Following modernization by SMS, Tata Steel Ltd. has rolled the first coils at its Jamshedpur CSP (Tata Steel TSCR) plant in Jharkhand, India.
The modernization included the integration of a new F7 finishing stand as well as improvements to the old X-Pact automation systems, such as the complete renewal of hardware and software. As a result, the plant is now able to produce thinner and higher-quality products, according to SMS.
The existing CSP plant, which was originally supplied by the German company in 2011, has an annual output of around 2.5 million tons and produces strips in widths of 900 to 1,680 mm and thicknesses of 16 to 1 mm.
Additional rolling stand for processing harder steels
In addition to the new F7 roll stand, the project also included adapting the roll changing equipment. With an additional roll stand, the rolling load distribution can be improved, particularly for harder materials with larger widths and thinner thicknesses. The F7 stand ensures that fewer bottlenecks occur for certain products in the finishing line. This increases the output for such grades and the CSP casting machines can be operated with an optimized casting thickness.
Another aim of the modernization was to improve the rolling stands F1 to F5 by installing a new, hydraulic rolling line adjustment. Five laminar cooling sections were replaced by four reinforced cooling units with edge covers. The modernization of the run-out area also included a new measuring house and preparations for a second multifunction measuring device in the future.
The technical enhancements also included Sieflex toothed spindles with internal oil return. The Sieflex toothed spindle is designed to transmit up to twice as much torque as conventional shafts thanks to its hardening, tooth geometry and tribological system. At the same time, it has continuous oil lubrication, which ensures cooling, eliminates the need for re-greasing and reduces rolling mill downtimes.
© SMS
Automation brought up to date
As part of the modernization, the Level 1 and Level 2 automation systems within the X-Pact Probas platform were upgraded on the basis of X-Pact Embedded Controllers and the human-machine interface (HMI) was updated. These technical advances enable high-speed control of the CSP plant and ensure reliable and efficient plant operation.
Level 2 automation includes process models designed to maximize the efficiency and quality of production processes. The X-Pact Pass Schedule Calculation (PSC) model enables the creation of rolling schedules that are tailored to production requirements. It ensures synchronized workflows through accurate planning of rolling parameters.
Another component is the X-Pact Cooling Section Control model, which ensures automatic cooling of the rolled material. This technology maintains a constant material temperature during the rolling process. The control of cooling parameters ensures a uniform material structure. In addition, the X-Pact Profile, Contour and Flatness model increases process stability by maintaining thickness and flatness tolerances. With this technology, better quality products can be manufactured that cover many specifications and dimensions.
From the first day after the conversion, fourteen coils were rolled without any faulty rolls and on the sixth day the system was able to process thicknesses of up to 1.2 mm.
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