.
Within our global MSC network, the most important elements are the local Siemens units. Local Siemens personnel have an excellent technical knowledge, they speak the
customers language, they are on site and they know the
customers management and maintenance personnel.
Main benefits:
Trouble-free and reliable operation, increased avail
ability, and consistently high overall performance
Fast automation and process support thanks to
contractual response times and remote access
Reliable experts knowledge of the complex
functions of automation systems
19

Solutions for energy and power supply

Power distribution in the mill and backward integration of meltshop

Switchyard expansion and integration of three compensation systems for melt shop and mill, Nucor, Crawfordsville, U.S.

Flicker compensation in Acindar, Argentina

One phase of thyristor valve tower for compensation system

In the metallurgical industry, nothing functions without power. This is why the generation and distribution
of electrical power is one of the basic prerequisites
for success after all, the safety, reliability, and costeffectiveness of the plant largely depend on the power
supply. The SIMETAL/SIROLL Power family offers a spectrum of world-class solutions for every requirement.

solution. But most importantly, the specific technological

requirements of your production process must be considered during the conceptual design of a customized network concept. It goes without saying that our SIMETAL
Power solutions are designed to meet the industrys requirements as well as its high demands for operator safety
and operational reliability.

Power to your plant

With a worldwide network of experienced experts, we develop, manufacture, and install systems for substations
and distribution systems customized to your process requirements, including complete turnkey solutions. Benefit
from our extensive expertise in the fields of high-, medium-,
and low-voltage stations. All this, combined with our knowledge about the specific needs of your technological processes, allows us to create a solid basis for smooth production processes.

Whether its switchgear, substations, or plant components, transformers, reactors, or accessories our product
base always represents the state of the art, from engineering through manufacture, installation, and commissioning.

Power quality: more safety, more stability

Large electrical loads in steel plants and rolling mills have a
significant effect on the public electrical supply network.
Network disturbances such as reactive power generation,
voltage distortion, and voltage variation frequently occur.
Utilities impose penalties on the operators who cause disturbances beyond certain limits. In the worst-case scenario, the plant could be shut down.

Filter circuits require the lowest investment costs and can

be used to reduce reactive power consumption and harmonic voltage distortion. Dynamic reactive power compensators (SVC and SVC Plus) also comprise a thyristorcontrolled reactor (TCR) and a voltage source converter
(VSC), respectively. In addition to the features provided by
filter circuits, they reduce flicker and keep the bus voltage
constant which in many cases facilitates an increase in
production output, for example, in three-phase electric arc
furnaces.

Proper distribution does the trick

Voltage dips, reductions, or outages can incur high costs
when they lead to production downtimes. Therefore, a secure power supply that is the result of a well-designed and
equipped supply network is one of the prerequisites for
successful plant operation. High-performance transformers, for example, are as important as the right switchgear

You can always expect products that are easy to use and
highly cost-effective. But their key quality is that they enable your production to run smoothly and reliably without downtimes caused by power failures or fluctuations.
Main benefits SIMETAL Power:
Higher productivity ensured by safe energy supply
throughout the plant
Greater operational safety
Same hard- and software base for lower-cost energy
and process automation
Solid emergency power strategy reduces risk for production plants

Our solution: SIMETAL PQ

Compensation systems not only reduce the negative impact of typical plant loads to specified limits, they can also
result in savings in energy costs and can therefore pay
off quickly. Based on our extensive experience with the
processes in melt shops and rolling mills, we can
reliably evaluate the potential disturbances that
can arise in a given network configuration
support our customers in their negotiations with
public utilities

If a standard SVC system cannot fulfill very demanding

flicker requirements, an SVC Plus system consisting of a
voltage source converter (VSC) can be provided.
For greenfield sites as well as modernization projects,
the best results are achieved if all equipment comes from
a single source from the power supply and compensation system to the arc or roll bite ensuring a safe, stable
production process.

implement the compensation system that offers the

best price-performance ratio for the specific application.

Main benefits SIMETAL PQ

Improved energy supply

Siemens Metals Technologies systems filter circuits and

dynamic reactive power compensators (SVC and SVC Plus)
can be connected to an existing supply network.

Compliance with limit values

Unprecedented operating reliability
Appropriate for restricted spaces
Short amortization period

20

21

Excellence through experience

Selected success stories in rolling mills

E/A modernization of two-strand wire rod mill (700,000 tons per year)

Customer: Wuhan Iron & Steel China

The task: Major modernization of a two-strand wire rod mill in order to react to local market demand, using the shutdown period to create a state-of-the-art automation system with highest performance and availability.
Our solution: Exchange of complete automation, upgrading existing controls to SIROLL LR with CTRL, ROD1, and ROD2.
DC drives upgraded to SINAMICS DC digital control, new AC drive systems with SINAMICS drive systems.

