Solutions for long product rolling mills

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Metals Technologies

Solutions for long product rolling mills

Technology, mechanics, automation and electrical engineering for bar mills, rod mills and section mills

The most reliable and innovative technology from a single source

For a large range of applications, steel must first be processed in a rolling mill before it can be used.

Our job is to perfectly coordinate and match a number of factors to ensure not just the quality of the

steel, but an exceptional level of mill productivity. As the pioneers of key technologies in long rolling,

such as the Morgan Vee No-Twist Mill, Red Ring Stands, multi-slitting rolling, Morgan Reducing/Sizing

Mills, Morgan Stelmor controlled cooling systems and thermo-mechanical rolling, we have the know-

ledge and experience to provide the best solution for your mill.

You expect …

K Consistent reliability of all units within the mill

K Increased productivity through intelligent process design

K Maximum plant flexibility, minimum set up times

K Optimum cost efficiency through integration of automatic equipment

K Excellent product quality with precise tolerances

K Responsible handling of emissions and recycling.

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Your challenges: Greater production. Higher quality. Lower costs.

Factors to consider

You should expect a great deal from your solutions partner. Reliable equipment, process consistency, production flexibili-ty and waste minimization. All in one package, managed from start to finish. All of these factors have to be taken into account in designing the optimal solu-tions for your mill.

Maximizing productivity through process optimization

How much time is needed for each process step? What temperature profiles are required? How can transfer areas be made more efficient? For the best an-swers to these questions, your rolling mill partner should have expertise with equipment technology and know-how to optimize complex plant layouts.

Flexibility comes first

Short delivery times and fast production changeover are key criteria for you to meet your customers’ demands. That’s why you need to be ready to convert your rolling stands to the next order while still processing the current one, and change your line from one product to another with virtually no downtime.

Quality throughout

You can achieve very high precision with rolling stands designed to with stand high loads and changing temperature requirements. That same capability, coupled with sophisticated control technology, allow a wide range of process conditions for desired product qualities.

Cost reduction

Cost optimization has many facets, including process-controlled yield maximization, downtime reduction and maintenance cost controls. When the entire system is managed through one source, you benefit from a high degree of standardization.

Environmental influences

There are sound legal and cost reasons for conservation of resources within your plant, such as water application for tem-perature control. You should also evalu-ate your solutions provider by how well they support you in this area.

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The right starting point:Siemens VAI long product rolling mills

Top quality of all individual rolling components …

All components from Siemens VAI are designed for high durability and maxi-mum uptime.

The high quality of the components, and a reliable supply of spare parts thanks to extensive standardization, ensure we meet or exceed our customers’ expecta-tions. Siemens VAI rolling stands are suit-able for use in a wide range of situations. Our convertible stands, for example, can be switched over from horizontal to ver-tical operation at the press of a button. In the past, set up times were measured in minutes, whereas now production can be changed in a matter of seconds.

… and in the complete system design

A state-of-the-art rolling mill needs more than just first-class components. It takes analysis and mapping of all processes, and possibly their redesign, as part of an integral system layout, to create a solution that’s not simply a rolling mill.

In concrete terms, that translates into considerably higher productivity through minimized downtime and seamless inter-linking of production stages.

Automation from the global market leader

All processes of our rolling mills are moni-tored and controlled by an integrated automation solution from Siemens VAI. Beyond the actual process control, we also offer:

�K standardized mill automation utilizing technological know-how

�K continually developed and partially self-learning process models for the reproducible manufacture of steel products of defined quality

�K an MES (Manufacturing Execution System) solution for optimized produc-tion planning and for minimizing rejects

�K a Level 2 and mill management system for maximizing everyday performance and reliable product tracking through the mill.

Resource management included

We take care to ensure that your most important resources are available with absolute certainty, such as efficient power quality solutions for a dependable and stable power supply, or with a tailor-made concept for closed-circuit water treatment to match the process requirements.

Naturally, we also take all current emis-sion levels into account in the design of a rolling mill – and if necessary, anticipate tomorrow’s standards as well.

Success from a single source

Our turnkey solutions ensure that all as-pects of the mill’s design, manufacture, installation and start-up are managed with close coordination and expertise. This comprehensive approach is unique. As prime contractor, we handle the complex details, and monitor all required rules and regulations, so you can concentrate on your core business of manufacturing long products and marketing them profitably.

Guaranteed performance throughout the entire life cycle

Knowledge transfer by our training experts, combined with a dependable supply of spare parts, ensures reliable operation. A full range of services from Siemens VAI helps maintain high mill availability over the entire life cycle. This is backed by carefully planned mod-ernizations for cost-effective technical upgrades.

Where’s the proof?

The numbers demonstrate the success of our concept. More than 1,000 rod, bar and billet mills all around the world are Morgan, Pomini, Ashlow and VAI mills, now all joined within Siemens VAI. These mills have set world wide bench-marks for technological leadership, reli-ability and performance, and have cap-tured the greatest market share in long rolling equipment.

Our experience in the field of rolling mills dates back to 1886, with the founding of Pomini in

Castellanza, Italy, and 1888, when Morgan Construction began U. S. operations in Worcester,

Massachusetts. Siemens VAI continues to innovate for competitive advantage, with the

expertise required for all elements of plant construction: process, engineering, manufacturing,

installation and commissioning, plus life-cycle management. No other rolling mill manufac-

turer today can offer a comparable range of products, solutions or experience.

Good reasons to choose our rolling mill solutions

�K Maximum reliability, thanks to 250 years of combined experience

�K Thousands of roll stands commissioned

�K Over 1,000 rolling mills installed or upgraded on six continents

�K Verifiable expertise for all elements of plant design and construction

�K Global presence and economicm strength as a part of Siemens

�K Solution providers to cover all aspects of long rolling

– Mechanical

– Electrical

– Automation

– Fluids

– Process and plant services

– Metallurgical services

– Services

�K In-house manufacturing and testing of proprietary technology equipment

�K One contact for all questions.

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Every rolling mill is different, varying

in design according to the desired products,

qualities and volume. Siemens VAI offers you

the right solution for every requirement –

for high-speed production, for precise micro-

structure qualities, for the shortest possible

changeover time from one long product to

another – and much more.

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Our rolling mill products – a well-coordinated ensemble

Coilhandling

Coilcompactor

Barbundling

MorganStelmorCoolingconveyor

Layinghead MorganRodReducing/SizingMill

HighspeedentrytocoolingbedCoolingbed

MorganNo-Twistmill Pouringreel Billetwelding

RedRingstands

Cropandcobbleshear WatercoolingsystemBarsizing

Automation SIROLL LR

From mill management, supervisory and control systems, all the way to motors, drives and individual component and sensor controls, Siemens offers a complete solution to your rolling mill automation needs from Level 1 to Level 3. With a full array of mechatronic packages for equipment units through-out the process, a totally integrated automation solution is available from the factory floor to upper management.

Commissioning

In supervising installation and start-up of electrical and automation, the task is to reach full production and consistent operation in the shortest possible time. That requires experienced automation and electrical engineers knowledgeable in long products to support the customer. For easier and quicker trouble-shooting, the automation system is pre-pared for remote access.

Across all processes:Expertise, automation, services

Services and life-cycle management

Ongoing availability calls for a well-designed service concept, up to and including around-the-clock moni-toring of the plant by Siemens. Clearly defined pro-cesses, uniform manuals, assured parts availability and a globally available team of specialists ensure minimized shutdown times and high performance throughout the life cycle of the plant.

Total engineering

Accurate planning that addresses everything from energy supply and raw materials logistics to through-put targets is a prerequisite for a successful start of your plant. We provide all the up-front necessities to make sure your project gets off to a safe start, including technical consulting as well as simulation of all processes.

