For Shandong Iron & Steel Group Rizhao Co., Ltd., the modernization marked an essential step toward long‑term production stability and enhanced competitiveness. The level 1 automation upgrade required exceptional precision, as the entire revamp had to be executed within Shandong Rizhao’s regular maintenance window. With the zinc pot operating continuously and the heating furnace unable to be shut down without major consequences, the project demanded a genuine “plug and work” approach. SMS group delivered state-of-the-art X-Pact® level 1 automation for the continuous galvanizing line — fully based on the Siemens TIA platform with the latest S7‑1500 controllers — along with all required software and comprehensive on‑site commissioning. This provided the customer with a reliable, robust, and future‑proof automation foundation.
Integration test ahead of shutdown
To ensure performance under real operating conditions, SMS group’s X‑Pact® Plug & Work integration test played a pivotal role. Based on advanced simulation models, engineers meticulously validated every link in the process chain, from correcting program anomalies to tuning parameters. Multiple iterations of debugging refined the system step by step, significantly enhancing overall reliability before installation even began.
A modernization designed around production continuity
The true challenge came during the maintenance window itself. With the zinc pot remaining online and the heating furnace unable to cool, the team had only a narrow time frame to replace controllers and reestablish full process functionality. Working under zero‑tolerance conditions, SMS group restored the line’s key functions within three hours, achieved full-line reconnection after five hours, and met the customer’s production restart target after 27 hours of continuous effort. The rapid return to operation demonstrated not only technical precision but also the strength of an experienced team capable of delivering under intense operational pressure.
As the line moved into continuous production, the galvanizing process required uninterrupted stability, with any deviation risking significant material loss. SMS group maintained a 24‑hour on‑duty response by X-Pact® Service experts during this phase, addressing potential system abnormalities within seconds and securing the smooth, steady operation essential to Shandong Iron & Steel Group Rizhao’s customers in the automotive and home appliance industries.
The project adds another chapter to the longstanding cooperation between Shandong Iron & Steel Group Rizhao and SMS group, built over years of successful work across the flat‑rolling complex, including the pickling line/tandem cold mill, two annealing lines, and the hot‑dip galvanizing line with its three inline skin‑pass mills. It reinforces a partnership defined by trust, technological depth, and the shared ambition to ensure high‑performance steel processing in one of China’s most competitive industrial sectors.