Çolakoğlu Metalurji Hot strip from Istanbul

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1 Çolakoğlu Metalurji Hot strip from Istanbul

Çolakoğlu MeTalurJI Çolakoğlu Metalurji Hot strip from Istanbul

the Turkish metropolis of Istanbul, is currently the most

equipment and the electrical and automation package, we were able

This paid off for Çolakoğlu Metalurji already during the

Çolakoğlu Metalurji has developed from a steel trader into a steel

2 Çolakoğlu MeTalurJI Çolakoğlu 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 group. 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. 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. 2

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

3 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 Right on the Sea of Marmara: the new hot strip mill of Çolakoğlu Metalurji. 3

Çolakoğlu MeTalurJI 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 product mix includes a wide range of carbon steels including HSLA grades, tube and pipe grades, dual-phase and TRIP grades.

4 Çolakoğlu MeTalurJI 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. The rolling mill was erected on stilts in order to avoid groundwater 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. Wide-angle photograph of the rolling mill with roughing stand (left), coilbox and finishing mill. Technical data Commissioning June 2010 Annual production 3.0 million t Steel grades 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 mm Coil Inside diameter 762 mm Outside diameter max. 2,200 mm Spec. coil weight max kg/mm Weight 39 t The utility supply lines under mill floor level structured design. 4

5 also have a well thought-out, clearly The layout of the compact hot strip mill. 5

Çolakoğlu MeTalurJI electrical and automation systems The entire hot strip mill operates with SMS group s X-Pact electrical and automation package.

6 Çolakoğlu MeTalurJI electrical and automation systems The entire hot strip mill operates with SMS group 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 group supply scope. 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. 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 physical models which provide the settings for the various equipment items of the rolling mill under consideration of the material properties. 6

7 Process visualization in the HMI systems. Perfectly coordinated with each other: mechanical equipment and electrical und automation systems. 7

Çolakoğlu MeTalurJI 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

8 Çolakoğlu MeTalurJI 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 mill stand chocks, gear units and drive spindles, coilers and hydraulic roll-gap 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. 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. The automation system of the hot strip mill was tested by SMS group 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 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. Pre-assembly and function testing of mill stands. 8

9 The test field for the Plug&Work tests. Operator training. Gearwheel production. 9

Çolakoğlu MeTalurJI rapid commissioning and excellent rolling results The first strip was rolled by Çolakoğlu Metalurji on the new hot strip mill on June 15, 2010.

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

10 Çolakoğlu MeTalurJI rapid commissioning and excellent rolling results The first strip was rolled by Çolakoğlu Metalurji on the new hot strip mill on June 15, 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. 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. Also with regard to the strip quality, the benefits of SMS group 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. Measured data of the first strip with a gauge of 1.2 mm. 10

11 A view of the coilbox and the seven-stand finishing mill. 11

Çolakoğlu MeTalurJI roughing mill with camber-free rolling The production process starts with heating of the slabs in the walking beam furnace.

12 Çolakoğlu MeTalurJI 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 of 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, positioncontrolled 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 Edger Roll diameter Edging force Width reduction Opening dimension Main drive Rated torque at the rolls 200 bar 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 X-Roll Oil Bearing 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; X-Roll Oil Bearing; spade-end spindles Reheating furnace and high-pressure descaler. 12

13 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. 13

Çolakoğlu MeTalurJI 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.

14 Çolakoğlu MeTalurJI 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 last 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. 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, widthadjustable heat-insulation hoods additionally reduce the thermal radiation from the coiled transfer bar. 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 tailingout. 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. Technical data Mandrelless coilbox Transfer bar thickness 25 to 40 mm Transfer bar width 800 to 1,650 mm Coiling temperature 900 to 1,100 C Entry speed max. 4.0 m/s Coiling speed max. 5.0 m/s Uncoiling speed max. 2.0 m/s 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 Entry side of the finishing mill with coilbox, crop shear and descaler. Start of uncoiling. 14

15 Drum shear. The crop ends are proof of the low loss of material due to cropping. 15

Çolakoğlu MeTalurJI 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.

16 Çolakoğlu MeTalurJI 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. Work rolls are changed fully automatically, which takes just a few minutes. A roll-changing car transports the work rolls back and forth between the roll bay and roll workshop. Technical data Roll force F1 to F4 F5 to F7 Work rolls Barrel length Diameters F1 to F4 Diameters F5 to F7 42 MN 36 MN 1,850 mm 820/720 mm 700/630 mm Back-up rolls Barrel length Diameters F1 to F7 Bearing assembly Main drive motors Rated power 1,850 mm 1,500/1,350 mm X-Roll Oil Bearing 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); workroll quick changing system (F1 to F7) 16

17 The seven-stand finishing mill. Control room of the finishing mill. 17

Çolakoğlu MeTalurJI 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.

18 Çolakoğlu MeTalurJI 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 opti mized for easy maintenance. The finishing stands are driven by three-phase AC motors, which are fed by direct-current intermediate circuit converters. The drive power is transmitted in stands F1 to F4 via main gear units, mill pinion gears and Sieflex spadeend spindles, while stands F5 to F7 are directly driven. The gear units are equipped with case-hardened 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. 18

19 Fully automated changing of the work rolls. 19

Çolakoğlu MeTalurJI Strip cooling for implementing the optimum cooling strategy The cooling section uses selective cooling to produce the exact material prop erties for the rolled stock.

20 Çolakoğlu MeTalurJI Strip cooling for implementing the optimum cooling strategy The cooling section uses selective cooling to produce the exact material prop erties 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 quick-change units, can be replaced within a very short time. Technical data Laminar cooling section Total volumetric flowrate 12,700 m³/h Length 80.5 m Cooling groups with micro zones 15 with trimming zones 2 20

21 The 80 m long laminar cooling section for flexible cooling patterns. 21

Çolakoğlu MeTalurJI Coiler with automatic step control and gentle coil transfer The rolled strips are coiled by two fully hydraulic downcoilers.

22 Çolakoğlu MeTalurJI 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. 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 opti - mum utilization of the shop crane. Empty pallets are returned simultaneously with the loaded pallets. The downcoiler unit. Control room in front of the downcoiler unit. 22

23 Pallet-type conveyor system. The coils are conveyed into the coil storage yard on the pallets. 23

24 SMS group GmbH Flat Rolling Plants Wiesenstrasse Hilchenbach, Germany Phone: Telefax: W4-311E SMS group GmbH Published on Circulation 500 Printed in Germany Ky 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.

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