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Mastering the processes – SIROLL LR

A precise understanding of all aspects of production is our basis for developing practical,

integrated, standardized solutions for your rolling needs, developed by systems engi-

neers who understand the mechanical equipment and process. To insure that individual

im provements do not negatively affect other part of the process, all steps must be

understood within their own context as well as in their role in the process chain. That’s

why we give top priority at Siemens VAI to developing process-oriented solutions for

everything from the mechanical equipment to the process control. The solution 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 auto-

mation components and software that run on user-friendly Human Machine Interfaces,

provide operators with simple and efficient tools to master the processes.

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Main & Aux Drives

XpertManager/ SIROLL LR Level 2

SIROLL LR Basic Auto -

mation System

Mechatronical Packages

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Mill automation and process control

Providing a total solution

The combination of process technology, electrotechnology, and automation is a crucial aspect of Siemens VAI solutions. From initial mill design to maintaining your systems for years to come, Siemens VAI offers:

Electrical … defining project scope and requirements from Level 0 to Level 2, in-cluding AC and/or DC drives, full voltage devices and various controls; providing full technical documentation and inte-grated system testing.

Automation … Leading basic automation SIMATIC S7 process control engineering and process optimization created within our company play a key role in stable processes and greater system reliability, as we design the system to meet your specific requirements right from the design phase. Therefore we offer engi-neering of well-proven equipment, fully integrated mill control systems SIROLL LR and stand-alone systems, including super visory control, maintenance sched-uling, process monitoring, product han-dling and alarming systems.

Some of the systems available:

Basic automation functions

�K Mill setup and control

�K Tension and loop control

�K Sequencing and tracking.

Technological functions for optimization

�K Cut length optimization

�K Self adaption.

Mechatronical packages

�K Non-contact speed measurement and control

�K Mechatronics systems for all key equipment components

�K Bar counting.

Higher level automation

�K XpertManager, Level 2 setup and recipes

�K Mill management

�K Interfaces with production planning and ERP.

Commissioning … supervising installation and start-up of electrical and automation systems to ensure the shortest possible time to reach full production and consis-tent operation, by experienced automation and electrical engineers knowledgeable in long products; remote access via cRSP.

Revamps … Our solution SIROLL LR can also be used for revamps including upgrades of DC-Drives.

Drives

For new plants, using only two types of drives – SINAMICS as auxiliary drives and low-power main drives, and SINAMICS SM 150 as larger block drives – results in significant savings on spare parts, train-ing, maintenance, and upgrades.

Features

�K Latest semiconductor technology: IGBT and IGCT

�K Fast processors and optimized drive algorithms

�K Design according to required power, speed and field weakening, also consid-ering the total power supply network

�K Defined interface systems to automation system.

Typical two strand WRM overview screen

SIROLL LR SIROLL LR

Typical diagnostic screen

XpertManager – a Manufacturing Execution System and much more

From the initial Manufacturing Resource Planning stages to the actual production process, our customized design provides seamless integration of process data in real time. By applying proprietary algo-rithms to the collected data, XpertMan-ager generates comprehensive reports of current production performance, trends and history. With Level 2 capabilities, the production plan, the process and the finished product are all integrated in a seamless system of mill automation.

Features

�K Automates and unifies mill setup and control

�K Provides operators with comprehen-sive information

�K Facilitates use of best operating practices

�K Enables optimization of mill performance

�K Eliminates obsolete, stand-alone systems

�K Interfaces well with SAP

�K Generates QA certificates.

Mechatronic solutions

Mechatronics merges mechanical, elec-trical, control systems and software as an intelligent approach to the design of electromechanical systems. At Siemens VAI, we use this technology to integrate our process know-how along with our advanced equipment to give you en-hanced products that provide functional-ity, flexibility and ease of use.

From a single-source supplier, you can get these robust and proven systems to help your operation run smoothly.

When supplying a full rolling mill solu-tion, these systems are integrated into the mill control SIROLL LR. For modern-ization solutions, they can be supplied as stand-alone systems and interfaced with the existing mill control.

Standard mechatronic packages:

Can be easily integrated in new or exist-ing systems. When supplied as part of a full mill control system, the mechatroni-cal packages are embedded into the SIROLL LR.

RollMaster

For Compact Cassette Rolling (CCR) stands and Flat Rolling Blocks, this system determines – according to the finished product – the rolling rolls, the grooves and the guides to be utilized and all the essential rolling parameters such as speed, torques, and other requirements.

This well-proven software has already been applied in more than 15 mills.

Features

�K Easy computer-aided creation of pass schedules

�K Calculation of material spread, mill load and bar temperature on the basis of a database containing the properties of more than 200 steel grades and special alloys

�K Accurate setting of the mill guides for product-dimension changes, including print out of the set-up protocol

�K Creation of the mill setup considering the actual condition of all components

�K Easy management of all important data related to mill grooves, guides and rolls.

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SINAMICS SM150 IGBTXpertManager mill management system interface

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Mechatronic solutions in long rolling mill

Water box control system (mill floor) Water box control system (HMI)

�K Shear control

�K Temperature control

�K High speed finishing blocks

�K Morgan Reducing/Sizing Mills

�K Pinch rolls

�K Laying heads

�K Morgan Stelmor conveyor

�K Reform area

�K Coil handling

�K Compactors

�K Cooling bed entry systems

�K Bar counting

�K Stackers

�K Tyers and bundlers

�K Fluid systems

�K Inline measuring systems

�K Non-contact measurement systems.

Further stand-alone packages:

�K Flat Rolling Block

�K Compact multi-rougher

�K Rail pre-cambering.

Morgan Bar Reducing/Sizing Mill

�K Fully automated control of stand change and roll parting

�K Fully automated control of drive system clutches

�K Automated setup, with mechanical expertise incorporated in gear change strategy

�K Direct interface to the SIROLL LR mill control system

�K Integrated tension control

�K Easy-to-navigate HMI interface for the pulpit operators

�K Full local and remote control options.

High speed shear

�K Eliminates oversized front and tail ends, reducing wear and impact stress on downstream equipment

�K Automatic trimming of uncooled product

�K Synchronized with laying head front end orientation

�K Minimum deflection of rod from cutting position

�K Increases product yield by eliminating manual cutting errors

�K Direct interface to the SIROLL LR mill control system.

Lubrication systems

�K Monitors temperature control and oil cleanliness

�K Operates under a wide range of ambient conditions

�K Incorporates vacuum dehydration.

Water systems/ product temperature control

�K Designed specifically for in-line water boxes for product controlled cooling

�K Incorporates specially designed water valves for high speed operation

�K Balanced design avoids water hammer

�K Valve stands designed to be compact and maintenance-friendly

�K Closed loop control

�K Direct interface to the SIROLL LR mill control system.

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Rolling stands

�K Self-balancing spindle support for minimum and positive engagement

�K Long-life bearings

�K Automatic utility connections.

Compact roughers

Compact roughers can be used where space is limited or if higher reductions are required. These roughers are equipped with special shoe plates and clamps to allow for minimized centers. Greater reductions are possible by using the billet’s own beam strength to help it enter successive passes. When the cen-ters are close, the stands can be shifted in and out of the pass line to adjust or change the guides.

Features

�K Small space requirement

�K High reductions possible

�K Easy guide change.

Red Ring stands

The Red Ring stand design has been a popular solution for many roughing and intermediate mill applications.

Red Ring stands are renowned worldwide for their rigidity, ease of maintenance and load capacity.

Different versions of these stands are available, including vertical, horizontal and convertible, which allow for rapid adaptation to a variety of rolled products needed to fulfill stringent market demands.

With the quick disconnect capability of the spindles and fluid utilities, the stands can be interchanged very quickly.

Features

�K High rigidity

�K Reduced stress path

�K Fully automatic operation

�K Axial roll adjustment

�K Automatic screw-down system

�K Adjustment under load available

�K Roll balance system to eliminate backlash

Red Ring standsRed Ring stand

Reversing 2-high stands

Cast or forged billets can be rolled by a group of two Red Ring stands in horizon-tal and vertical (H-V) arrangement. Every two passes, the roll gap is adjusted and rolling direction changes. At the end of the rolling process, a large-dimension cylindrical bar is obtained for use as a final product to be re-rolled.