Seamless introduction of new bar mill

Customer:

Arcelor Mittal Temirtau, Kazakhstan

The task:

New bar mill for the production of 400kt/a: rebars, bars, and profiles.

Our solution: Complete new mill using SIROLL LR for the entire line, with CTRL, COOL, and BAR. All drive systems are
SINAMICS series AC drives (first application in a long rolling mill).
The result:

The result:

Modernization improved tolerance to 0.1 mm and ovality to <0.12 mm, and improved mechanical properties
through thermomechanical rolling, allowing Wuhan to enter higher-quality markets (CHQ, tire cord). Auto
mation and process improvements increased production to 700 kt/a (design) with a record 850 kt/a (actual).

New bar and rod mills, each 500,000 tons per year, and SIROLL LR for H-beam production

Customer:

Hebei Iron & Steel Handan, China

The task: Extend production capacity by adding complete new wire rod mill for 500 kt/a, bar mill for 500 kt/a,
and H-beam mill for 800 kt/a.
Our solution: In each mill, the customer decided to use our successful SIROLL LR for all three production lines CTRL and
ROD for the rod mill; CTRL, COOL, and BAR for the bar mill; and BD, TM, COOL, and BAR for the H-beam
mill; as well as our SINAMICS products for nearly all drives.
The result: Fully integrated mills with high-performance rod, bar, and H-beam production. Obtaining all electrical
and mechanical equipment from one supplier lowered maintenance costs and improved mill capacity.

New bar mill with excellent overall performance for profile and bar production, with a successful start-up in 2008.

E/A modernization for cost reduction and performance improvement

Two new rod mills, two new bar mills

Customer: JSW and JSPL India

Customer: Walsin Lihwa, Taiwan

The task:

The task:

Our solution: In all four mills, the customer decided to use our successful integrated single-source solution mechanical
and electrical equipment based on SIROLL LR for the 2 + 2 production lines using CTRL and ROD for the rod
mill; CTRL, COOL, and BAR for the bar mill; and our SINAMICS products for nearly all drives.

E/A upgrade needed due to lack of available spare parts and the need to avoid production losses.

Our solution: Phased upgrade strategy using SIROLL LR packages for CTRL, ROD, COIL, COOL, BAR (SIMATIC PCS 7) to
bring all drives to the newest communication level, and to attain the same or better performance and
availability.
The result: Successful integrated upgrade to the latest process, automation, and drive technologies with shortest
shutdown, minimal downtime, and zero adverse effects on production. Performance and availability are
higher than previously.

E xtension of production capacity by adding complete new wire rod mill for 500 kt/a, bar mill for 500kt/a.

The result: World-class high-speed wire rod mill and slit rolling mill with the highest production via the latest process,
automation, and drive technology. Reduced mill start-up costs by installing two similar mills concurrently,
with all mechanical and electrical equipment from a single integrated solutions supplier.

Combination bar, rod, and flat block mill

Specialty steel bar mill

Customer: Bhler Austria

Customer:

Vizag Steel India

The task:

New specialty steel bar mill with a production rate of 750 kt/a.

The task: Major upgrade of the obsolete CNC control of existing production line and upgrade of hydraulic motors
to new modern AC drives, with a short shutdown time for the entire renovation.

Our solution: Complete new mill using our SIROLL LR for the entire line, with CTRL, COOL, and BAR. All drive systems are
SINAMICS series AC drives.
The result: Flexible and reliable operation in a modern bar mill facility for advanced production, with world-class
maintenance and troubleshooting support.

22

Our solution: SIROLL LR for the entire 16-stand compact cassette Konti line, using CTRL and Mill. Replacement of
hydraulic motors with 32 new modern AC drives for the 16 rolling stands.
The result: Increased production and replicable operations, thanks to implementation of the RollMaster package
for flexible pass design and storage in perfect coordination with our Level 1 SIROLL package.

23

Competence Center:
Siemens AG
Industry Sector
Metals Technologies
Schuhstr. 60
91052 Erlangen, Germany
E-mail: contact.metals@siemens.com
Headquarters:
Siemens VAI
Metals Technologies GmbH
P.O. Box 4, Turmstr. 44
4031 Linz, Austria
siemens-vai.com
Order No. E10001-M6-A34-V1-7600
Dispo No.: 21661 K-No.: 28107 | Printed in Germany
GB 110771 WS 09121.0 | 09.2012, Siemens AG

The information provided in this brochure contains merely general

descriptions or characteristics of performance which in actual case of
use do not always apply as described or which may change as a result
of further development of the products. An obligation to provide the
respective characteristics shall only exist if expressly agreed in the
terms of contract.
All rights reserved. Subject to change without prior notice.
SIROLL and SIMETAL are trademarks of Siemens AG.
No Twist and Stelmor are trademarks of Siemens Industry Inc.