Following an extensive upgrade project completed by SMS group, Tata Steel Ltd. has successfully rolled the first coils at its Jamshedpur CSP^® (Tata Steel TSCR) plant in Jharkhand, India. The revamp included the integration of a new F7 finishing stand as well as comprehensive enhancements to legacy X-Pact^® automation systems, such as the complete renewal of hardware and software, for example. As a result, the mill is now capable of producing thinner gauges and higher quality products, underscoring SMS group’s lifecycle partnership approach.

The existing CSP^® plant, originally delivered and commissioned by SMS in 2011, has an annual output of approximately 2.5 million tons, producing strip in widths from 900 to 1,680 millimeters and thicknesses from 16 down to one millimeter.

In addition to the new F7 rolling stand, SMS’s upgrade project included the adaptation of the existing roll-changing equipment. With one additional mill stand, the rolling load distribution can be optimized for harder materials at wider widths and thinner gauges, in particular. The F7 mill stand ensures there are fewer bottlenecks for certain products in the finishing mill. This boosts output for such grades and allows the CSP^® casters to operate at an optimized casting thickness for improved overall efficiency.

Additionally, the modernization aimed at enhancing mill stands F1 to F5, with the installation of a new hydraulically-operated pass line adjustment system. Five laminar cooling sections were replaced by four reinforced cooling units with edge masking. The entire exit area was upgraded, including a new measuring house, and provision was made for a second multifunction gauge in the future.

Among the technical enhancements, SIEFLEX^® gear-type spindles with internal oil return line were also incorporated. The SIEFLEX^® gear-type spindle is designed to transmit up to twice as much torque as conventional shafts through advanced hardening, optimized tooth geometry, and a proprietary tribo system. At the same time, it features a continuous oil lubrication system that ensures effective cooling, eliminates the need for grease maintenance, extends the service life, and reduces rolling mill downtimes.

As part of the revamp, SMS level 1 and level 2 automation systems were upgraded within the powerful X-Pact^® ProBAS platform based on X-Pact^® Embedded controllers, and the existing Human Machine Interface (HMI) was updated. These technological advancements provide high-speed control capabilities for the CSP^® rolling mill, ensuring reliable and efficient plant operations.

The level 2 automation system incorporates state-of-the-art process models specifically designed to maximize the efficiency and quality of production processes. The X-Pact^® Pass Schedule Calculation (PSC^®) model facilitates the precise generation of rolling schedules tailored to specific production requirements. By accurately planning rolling parameters, it ensures perfectly synchronized workflows.

Another key component is the X-Pact^® Cooling Section Control model, which provides fully automated cooling of the rolled material. This technology maintains a consistent material temperature during the rolling process, which is critical for the quality of the final product. By precisely controlling the cooling parameters, a uniform material structure is achieved, which in turn enhances the product’s mechanical properties. Additionally, the X-Pact^® Profile, Contour, and Flatness model ensures precise thickness and flatness tolerances, meaning greater process stability. With this technology, high-quality products covering a wide range of specifications and dimensions can be manufactured. The integration of these advanced automation solutions into the CSP^® rolling mill ensures that production processes are not only efficient but also flexible and adaptable to changing market demands.

From day one after the revamp, fourteen coils were rolled without any cobbles, and by the sixth day the mill successfully processed thicknesses up to 1.2 millimeters. Although the shutdown was a difficult operation, these early achievements reflect careful preparation and thorough pre-commissioning tests.

Hendrik Trimborn, Project Manager at SMS, said, “Thanks to the excellent cooperation between Tata Steel and SMS group during the execution phase and especially during the shutdown and ramp-up, in which several team members from the original commissioning also participated and thus reinforced our partnership approach with our customers, this complex revamp project was a success. The open and trusting communication made it possible to identify challenges early on and to find solutions together. This very short and effective ramp-up phase exceeded the expectations of all parties involved, which impressively underlines the value of this strong partnership.”

The integration of the F7 stand and the state-of-the-art X-Pact^® automation highlights SMS’s long-term commitment to supporting customers throughout the entire lifecycle of their equipment and adding value to our customers. Notably, some team members from the original commissioning were also involved in this upgrade, reinforcing our partnership approach with our customers.