Sliding stands

Modern 2-high sliding stands are revers-ible and fully automated. They represent an innovative solution for roughing and intermediate trains.

Features

�K A fixed rolling line with sliding stands to match the exact groove in the pass design

�K Reduced roller table width

�K Advanced billet manipulation system

�K Automatic roll gap adjustment

�K Simple foundations

�K Compact multi-rougher arrangement.

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Convertible stands

Today’s mills can be used in a wide range of configurations in order to provide an unlimited selection of products from a single mill layout. It is possible to change from one product to an unrelated one by simply pushing buttons, without the lengthy procedures needed for an old-style mill changeover. Convertible stands allow either horizontal or vertical posi-tioning and are mainly used in the inter-mediate and finishing trains, in accor-dance with production requirements.

Features

�K Less than two minutes to change position

�K Reduced foundation depth

�K Excellent stand rigidity

�K Quick stand change system without crane requirements.

Red Ring universal stands

This new generation of universal stands uses the Red Ring design for the rolling of structural shapes. In addition to the horizontal rolls, the stands are fitted with a set of idle rolls to work the flanges. Red Ring universal stands can easily be converted to conventional horizontal rolling, accord ing to production require-ments, thus avoiding the need for addi-tional horizontal stands.

Features

�K Fast stand and roll change

�K Hydraulic vertical and horizontal roll adjustment

�K Modular design to reduce crane requirements

�K Highest stiffness with a housingless design.

Compact Cassette Rolling (CCR) stands

The compact and rigid cassette design is suited to many special bar mill rolling requirements. The extremely rapid cas-sette change facility, in conjunction with a high degree of automation, allows for flexible and efficient production, even for orders with a small number of billets.

Features

�K Three possible arrangements for twist-free rolling: horizontal, vertical and 45° (X)

�K Most compact stand design available on the market

�K Automated groove changing

�K Reduced bay height requirements

�K Open access to top of cassette

�K Possibility for automatic cassette change robot system

�K Fast roll change, with no need for special equipment

�K Interchangeable H-V-X cassettes within the same stand size

�K Available with monogrooved or multi-grooved stands and also as a reversing block.

Compact Cassette Rolling standsSliding rougherConvertible stand

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Bar sizing technology

Sizing for bar-in-coil products

The Morgan Bar Reducing/ Sizing Mill (BRSM) is the preferred solution for roll-ing small- to medium-diameter product typical of bar-in-coil production.

Features

�K Compact arrangement to minimize space

�K Single or double groove to reduce roll cost and downtimes

�K Guideless rolling

�K High speed capability

�K Symmetrical mechanical preload

�K Split roll housing design for fast roll changes.

High precision rolling coupled with pro-cess flexibility and equipment durability describes the Siemens VAI bar sizing technology. Based on the two-roll ar-rangement, various solutions are avail-able, which meet every need for size, load capacity and productivity.

The two-roll design

The two-roll design offers user-friendly operation as well as simplified mainte-nance. It produces superior surface quality, high dimensional precision and ultimate processing flexibility. The two-roll design can use multi-groove rolls, which signifi-cantly lowers the investment and conver-sion costs as well as reduces operation downtimes.

Pass schedules provide reduction rolling in the first stands followed by high pre-cision sizing in the final stands.

The rigidity and load capacity of the equipment permit the processing of a wide range of steel grades, with both conventional and low temperature, such as thermomechanical, rolling practices. Under-load remote adjustment of roll gap is also possible.

Features

�K Single family rolling capability

�K Free size rolling capability

�K 3-stand or 4-stand configuration

�K Pre-loaded stands with under-load remote adjustment of roll gap

�K Automatic couplings of service utilities

�K Inline quick change of stands

�K Off-line quick change of rolls

�K Easy preparation of rolls and guides with off-line presetting for “plug & play” rolling campaign

�K Single or multi-groove rolls

�K Possibility to use both cast iron rolls, tool steel and tungsten carbide rings

�K Unique and patented pass designs

�K Possibility of automatic gap control

�K Over-driven stand arrangement provides minimal impact on foundation works.

4-stand Morgan Bar Reducing/Sizing Mill 3-stand Morgan Bar Reducing/Sizing Mill

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Sizing for straight bar products

The Pre-stressed Sizing Group (PSG) is the preferred solution for rolling medium- to large-diameter product typical for straight bar mills. The available stand sizes cover a range of finished bar diam-eters up to 150 mm.

Features

�K Higher mill utilization with multi-groove rolls

�K Hydraulic preload systems for both radial and axial directions guarantee very high rigidity

�K Automatic gap control

�K Motorized adjustment of guides and axial roll movement.

Other solutions

The Cantilever Sizing Stand is the simple solution for a quick and economical proj-ect, to improve the size tolerance at 90° to the last finishing stand.

Features

�K Easy and economical installation in existing mills

�K Small dimension and weight

�K Easy positioning close to finishing stand

�K Stand, gearbox, motor and hydraulic unit are contained in a single trans-ferable block

�K Can use cast iron rolls, tool steel and tungsten carbide rings.

Mechatronic solution

Fully featured mechatronic packages provide complete and effective control of Siemens VAI’s bar sizing technologies to ensure guaranteed performance.

Features

�K Full local and remote control options

�K Fully automated control of stand change and roll gap

�K Fully automated impact compensation and stand speed referencing

�K Automatic setup

�K Automatic under-load gap control

�K Direct interface to mill control system

�K Integrated tension control

�K Straightforward, easy-to-navigate HMI interface for the pulpit operator

�K Electro-mechanical systems fully tested prior to shipment for shorter site commissioning times

�K Fully integrated into standard SIROLL solution.

3-stand Pre-stressed Sizing Group 4-stand Pre-stressed Sizing Group

Technologies for rails and sections

Red Ring universal stands

As with the 2-high Red Ring stand, the Red Ring universal stand has no require-ment for a standby stock of chocks. In-stead, roll changes are performed using a robot system, which mechanizes the assembly/disassembly of roll chocks. The process of disengaging a Red Ring universal stand from the rolling line, such as for stand clamping or spindle holding, is exactly the same as for a normal 2-high Red Ring stand.

Features

�K Easy conversion to conventional horizontal stands

�K Four-row cylindrical bearings with separate thrust bearings allow maxi-mum load carrying capability

�K Fast roll and stand change

�K Vertical frame separates from tie rods for quick assembly

�K Hydraulically adjusted horizontal and vertical rolls.

Increased life span and cleaner operation

�K Main bearings and labyrinth seals have extended life with oil/air lubrication in-stead of automatic grease

�K Flume water contamination reduced.

Counterbalanced spindle support

�K Wrapped bearing design eliminates hub wobble, reduces wear

�K Generous tapers on hub entry and roll ends allow stand changing without moving spindles.

Automated roll change operation

�K Significantly reduces roll assemblies’ changeover time

�K Roll change robot with hydraulic unit furnished for change operation.

Pre-cambering systems

Rails may require an additional pre-straight ening operation that’s applied at the cooling bed’s entrance. In fact, non-uniform mass distribution in the cross section of the rail tends to bend it inwards on its head side. If not corrected, this would make post-cooling straighten-ing very difficult.

Features

�K Rails pre-cambered before cooling bed

�K Rails hydraulically clamped and lifted

�K Individually programmable travel strokes allow application of different pre-camber patterns.

Stacking systems

The layers of sections arriving from the straightening and cold-cutting area are properly braked and buffered onto the first transfer table of the stacking area.

Aligning rolls and stoppers give bars an orderly disposition.

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Continuous finishing mill for rails and sectionsRed Ring universal stand

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Features

�K Special system directs out-of-tolerance bars to separate cradles

�K Disappearing stoppers and variable-speed devices form and separate individual layers

�K Synchronized operation of suitable devices ensures correct sequence of straight and 180-degree rotated layers

�K Electromagnets equip devices for firm grip on bar

�K Adjustable width roller table transfers stacks to binding area

�K Horizontal and vertical rollers maintain good stack alignment in transit

�K Operations all fully automatic and computer-controlled

�K Divisible design provides flexibility needed to process different stacks of different lengths for greater productivity

�K Combined mechanical-magnetic type processes small to medium sections

�K Working sequences of stacking and binding fully automated and interfaced with the other areas of the rolling mill.

