• Avoidance of significant downtime through modernization during annual maintenance shutdowns
• Increased system availability, maintenance efficiency and operational safety
• New automation system with open hardware and system platform provides flexibility for future expansion and integration projects

SMS group has successfully completed an automation system upgrade for the five-meter heavy plate mill at Jingye Steel Co., Ltd. in Yingkou, Liaoning Province, China. Originally installed by SMS group in 2009, the mill resumed production after an efficient ten-day shutdown. The strong partnership with Jingye Steel, bolstered by an annual X-Pact^® Service contract for automation support, facilitated meticulous modernization planning for the replacement of obsolete or inoperative components, thereby preventing significant downtime. Consequently, the upgrade, which took only eight days to complete, was seamlessly integrated into the mill’s annual maintenance schedule, eliminating the need for additional shutdowns.

SMS brought the X-Pact^® ProBAS level 1 automation system up to the latest state of the art for the roughing mill, finishing mill, and hot plate leveler, substantially improving system reliability and maintenance efficiency. The new automation system was raised to a new technological level with X-Pact^® Embedded controllers and a high-speed EtherCAT I/O system for rapid communication and efficient data handling. This advancement boosted the system’s overall performance and ensured the sustained availability and serviceability of components and technological packages. Furthermore, the safety modules were replaced with the latest models to enhance operational safety.

The upgrade incorporates a future-oriented open hardware and system platform. This approach means that the platform is not locked into a single vendor or protocol, providing flexibility for later expansion and integration projects. The open platform adheres to international standards and allows for seamless interaction with a wide range of hardware and software solutions. This adaptability is crucial for the steel industry where technological advancements are rapid and continuous.

The automation upgrade far exceeded the customer’s expectations. The plant director at Jingye Steel, Wang Hailong, praised the SMS project team: “We were supported in this automation project by an excellent team from the SMS Automation, Digital and Service Solutions unit, who worked diligently and efficiently in such a short time to ensure a successful outcome.”

Designed for an annual output of 2.3 million tons, the heavy plate mill at Jingye Steel boasts an impressive production capacity. Its extensive product portfolio includes steels for shipbuilding, pipelines, pressure vessels, boilers, and high-strength structural applications.

Christoph Stappenbeck, Vice President of Automation, Digital and Service Solutions at SMS group in China, summarized: “SMS designs and builds plate mills for the long run. Our goal is to maintain and expand the performance of our customers’ plants throughout their entire lifecycle. By collaborating closely with our customers, we develop integrated solutions tailored to their specific use cases. Through modernization and service, SMS can ensure that the plants remain up to date, enabling plant owners to achieve a broader portfolio and higher production levels.”