Metals Industry SOLUTIONS

Cleveland Offi ce34525 Melinz ParkwayEastlake, OH 44095P: 440-918-9900F: 440-918-9901

Pittsburgh Offi ce8800 Barnes Lake Road – Suite 100North Huntingdon, PA 15642P: 724-861-3500

www.integratedmillsystems.com

To achieve total customer satisfaction by doing the right thing the fi rst time

To deliver premium value systems and services, second to none

To provide vertical startups of new or replacement systems through design for startup methodologies

To provide the customer with a reliable and readily maintainable high performance automation system

OUR MISSION

Who We AreIntegrated Mill Systems (IMS) is a processautomation solutions provider for the metalsindustry. Our staff has a broad range of expertisein a variety of metals processes. We provide openarchitecture designs, commissioned by the engineerswho created them. Since our inception in the early90s, our approach has been to fully understandthe manufacturing processes and develop systemarchitectures that best fit the application usingstandard products that seamlessly integrate withexisting plant systems.

What We DoIMS focuses on the Metals Producing and Processingmarket and provides a wide range of equipment andservices for both new and retrofit projects

n Hot Strip Roughing & Finishing Millsn Cold Rolling (Single & Tandem) Millsn Strip Processing Lines (Pickling, Galvanizing,

Color Coating)n Automatic Gauge Control systemsn Castersn Plate Millsn Z-Millsn Flash Butt Weldersn Pipe mills & Pipe Carriage Cut-Offn Coke Makingn Tension studiesn Drive regulator upgradesn Level 2 Computer & Data Acquisition systemsn Onsite service

IMS provides controller and drive combinations thatmeet maintenance and operating needs. We utilizereadily available industrial products and openarchitecture designs.

n Programmable Logic Controllers: Allen-Bradley Logix, GE FANUC, PACSystems RXi, Siemens S7

n Adjustable Speed Drives: Siemens, Allen-BradleyPowerFlex, Reliance FlexPak, ABB DCS/ACS, GE

n HMI Software: CITECT SCADA, GE FANUC Proficy,Rockwell Software, RSView, Wonderware

DOING IT

RIGHTTHE FIRST

TIME

How Do We Do It?

Our MethodsIMS begins each project by working with our customer to define thefunctional goals of the system. This functional understanding guidesevery facet of the project’s execution. The system configurationtranslates functions into the necessary hardware and illustrates howthese components interact. Upon customer approval of these basicdocuments, IMS continues with the detailed design of the system.The detailed design documents include a program organizationplan, a detailed explanation of the how the functionality will beaccomplished, and the system schematics. The system is built andsoftware is developed using these documents as a basis. A test planis written to rigorously test the functionality defined at the initiationof the project. Our systems ship only after a thorough and successfulfactory test. Customer participation is strongly encouragedthroughout all phases of development.

Process Study and BenchmarkingFor retrofits, site visits are made to define the current performanceand operating methods. Submitted as overview documentationoutlining the existing control and electrical systems, equipmentlocations and take-over points.

Project Execution PlanSubmitted as a general plan developed for larger scope projects.

System Wide Design SpecificationSubmitted as an overview document outlining the project scope,control system overview, HMI, design concepts, control strategiesand design standards.

First Engineering Submittal (FES)Submitted as a basic design document that includes a descriptionof operation, I/O requirements, and preliminary equipment designs.

Second Engineering Submittal (SES)Submitted as a design document that details the softwareimplementation prior to coding. The description of operationand design standards are refined during this phase andelectrical schematics are issued for construction.

This includes refinements to the description of operation anddesign standards.

Interface Design Specification (IDS)Submitted as a design document providing definition of information(data) exchanged between new and existing systems, such as anew Automation Controller with a new or existing client’s 3rd partyequipment and Level 2. This document includes memory structuresand communication methods.

Factory Acceptance Test (FAT)Submitted as a test document outlining the general test setup,equipment necessary to conduct the test, specify the requiredhardware connections, define the testing procedure, andsummarize changes as required. Documentation is submittedfor each supplied equipment item.