Medium section straightening system Rail pre-cambering system

Straightening systems

When sections are cool enough, below approximately 100 –120 °C, they must be individually straightened before being cut to their final length. This is necessary to remove the deformations caused by the asymmetrical cooling effects. The sections have to be subjected to a me-chanical deformation to reach the yield tensile strength (YTS) value.

Other types of straightening systems are designed for rail and special sections processing.

Features

�K Rigid frame contains two sets of double-supported horizontal rollers

�K Top rollers’ position is vertically adjusted according to bar size

�K Hydraulic counterbalance eliminates vertical movement backlashes

�K Axial adjustments for rollers

�K Rollers mounted in removable cassette for quick changing operation

�K Special combing devices or pinch rolls ensure bar separation for effective straightening process

�K Magnetic rollers at straightener’s exit prevent bars slipping

�K Suction system removes scale during straightening.

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Slitting and high speed cooling bed entry systems

Slitting systems

Siemens VAI’s powered slitters provide highly accurate and consistent dividing. They allow rebars to be rolled in multiple strands, significantly improving the pro-ductivity of small size rebars, without in-creasing their finishing speeds. Slitting rolls have ten times the life of slitting guides, while offering higher speeds and better-accuracy. Divided strands may be finished in the same rolling stands or individually, for better product quality and tolerance.

Benefits

�K Reheating furnace and rolling mill can be operated to full design capacity also for small size rebars, which become less costly to produce

�K Easily applicable to most bar mill configurations.

High speed cooling bed entry systems

High speed finishing maximizes rolling operation over the entire product mix. Beside consistent rolling at high speeds in the mill, this calls for high speed deliv-ery to the cooling bed. To meet these requirements Siemens VAI provides the Rotary Entry System (RES) as well as the Multichannel Braking System (MBS).

Rotary Entry System (RES)

Each strand has a pair of rotating drums, where bars are indexed after being braked by the high speed pinch rolls.

Benefits

�K Bar maximum delivery speed: 40 m/s

�K Accommodates 2-way slitting

�K Allows the discharge of one bar per notch, which gives a better alignment and separation of bars

�K Can be installed along with conven-tional run-in roller table and brake slides for large size rebars

�K Modular design.

Multichannel Braking System (MBS)

The system can be used to discharge single strand, multistrand, and up to 4-slit rebars. The bars are braked by pinch rolls into channels which open over the cooling bed.

Benefits

�K Bar maximum delivery speed: 40m/s

�K Smooth discharge of one bar per notch, for easier and flexible bar counting and handling

�K Applicable with all sizes of both cold (low carbon quenched) and hot material (microalloyed steel rebar)

�K A hydraulic system allows an easy off-line removal for maintenance and when larger sizes are processed via conventional brake slides.


An integral part of the bar mill’s high speed capability is the specialized mechatronics package developed by Siemens VAI for this application. This includes:

�K Coordinated speed control for powered slitter and rolling stands or Morgan No-Twist mill

�K Divide shear control

�K Bar cut length optimization

�K Braking pinch rolls control

�K Bar positioning system on cooling bed


4-slit rollingRotary Entry System Multichannel Braking System

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Cooling beds

Cooling beds

Siemens VAI cooling beds are designed using standard elements that can be combined in accordance with plant prod-uct mix requirements and production ca-pacity. Full mechanical component stan-dardization assures constant equipment quality, as well as high performance levels.

The design features cover a variety of applications: rounds from Ø 8 to 300 mm, light, medium and heavy sections up to 1,000 mm and rails.

For special applications, the cooling beds offer slow cooling with insulated covers and forced cooling through water spray systems or water tanks.

At the end of the cooling bed, bars are aligned by rollers, separated into orderly layers and transferred onto exit roller tables.

Features

�K Perfect repeatibility of braking cycle, at any speed

�K Bar separation during braking, if required by layout and speed

�K Pack annealing device available for spring steel flats

�K Bar alignment by rollers

�K Bar layer prepared by chains and transferred by cars.

Cooling bed for large rounds Cooling bed for rebars

Aligning rollers, chains and transfer cars

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High speed finishing blocks: Morgan Vee No-Twist mills

�K Designed for thermomechanical rolling, with capacity for low rolling temperatures

�K Capable of rolling to tight tolerances

�K Tungsten carbide rolls give better rod quality and longer roll life.

Modular No-Twist mill

This patented new design enables the changing of pairs of roll stands in a few minutes, so that size changes can occur very quickly.

The drive system is designed so that stands not used on larger sizes are dis-connected, thereby extending the overall life of the equipment and reducing main-tenance costs. This design also minimizes power consumption and thereby reduces operating costs.

Used in conjunction with a Morgan Reducing/Sizing Mill and single family rolling, the Modular No-Twist mill maxi-mizes utilization in the rolling mill.

High speed, high production capacity and reliability are critically important on the finishing end of your mill. The rolling equipment must have flexibility to pro-duce a wide range of sizes and steel qual-ities, while providing the best possible product dimensional accuracy.

Siemens VAI finishing blocks have been installed in scores of rolling mills through out the world, having set the standard for successful mill operations. These blocks are available in a variety of stand combinations and can satisfy virtu-ally any need on the finishing end. Roll-ing load capacity and pass design are tai-lored to the product requirements.

Morgan Vee No-Twist mills are capable of sustained, reliable operation at speeds of up to 120 m/s. This results in production in excess of 150 tons/hr – achieved under everyday operating conditions at mill installations worldwide.

When it comes to versatility, the Morgan Vee No-Twist mill can roll grades ranging from carbon steels to tough to roll, heat-resistant alloys. Mills can be supplied with pass reduction of anywhere from 10 % to 25 % per stand. Morgan Vee No-Twist

mills can be built with four, six, eight, or ten roll stands. The mills can be config-ured with any combination of 250 mm, 230 mm or 160 mm ultra heavy-duty (UHD) housings, depending on your mill’s requirements. All housings have provi-sions for remote adjustments under load. Moreover, they can be equipped with monitoring facilities for bearing condition.

Features

�K All major drive components are below floor level, thus reducing noise, im-proving visibility and providing conve-nience for mill crews

�K New entry end drive arrangement allows easier access to the motor and no restriction on motor size

�K Entry end drive enables disconnection of finishing line shafts when not in use to minimize wear on high-speed components

�K High-quality sealed roll housings provides reduced maintenance and long life

�K Roll housings are easily lifted out for quick change times

10-stand Morgan No-Twist mill Morgan No-Twist mill rolling stands

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Mini-blocks

The Morgan Vee mini-block is an innova-tive 2- or 4-stand mill expandable up to an 8-stand unit, with a host of benefits for rod and bar producers. In numerous existing installations around the world, mini-block mills have increased produc-tivity by as much as 50 %, permitted the rolling of various diameter rod and bars, and achieved thermomechanical rolling properties.

Features

�K Small footprint makes it ideal for retrofit situations

�K Can be used as a pre-finishing mill, usually in 2-stand or 4-stand configurations

�K Can be used as a mini-finishing mill after an existing finishing block to increase speed and productivity

�K Capable of improving tolerance of feed sections to an existing block

�K Increases finishing speed when used after an existing finishing block

�K Can be used to roll finished sizes from 4.0 mm up to as large as 35 mm

�K Able to roll at low temperatures

�K Perfect for retrofit applications in both bar mills and rod mills

�K Can be used upstream or downstream of existing finishing blocks.


The performance and reliability of the Morgan No-Twist Mill and Morgan Mini-Blocks can be enhanced with the application of specialized mechatronics packages, including:

Bearing temperature monitoring

�K Provides temperature status for bear-ings in the block

�K Issues warnings of high temperatures that can be caused by bearing wear or lubrication problems

�K Constant monitoring improves perfor-mance and prevents system downtime


Lube oil water content

�K Continuously monitors for any water ingress

�K Specifically monitors water content in the lubrication system

�K Real time trending of water content and lube oil temperature

�K Historical logging


Mini finishing block Morgan Vee mini-blocks as pre-finishing mills

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Rod sizing technology

Productivity features

�K Single family rolling dramatically increases utilization

�K Productivity on small sizes increases by as much as 60%

�K Quick change transfer car ensures rapid and error-free setup

�K Roll parting adjustment under load directly from the operator station with roll gap feedback

�K Patented built-in bypass troughs pro-vide immediate setup for dummying roll units

�K Guideless rolling in sizing stands allows for fast parting adjustments and free size rolling.

Morgan Rod Reducing/Sizing Mills

With over a decade of operational know-how on more than 60 installed strands, our engineers have advanced the Morgan Rod Reducing/Sizing Mill into the most versatile, sought-after rolling technology available. There is no other rod sizing system on the market today that can compare with this technology.

The advantages of the Rod Reducing/ Sizing Mill are nearly unlimited. It can be integrated after a conventional finishing block, boosting the mill productivity on small sizes by up to 60 %. Its extreme precision has been proven in many prac-tical applications.

Product dimension features

�K Produces all sizes to ultra-precision tolerances

�K Tolerances as low as +/–0.1 mm

�K Ovality at 0.12 mm about the nominal size and within 2 sigma statistical limits

�K Flexibility to produce a size range from 4.2 mm to 26 mm

�K Free size rolling capability.

Improves the operation

The patented pass design enables true single family rolling from the first stand after the reheat furnace to the last stand of the block ahead of the Morgan Reduc-ing/Sizing Mill. Added after a convention-al rod finishing block, the patented unit can significantly increase finishing speeds on smaller sizes.

Morgan Rod Reducing/Sizing Mill with off-line units

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Increases product quality

The combination of advanced technolo-gies allows very low-temperature rolling. This results in a more refined microstruc-ture that can eliminate additional processes.

Features

�K Degree of grain refinement possible with thermomechanical rolling results in improved properties

�K Unique oval-round-round-round pass sequence delivers high-reduction rolling for internal quality while enhancing surface quality and extending roll life.


The Morgan Rod Reducing/Sizing Mill mechatronics package is a proven system on dozens of mills around the world.

Features

�K Full local and remote control options

�K Direct interface to mill control system

�K Straightforward, easy-to-navigate HMI interface for the pulpit operator

�K Automated product change increases productivity

�K Incorporates Siemens VAI’s mechanical expertise in gear change strategy

�K Electro-mechanical system fully tested prior to shipment and commissioned on site


Morgan Rod Reducing/Sizing Mill in single strand high speed rod outlet Rolling stands

26

High speed laying heads and intelligent pinch rolls

�K Rapid roll closing times, 0.1 to 0.15 seconds

�K Repeatable roll close times, within +/-5 milliseconds.

A good coil package delivered from the laying head to the Morgan Stelmor con-veyor is important for achieving uniform metallurgical properties during the con-trolled cooling process as well as for get-ting a well-formed coil for shipping.

Laying head capabilities

�K High speed capability proven over 120 m/s

�K Ability to lay plain rounds, rebar plus quenched and temperature rebar

�K Handles rod sizes from 4.0 mm to 26.2 mm

�K Pipe change times of 15 minutes or less.

Other capabilities

�K Interchangeable vertebrae and roller-ized pipe features available for surface-sensitive grades

�K Twin pipe design available for produc-ing different coil dimensions for differ-ent product sizes

�K Pipe bending services available to pro-vide your mill with ready-to-use pipes.

The laying head and intelligent pinch roll system plays a crucial role in the success of a high speed rod mill. It must be capable of high speeds with smooth operation, while providing well-shaped rings cor-rectly positioned on the conveyor. This calls for a precise mechanical system, accurate control and continuous monitoring.

Our patented intelligent pinch rolls and laying heads are proven for sustained operation at high speeds and for flexibility across a large range of product sizes.

Features

�K Durable drive for reliable high speed operation

�K Universal design fits all installations

�K Closer calibration of pinch force

�K Faster set up after roll change

�K More compact installation

�K Pipe path designed to optimize wear

�K Easy-change pipe support

�K High quality bearings for reliability

�K Front end orientation to eliminate snags on the conveyor

�K Tail end control for good coil package.

Improving the ring pattern

The laying head design with patented tail end control helps improve the ring pattern on the conveyor for both small products at speeds up to 150 m/s and large prod-ucts at lower speeds. It allows increased production, improved yields and consis-tent product quality.


A key element to the success of our lay-ing heads and intelligent pinch rolls is the mechatronics system, which provides for:

�K Repeatable front end positioning of each coil

�K Speeds coordinated with pinch rolls for error-free operation on tail ends

�K Fine adjustment to allow control of coil diameter

�K Wobble adjustment for varying ring diameter on large sizes

�K Servo control of pinch force and position

�K Closed loop control of pinch force and pinch roll drive motor

�K Self-regulated system to avoid roll slip and remove user input from the pulpit

�K Fully integrated into standard SIROLL solution

High speed laying head with patented tail end controlHigh speed intelligent pinch roll and laying head

27

Morgan Stelmor conveyor exit endHigh capacity fans on Morgan Stelmor conveyorMorgan Stelmor controlled cooling conveyor

Morgan Stelmor controlled cooling conveyor and reform ring distributor

The Ring Distributor

The patented Ring Distributor collects rings high in the reform tub using a ro-tating blade for optimal placement. This system shortens the coil package, easing shipping and storage space concerns, which in turn reduces costs. Improved collection also results in better-shaped coils for fewer tangles and snags at payoff.

Features

�K Simple, low maintenance coil forming design

�K Allows for increased coil weight capacity

�K Works with new or existing horizontal hook and vertical pallet coil handling systems

�K Permits removal or change of blade in 5 minutes or less.

The Morgan Stelmor controlled cooling conveyor system enables processing in a wide range of conditions, including both fast and slow cooling modes within a sin-gle system. This capability enables mills to produce a broad spectrum of plain car-bon and alloy steels, as well as stainless steels and other specialty grades. The results are improved as-rolled rod prop-erties. This enables the production of more grades in a directly usable condi-tion, thus reducing or eliminating down-stream processes, such as spheroidize annealing.

Controlled cooling capabilities

�K Forced air cooling with high capacity fans gives fast cooling rates

�K Excellent cooling uniformity in fast cooling mode, accomplished with either the traditional Optiflex system or the new patented Optimesh system

�K Slow cooling with insulated covers

�K Hybrid cooling with combined fast, natural and slow cooling for custom-ized cooling of special grades.

The more than 350 Morgan Stelmor lines installed at mills throughout the world have established this system’s reputa tion as the best for product quality, processing versatility and equipment performance.

The robust design includes durable drives for reliable high speed operation and high quality components for reduced maintenance downtime and cost.

Other system possibilities

Optional capabilities that can be incorpo-rated into the Morgan Stelmor system include:

�K Slow cool pots

�K In-line heat treatment

�K Water quench baths.


To ensure the greatest benefits from pro-cessing and production, a mechatronic system provides for:

�K Automated product cooling setup

�K Conveyor speed control

�K Automated fan cooling control

�K Fully integration into standard SIROLL solution.

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Vertical stem pallet coil handling system Horizontal hook system for coil handling Horizontal coil compactor

Coil handling and compactors

Vertical or horizontal

From complete handling systems to sys-tem upgrades, Siemens VAI has many solutions to every coil handling need. Both the vertical stem pallet and horizon-tal hook carrier systems are of modular design, providing for unique configura-tions with standard components.