Level 2 Software and Models

Level 2 provides mathematical process models and the requiredsoftware for them to function. Level 2 distributes references tothe level 1 controllers and receives process feedbacks for modelupdates and data collection.

IMS has unique experience in system migration and upgrade ofolder legacy platforms and conversion to new windows based openoperating systems. This approach helps you stay ahead of the curvewith automation obsolescence.

747576

PG

Speed Bias

*Inter-Stand

TensionControl

PG

Massflow(by Screw)

FeedForward

Gauge-meter

Inertia-Comp

DeliveryX-Ray

Monitor

Massflow/Feed Forward

(by Speed)

PG

TENSIONREEL

PAYOFFREEL

TensionLimit

PG

X-RayMonitor

LC LC LC

ForceRegulator

ForceRegulator

Emphasis on System DiagnosticsWe design systems that can be maintained andself-diagnosed by the end user. Our HMI systemsare uniquely built to highlight machine statusat a glance by automatically displaying “smartpermissives” that anticipate operator intentionsbased on push-button attempts. Customizedmaintenance screens also provide supplementalinformation tailored specifically to help identifyand troubleshoot equipment failures, virtuallyeliminating the need for online connections tothe PLC.

Factory System TestThe engineering team conducts an exhaustive test in the large, fullyequipped system test lab, featuring:n Complete staging of the system with the controllers, servers,

networks, HMI system and all drive controllers.n Validation of all network interfaces to PLCs and DCS systems.n Customer operators and the commissioning team are integrated

into the factory testing for training.n Process inputs such as sensors and load cells are simulated

in the lab. The same software can be applied later for controlof the real process.

n Each drive in the system test has its own motor simulator basedon a mathematical model. All drive simulators are networkedwith the controllers and operator stations to test the entiresystem in real time. Response to manual inputs, LAN continuity,control interaction and drive configuration are all checked out.

This capability allows the IMS team to obtain an understanding ofthe system prior to the commissioning, ensuring a smooth, on-timestartup. The software can be switched “on the fly” between realand process simulation modes. This allows for easy implementationof Ghost Bar rolling where only the real metal is simulated, whilereal mill equipment is being controlled. The functionality contributesto shorter startup periods, saves material losses and aids in systemand mill maintenance.

Start-Up Plan (SUP)Submitted as a plan document outlining the inclusive process ofbasic power and device check-out on site with calibration, tuningand operational test of the supplied equipment. IMS provided testapparatus necessary for start-up and check-out is specified alongwith client provided equipment and manpower. A complete start-upschedule is developed along with acceptance criteria submitted.

Our ResultsBy following these methods, our results are predictable. With afocus on the system functionality through the project life, oursystems reliably meet the operational requirements. The project’sscope is well defined leading to excellent cost and scheduleperformance. Through our extensive testing, commissioning timesare minimized. The use of readily available components, combinedwith the quality of the documentation, and the troubleshootingtools we build into each HMI package, enable our systems to beseamlessly turned over to and maintained by our customers.

What Separates IMS from the Rest?n The use of “Off the Shelf” equipment for both complex and

simple tasksn The development and use of simulation code that enables an

incredibly realistic environment during testing and trainingn By adhering to our execution principles we deliver vertical start-upsn Risk mitigation, exceptional cost, and schedule performance

through exhaustive preparationn We take pride in providing systems that do not require a

system service contract

U.S. Steel

Arcelor Mittal

ATI Allegheny Ludlum

AK Steel

Nucor

Alcoa

Alcan

SDI

OUR WORLD-CLASSCLIENTS INCLUDE:

To achieve total customer satisfaction by doing the right thing the fi rst time

To deliver premium value systems and services, second to none

To provide vertical startups of new or replacement systems through design for startup methodologies

To provide the customer with a reliable and readily maintainable high performance automation system

OUR MISSION

Metals Industry SOLUTIONS

Cleveland Offi ce34525 Melinz ParkwayEastlake, OH 44095P: 440-918-9900F: 440-918-9901

Pittsburgh Offi ce8800 Barnes Lake Road – Suite 100North Huntingdon, PA 15642P: 724-861-3500

www.integratedmillsystems.com