Features

�K Standard modules can be arranged in highly customized installations

�K Individually driven and controlled modularized conveyor system offers high productivity and ease of maintenance

�K System movements provide scratch-free handling of the coils

�K Blowing stations available for acceler-ated cooling of selected grades

�K Patented heat retention tunnels available for slow cooling of sensitive grades.


For maximum benefits in the coil hand-ling system, a mechatronic system provides for:

�K Fully-automated coil transport system

�K Minimized installation and start up times

�K Individual AC drive motors

�K Customized coil distribution and storage

�K Automatic “pushing” and “pulling” strategies to maximize cooling time and product throughput

�K Recipe driven system

�K Coil tracking.

Compactors

Both the horizontal compactor and the vertical compactor systems provide a wide range of capabilities for all coiled products, with either wire binding or strapping.

Features

�K Standard compactor design allows for easy retrofit from wire to strap, or vice versa

�K Unique wire binding unit design with quick-replace wear cassettes

�K Low operating and maintenance costs.


The automation of the compactor system includes:

�K Automated compression of coils into compact bundles for efficient transport and storage

�K Automatic wire feeding and monitor-ing of coil compression

�K Different press force settings.

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Bar in coil

Process capabilities

In addition to forming a well-shaped coil with excellent surface quality, the bar-in-coil system is designed for optimal metallurgical and scale characteristics.

Features

�K Coiling temperature can be controlled with upstream water boxes

�K Blowing stations available for accelerated cooling

�K Insulated tunnels available for slow cooling of critical grades

�K System length and operational practice designed to give optimal final coil temperature.

Pouring reels

The Siemens VAI pouring reels, or Garrett coilers, enable the production of bar products in coiled form, typically for bar sizes of approximately 10 mm to 60 mm.

Features

�K Interchangeable entry spouts accom-modate a wide product size range

�K Multiple pinch rolls assist the bar into the tub and control tail ends

�K Traversable pinch rolls allow for quick groove change between sizes

�K Elevating coil plate for easy coil removal

�K Collapsing inner fingers minimize damage to rings on coil inner diameter

�K Wear strips prevent damage to rings on outside diameter of coil

�K No direct water cooling required, reducing maintenance

�K Designed for minimum foundation depth.

Coil removal and transfer

A pivoting mast supports a boom assem-bly for transporting the coil from the elevated coil plate to a pallet or coil con-veyor. Depending on the configuration when using a pallet system, elevators may transfer the pallets between levels in the mill.

Interface with coil handling

The coiling line can be provided with a new coil handling system or interfaced with an existing vertical pallet or hori-zontal hook system.

Interface components

�K Downenders

�K Transfer cars

�K Trimming stations

�K Inspection stations.

The coil handling system can be shared with a rod mill or rod outlet on a combi-nation mill.

Pouring reel Garrett coil

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Bar spooling system

The spooling system is the latest innova-tion in bar-in-coil production.

It creates a twist-free winding of round, flat and square bars.

Unlike with the Garrett coiler, the wire is distributed in sequential, regular, homogeneous and compact layers, producing high weight coils with small overall dimensions, which can be easily transported and stored.

As the spooled coil is twist-free, the de-coiling operation is smoother and faster.

The innovative spooling system is a considerable technological step forward in bar-in-coil production, offering bar producers the opportunity to be more competitive by offering final users a re-duction of post-rolling costs, as well as a better product appearance with easier transportation and storage.

Features

�K Higher efficiency, speeds and productivity

�K Fixed height and inner diameter

�K Variable outer diameter (depending on coil weight)

�K Greater compactness with very high filling factor

�K Easy uncoiling capability

�K Substantial cost reduction in coil transportation and storage

�K Higher material yield

�K Final product properties are uniform and consistent

�K No residual internal stresses (torsion).

Spooling system layout 3D rendering Spooling system mandrel 3D rendering

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Flat Rolling Block

The Flat Rolling Block is the perfect instru ment for the economic production of flat bars in any lot size. Flat bars can be rolled in a wide range of sizes with tight tolerances and sharp corners. Prod-uct size can be changed automatically within seconds.

Features

�K Grooveless rolling of an infinitely variable product size range

�K Product size changes within seconds

�K Sharp product edges

�K Fulfillment of highest product tolerances, reducing downstream machining requirements.

Mechatronic Solution

To ensure the greatest benefits from pro-cessing and production, a mechatronic system provides for:

�K Roll gap control with servo motors

�K Mill load control using load cells

�K Fully automated system integrating the roll pass set up (RollMaster) with the Level 1 control system.

Flat Rolling Block

Flat Rolling Block

Flat Rolling Block detail

Mill shears and saws

Hot shears

Siemens VAI offers a full line of hot shears necessary in a bar or rod mill for a wide variety of requirements, such as head/tail cropping, dividing, sampling or scrapping.

Available shear types

�K Pendulum, toggle or snap shears pre-vent the flow of material through the rolling line

�K Up & down shears for billets, blooms and larger sections, for cropping and dividing

�K Rotary, crank and convertible shears along the rolling mill, for flexible oper-ation according to bar size and speed

�K Bar cut length optimization available at dividing shear, so that only multiples of saleable length are sent to cooling bed.

High speed trimming shear and shear control systems

Enables inline rod trimming of out-of tol-erance head and tail ends in the finishing train. Used either ahead of a post-finish-ing block such as a Morgan Reducing/ Sizing Mill or immediately before the pinch roll and laying head, this results in substantial operational cost savings.

�K Flat or profiled blades according to use

�K Fully automated cutting procedures

�K Quick-change device for blade replacement.

Sawing units

For rails, medium-large sections, large bars, and special steel grades, where sawing is preferred over shearing. Better cut quality and precision are provided, and bar end deformation is eliminated.

Features

�K Metallic or abrasive disc technologies available

�K Pendulum or linear disc movement

�K Automatic removal of nose and tail crops

�K Collection of sawing swarf

�K Dust removal and filtering system

�K Fully automated sawing procedures.

Features

�K Synchronized with laying head control for front end positioning

�K Trimmable sizes from 5.0 mm to 26.0 mm

�K Maximum operating speeds of 120 m/s

�K Minimal disturbance of the rod path

�K High speed motion controller to mini-mize delays between tracking system and servomotor control

�K Dynamic positioning of shear blades to ensure cut length accuracy.

Cold shears

Siemens VAI designs flying and static type cold shears, with clutch and brake or direct drive, to produce the ultimate end product.

Features

�K Cutting table width up to 1,800 mm

�K Cutting speed up to 2.5 m/s

�K Direct start-stop drive for reduced maintenance and shorter cycle time

�K Very precise cutting

�K Compatible with high strength steels, as quenched rebar and high-alloy grades

Sawing unit Crop and cobble shear

33

Bar finishing components

Bundling system

Bundlers for round and flat bars are avail-able together with bar counting for rounds and small bundle processing systems. The packaging form can be round, square, rectangular and hexagonal shapes.

Binding systems

Automatic binding of the packages and bundles are available with strap or wire.

Weighing, labeling & unloading

All bundles can be automatically weighed and further labeled for quality-assured delivery of the finished products at the bundle unloading station. With accurate product tracking such as that provided by the Siemens VAI XpertManager sys-tem, tagging accuracy and reliability of the final shipment are assured.

In addition to the wide array of rolling stands, finishing blocks and cutting-to-length systems for every bar product, Siemens VAI has an extensive portfolio of equipment to cover the complete range of final processing needs. From counting to bundling and stacking, and then unloading bundles – everything can be arranged for a smooth final pro-duction process.

Bar counting

Fully-automated counting of bars moving from the cooling bed to the bundling station assures that customer orders are filled accurately and completely. The sys-tem is capable of high production rates and is accurate for all types and sizes of bars. Current count and end-of-batch signals can be output to downstream equipment and to the mill tracking sys-tem for full control and information on the process.

Bar bundling systemBar counting area Bar counting system

34

Water boxes and in-line thermal processing

Mechatronic solution: Temperature Control System

The Temperature Control System pro-vides monitoring and control of stock temperature to insure that the correct mechanical and metallurgical properties are obtained accurately and consistently throughout the process. By monitoring product speed and temperature, along with cooling water pressures and tem-peratures, the system can provide real-time feedback for closed-loop control of cooling zones, from the furnace exit to the laying head or cooling bed.

Benefits

�K Consistency of properties

�K +/–10 °C accuracy

�K Standard operating practices

�K Recipe systems for fast and consistent setups

�K Minimizes uncooled rings

�K Reduces disturbances to water system

�K Historical and real time logging

�K Improves detection of problems

�K Event sequence analysis.

The Siemens VAI proven water cooling systems can make a significant differ-ence in the operation of a bar or rod rolling mill, from improved utilization to better product quality. Available cool-ing elements include conventional solid injector and cooling pipe to the more advanced split nozzle design.

The high cooling efficiency in these water box systems results in reduced water usage, increased lifespan of pumps, valves and other critical compo-nents and lower water consumption costs.

Features

�K Sturdy water box construction

�K Replaceable wear parts within the cooling nozzles and extensions

�K Less water in contact with the product reduces the tendency for cobbles, enabling higher rolling speeds

�K Improved split-style nozzles are retro-fittable replacements for previous-gen-eration split nozzle design water boxes

�K Optional lift-out headers and travers-able water box designs for minimizing change times.

Rebar quenching systems

Water quenching systems with station-ary, lift-out or traversable water boxes provide efficient cooling of ribbed prod-ucts in straight lengths to a cooling bed or in coil form to meet virtually any worldwide specification for quenched and tempered rebar.

Features

�K Martensitic self-tempered outer surface, with ferrite-pearlite core

�K High yield strengths

�K Controlled values of tensile strength/yield strength ratio and elongation

�K Elimination of micro-alloying elements in melt shop (V, Nb)

�K Elimination of expensive post-rolling treatment (e.g. cold drawing or stretching)

�K Excellent weldability due to low carbon content

�K Up to 4-slit rolling.

Water cooling system Rebar quenching system

35

Thermomechanical rolling

Thermomechanical Rolling (TMR) re-quires a combination of proper arrange-ment of rolling and cooling equipment, adequate load capacity in the rolling stands and intelligent rolling and cooling practices. The result is a refined micro-structure in the product that has superior as-rolled mechanical and metallurgical properties.

By improving as-rolled properties and mi-crostructures of rod and bar products, subsequent downstream processes, most of which are done in-house by the major steel producers, can be eliminated or sig-nificantly reduced, therefore lowering the conversion cost.

TMR in a rod mill

Although high productivity and effi-ciency remain the main attraction of the Morgan Rod Reducing/Sizing Mill to most plain-carbon unalloyed steel producers, metallurgical processing flexi-bility is becoming an equally important benefit to the specialty steel and cold heading quality producers.

Through an engineered combination of high load design of the patented mill and proper mill layout, thermomechanical rolling at low temperatures becomes a practical production process. A success-ful combination of equipment design and process design has been developed, evi-dence of which is provided by more than 60 installed and operating post-finishing mill blocks in a variety of mill configura-tions, from existing two-strand rod mills to new high speed, high production rate single-strand rod mills.

Advantages of fine grain size

�K Low rolling temperatures reduce hardenability, promote ferrite formation and retard the evolution of bainite and martensite

�K More uniform grain size from surface to core

�K Reduction in as-rolled tensile strength

�K Increased ductility

�K Improved heat treat response including a reduction in spheroidize annealing times

�K Increased work hardenability.

With respect to rod structure, the refined structure associated with reduced rolling temperatures improves diffusion during heat-treating and can result in reduced heat treatment times and temperatures. For those rods which are not heat-treat-ed, the refined and complex structures resulting from low temperature rolling increases tensile pickup during cold deformation.

High speed rod rolling mill for thermomechanical rolling Effect of finishing temperature on rod microstructure

Endless rolling technology

In recent years, market demand is for bigger billets to increase material yield and produce higher weight coils.

Siemens VAI’s technology is based on JP Steel Plantech Co.’s EBROS.

The welding system is installed between the reheating furnace and the first roll-ing stand to weld together consecutive hot billets and therefore provide a con-tinuous rolling process.

The system operation consists of two main phases:

Phase 1 – Billet welding

Billets are clamped in the welding machine, which is moving at a speed to follow the entry speed of the rolling mill. Incoming billets are joined by flash weld-ing, through rapid heating of billet ends, followed by application of a counter force to complete the joining.

Phase 2 – Burr removal

The welding machine has an efficient burr cutting system at the exit to com-pletely remove the burr from the welded zone and to avoid potential defects dur-ing rolling operations.

Features

�K No inter-billet time

�K Improved yield by reducing losses at both head and tail ends

�K Lower risk of cobbling

�K Possibility of producing higher and customized coil weights, without in-creasing billet size, for better product marketability

�K Reduced maintenance costs

�K High quality of the flash process weld, so that the joint area does not affect final rolling quality

�K Able to weld rough and oxidized surfaces

�K Welded joint area free from inclusions, filler metal or other impurities, for ho-mogeneous and consistent product quality

�K Highly efficient operation, for reduced energy consumption.

Welding machine

Welded joint Before deburring After deburring

Welding machine 3D rendering

37

Turnkey solutions Success from a single source

There are many requirements involved in building or modernizing a rolling mill, including on-time and cost guarantees, reliable start up and rapid achievement of expected production volumes and product qualities.

To ensure that these require ments are met, Siemens VAI offers a turnkey solu-tion. We take on complete responsibility for project implementation and start up production, so you can concentrate on your core business of manufacturing long products and market ing them profitably.

Our responsibility, not yours

Most projects require the coordination of a large number of suppliers on timing, technology, and logistics. Given the number of players involved, we offer a solution as prime contractor.

�K We work through all technical inter-faces so that all components work efficiently together in the overall plan

�K We work in partnership with all sub-contractors, and guarantee overall quality

�K We ensure on-time completion and a smooth start-up, so you can pay down debt on schedule

�K We construct your plant for a fixed price.

Secondary processes are no minor matter

We provide our own Siemens solutions for nearly all processes associated with production, from the power supply to water treatment, and from fire protec -tion to railway siding. And everything is backed by services from our local partners. This comprehensive approach is unique. Cross-functional concepts such as Totally Integrated Automation and Totally Integrated Power provide syner-gies and a high degree of standardization.

Your security: our financial strength and project expertise

In a turnkey project you profit from the global strengths of Siemens: our sound financial base as well as our ability to plan projects with foresight and imple-ment them reliably. We bring to each project many years of experience in com-plying with all rules and requirements, from customs regulations to approval conditions.

Another benefit is the enthusiasm of our engineers, fitters and start-up engineers, all eager to work together with you to create a world-class system.

If you’re planning to invest in a long product rolling mill, we can provide the comprehensive product, system, inte-gration and service expertise you need for success.

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Our services For the best performance of your plant throughout its lifetime

Long rolling services from Siemens VAI enables you to take advantage of the combined experience of our people and deliver comprehensive life-cycle support for your mill. The rolling mill is a long-term investment, and therefore you want a long service life, along with productivity and high utilization, profitability, and product quality.

The range of services we offer is compre-hensive and covers every aspect of your operation.

Services available

�K Maintenance

�K Reconditioning

�K Rebuilds

�K Guides

�K Upgrades

�K Spare parts

�K Equipment and process audits

�K Training

�K Metallurgical.

“Peace of Mind” maintenance

This new program maximizes mill utiliza-tion by maintaining optimal running con-ditions on your critical equipment. This is particularly useful for high-speed equipment in rod mills.

Mechanical and lube system audits

With detailed studies by our mill experts, we can determine if the components are meeting current demands and look for ways to improve their performance.

Predictive maintenance

Through vibration monitoring, we can predict when individual pieces of equip-ment in your mill will probably need maintenance. Therefore, you can better plan for downtimes.

Reconditioning and rebuilds

We can help you get more out of your existing equipment through this service, and possibly introduce some new innova-tions while minimizing the downtime in your operation.

24/7 Spare parts delivery

By using our spare parts in your equip-ment, you receive guaranteed perfor-mance quality for your needs. To help maintain and service your operation, we have parts warehouses in strategic loca-tions around the world, providing deliv-ery 24 hours per day, 7 days per week, every day of the year.

Guides

Backed by our comprehensive process knowledge in long rolling mills, Siemens VAI expertise in guides provides solu-tions for all conceivable rolling applica-tions. This expertise, together with a wide array of designs for mounting and ancillary guiding equipment, means that no problem is too difficult to solve.

Training

A wide range of training programs are available for maintenance, operations and processing. To handle special re-quirements, we can develop customized training for your people.

39

RecyclingModernization

New investmentOperation

• Investigation/inspections & feasibility study• Design• Layout• Construction• Installation• Commissioning

Consulting | Planning | Financing

• Service contracts • Spare parts and components • Consulting and training • Online and offline

maintenance • Maintenance contracting

• Migration packages • Upgrading and

modernization

Life-cycle managementPartnership never ends

Siemens VAI life-cycle services

As a plant operator, you have conflicting needs. On the one hand, your perfor-mance is measured each quarter against short-term profitability expectations. On the other hand, you have to think on a totally different timescale compared with the capital market. Depending on the lifetime of your plant, you have to con-sider the next 15 years or more – at the very least, that is 60 full quarters.

Thanks to our comprehensive expertise and integrated approach to solutions, you can benefit both short-term and long-term from our life-cycle services.

In the short term: Backed by our exten-sive experience with many reference plants, we provide you with the certainty of fast, dependable production, start-up and shorter amortization periods.

In the long tem: Our master plan guaran-tees competitive performance for your plant in every phase of its life cycle. Whether we’re providing 24/7 technical or spare parts service, optimizing main-tenance, or making permanent plant improvements, we’re always working to ensure the cost-effective operation of your plant.

40

Profitable expansion for rapidly growing market

Customer: �Vizag Steel, Visakhapatnam (Andra Pradesh), India, part of Rashtriya Ispat Nigam Ltd.

The task: One of the largest Indian steel producers, Vizag wanted to expand to 6.3 million tpy, improve productivity and optimize costs of its Special Bar Quality production line.

Our solution: A new mill with 18 Red Ring rolling stands followed by a 3-stand Pre-stressed Sizing Group, with a double finishing area with cooling bed and three Garrett reeling stations. Initial mill capacity of 750,000 tpy.

The result: �Flexible and reliable operation in expanded modern facility that profitably positions Vizag in one of the world’s most rapidly developing areas.

Achieving huge capacity, productivity gains

Customer: �Villares Metals, Sumaré (São Paulo), Brazil, part of Voestalpine Group

The task: �One of the most important South American producers of high-alloy steels and specialty alloys, Villares wanted to expand its portfolio, increasing rolling capacity and productivity, and optimizing operation costs.

Our solution: �A new multiline mill, including a straight bar line with 16 Compact Cassette Rolling stands, a rod line with two finishing monoblocks and a line with a Flat Rolling Block.

The result: �Rolling capacity increase of approximately 40 %, with optimized costs and an installation schedule that eliminated potential impact on existing production.

Excellence through experience Selected success stories with rolling mills

Meeting speed and quality goals

Customer: Votorantim Metais, Resende (Rio de Janeiro), Brazil

The task: Add capacity for coiled rebar and other rod products to support growing South American market on green-field site with the best technology for high production rates and quality.

Our solution: New single-strand rod mill with roughing and intermediate train, pre-finishing Morgan Mini-Blocks, finish-ing Morgan No-Twist mill, in-line quenching, Morgan high speed pinch roll and laying head, Morgan Stelmor conveyor, reform and coil handling system. Provisions for future second strand.

The result: �High quality rod and coiled rebar produced at finishing speeds up to 110 m/s for at least 500,000 tpy on single strand. Mill has rolled HYQST quenched and tempered rebar products at highest speeds in the world.

Modernization yields production growth

Customer: Global Steel Wire, S.A., Santander, Spain, part of the Celsa Group

The task: As a renowned supplier of high quality rod products, Global Steel Wire needed to expand product size range, increase production and improve quality for changing markets, including new bar-in-coil market.

Our solution: Series of mill modernizations: equipment improvements and additions to 2-strand rod mill to increase pro-duction rate and productivity, including Morgan Mini-Blocks, Morgan No-Twist mills, Morgan Rod Reducing/Sizing Mills, rod outlet; bar-in-coil outlet with water cooling and Morgan Bar Reducing/Sizing Mill for high quality bar products.

The result: Over 10 years of mill modifications, Global Steel Wire has increased production from 570,000 tpy to over 900,000 tpy, with increases in coil weight, product size range and quality.

Longer long products

Customer: Corus, Scunthorpe, UK, part of Tata Group

The task: As part of company’s overall investment program, mill revamp needed to improve Corus’ production capability and cost-effectiveness.

Our solution: A new finishing mill with 7 in-line Red Ring universal stands, cooling area with rail precambering, and handling equipment.

The result: The mill enables Corus to roll rail lengths up to 120 meters in an in-line continuous finishing mill. It offers unsurpassed flexibility to process both rails and sections, with minimized change operations and improved tolerances.

Highest productivity in the Middle East

Customer: Habas Sinai Ve Tibbi Gazlar Istihsal Endustrisi A.S., Aliaga, Turkey

The task: One of the leading players in the Middle East, Habas needed a greenfield rebar rolling mill, with high productivity and equipment reliability.

Our solution: A state-of-the art fully automated multi-slitting rolling mill with 25 Red Ring stands, including a double finishing train, with in-line bar quenching, Multichannel Braking System for high speed delivery to a 120 m cooling bed and handling areas. Bars ranging from 8 to 42 mm diameter rolled in up to 4-slit process.

The result: Designed for 1,185,000 tpy, one of the most productive rebar plants in the world. Production exceeds 4,500 tons per day, equivalent to an average rebar production of 180 t/h.

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World-class slit rolling bar mill

Customer: TataIron&SteelCo.Ltd.,Jamshedpur,India

The task: �Asoneofthelargeststeelproducersintheworld,TatawantedtoexpandcapacityinIndiatosupportgrowinginfrastructurewithlatesttechniquesforrollingrebar,andremainbest-qualityconstructionsupplier.

Our solution: �Newsingle-strandbarmillwith16standsforroughingandintermediatetrains,two-wayslittingunit,two6-standMorganNo-Twistmills,waterboxesforHYQSTprocessing,dividingshears,patentedhighspeedRotaryEntrySystemtothecoolingbed,coldshear,plusbundlingandstrappingequipment.

The result: �Designed to produce 600,000 tpy, mill exceeded production targets several times at commissioning. One of the fastest and most efficient mills in the world for slit rolling in straight lengths, with rolling line yields above 95 %.

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www.siemens-vai.com

Siemens Industry Inc.

15 Belmont Street Worcester, MA 01605-2665, USA

Phone: +1 508 755-6111 Fax: +1 508 832-0139

E-mail: [email protected]

Siemens VAI Metals Technologies S.r.l.

Via L. Pomini, n. 92 21050 Marnate (VA), Italy

Phone: +39 0331 741211 Fax: +39 0331 741386

Siemens VAI Metals Technologies GmbH & Co.

P.O. Box 4, Turmstr. 44 A 4031 Linz, Austria

E-mail: [email protected]

The information provided in this bro-chure contains merely general descrip-tions 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.

Order No.: E10001-M3-A14-V1-7600 Printed in Germany Dispo No.: 21661 K No.: 28104 GB 100026 WS 10101.5 Subject to change without prior notice

© Siemens AG 2010. All rights reserved.

No Twist is a registered trademark of Siemens Industry Inc.

Stelmor is a registered trademark of Siemens Industry Inc.

EBROS is a registered trademark of JP Steel Plantech Company

Documents

Solutions for long product rolling mills