Who Will Benefit?

COURSE OBJECTIVE: “To explain the major concepts and characteristics of flat rolling needed to guide and stimulate individuals in solving problems specific to their area of interest”.

The course is aimed at mill technologists and engineers involved in the design, operation, maintenance and improvement of modern, automated flat product rolling mills. The course has been extensively used by companies to “kick start” their newer recruits into the field of rolling.

Delegates receive an extensive set of detailed course notes for each lecture, together with other reference documentation, tutorial workbook and a training CD. Delegates have on-line access to demonstration versions of several simulation programs after the course and the opportunity to purchase this software at a discount.

Course Program

Tino Domanti - Tino commenced work with IAS in 1987 as a software engineer. In 1993 he completed his PhD in the modelling of residual stress in flat metal rolling. He currently heads the Research and Development group within Hatch IAS. Tino has developed models for thin strip, temper, foil and asymmetric rolling and has been involved

in a number of consulting projects covering aspects from mill shape and profile performance to control system design.

Stewart Paardekooper - Stewart completed a BE (Hons) degree in Electrical Engineering (1982) and a graduate diploma in Computer Science (1985). His previous experience included developing plant information systems, before joining IAS in 1988. Initially involved in aluminium casting and coal loading automation and systems, since 1990 he has worked in most aspects of sheet metal rolling (steel

and aluminium), primarily in the development of setup models. Projects involve automation, setup model and shape control systems on cold tandem, temper, reversing, non-reversing and hot finishing mills. His broader scope of experience includes offline simulation and modelling, consulting, mill audits and training.

Stuart Critchley - Stuart has over 30 years technical and operating experience in rolling and finishing. Working out of Hatch’s Canadian headquarters, his project experience includes initiating, participating and leading teams to complete major capital projects on new mill installations and on control systems upgrades. His interests span a range of topics, from roll grinding to thickness control, however tandem

mill vibration remains a specialty. The optimising of existing mills to improve safety, throughput and quality has allowed him to visit and benchmark plants all over the world.

Ray Davies - Employed by BHP Steel for eighteen years, and having completed a Metallurgy degree and Graduate Studies in Control, Ray has gained extensive experience in the rolling industry. Projects with BHP included the automation of a hot rolling mill, two tandem cold mills and coil painting line. Since joining IAS in 1988 Ray has been involved in a range of consultancy, training, rolling simulation

and automation projects, including tandem cold mills, single stand reversing cold mills and hot strip finishing mills. As Consulting Manager he has had extensive involvement in hot mill and cold mill performance audits. His area of interest is in mill control systems.

Course Lecturers - Hatch IAS

Presented by lecturers who, collectively, have over 120 years of practical and theoretical experience in the design and implementation of control systems, rolling mill models and mill instrumentation

Hot Tandem Mill Control - Design of actuator and mill responses to various process and actuator disturbances leading to the design of thickness, tension and temperature controls for tandem hot finish mills.

Actuator, Instrumentation and Mill Performance - The operation and performance of a rolling mill is influenced by many factors, key being the design, speed, accuracy and robustness of the instrumentation and actuators. An introduction to the major instrumentation and actuators associated with the production of the correct final strip thickness is presented. The merits of each type of instrument and actuator are discussed, with typical response times and design limitations.

Shape Control Systems - Design of integrated shape control systems for cold mills and a discussion of the areas where practical problems may arise.

Profile Control Strategies - Mathematical formulations of a vector based profile setup model algorithm. Application of insights from shape simulation studies to the design of profile control systems. Discussion of practical constraints and achievable performance.

Mill Thickness Control - Logical procedures for designing mill control systems and for decoupling interactions between tension and thickness control in single stand and tandem mills.

Tandem Cold Mill Setup Strategies - Techniques for scheduling tensions and thickness reductions on tandem cold mills in an on-line environment. Calculation of control actuator references for threading of tandem cold mills to minimise off-thickness material and threading delays.

Case Study in Reversing Cold Mill Automation - Discussion of issues involved in automating single stand rolling mills, highlighting the areas of similarity and difference with tandem cold mills.

Hot Finishing Mill Setup Strategies - The selection of drafting strategies to meet the conflicting constraints of power, profile and flatness, and finishing temperature, is reviewed. Tension and temperature policies are also described.

Adaption of Rolling Mill Models - Motivation for adapting rolling models and derivation of simple algorithms for achieving enhanced on-line model performance. Practical aspects of model adaption schemes for reversing and tandem mills.

Scheduling of Hot Reversing Mills - Operating constraints are discussed and algorithms described for mill drafting and calculation of pass speeds to achieve specified exit conditions.

Strip Width Control - Conceptual design of width control systems typically employed at the roughing and finishing stands of steel hot strip mills. Edging reduction constraints, typical practices and the control of slab end effects by dynamic edger position control is addressed.

Mill AutomationThe Flat Rolling Process

Florence is a beautiful quaint city located in the centre of Italy. It is most famous for its history and its importance in the middle ages and in the Renaissance, especially renowned for its art and architecture. The city offers plenty to see and do, with numerous monuments and museums, and a variety of fine shops, bars, and restaurants. IRTC36 will be held at the elegant 4 star 'Hotel Londra'. Conveniently located in close proximity to the city centre and all major attractions, the hotel is known for its high level of service and is equipped with all comforts.

Accommodation rate for IRTC delegates is Euro189 (Double/single room),inclusive of American buffet breakfast, taxes and services.

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Rolling Mill Configuration - Discussion of the latest technology in rolling mill design and instrumentation.

Introduction to Rolling Concepts - Rollgap mechanics, tabulation of relevant properties of roll and strip, definition of terminology and variables, effect of roll and strip roughness on friction, forward slip definition, yield stress dependence on temperature and strain rate.

An Introduction to the Metallurgy of Sheet Products - Reviews the structure of metals and examines the development of the properties of steel and aluminium sheet during each stage of production, from smelting and casting to rolling and heat treatment. Tensile testing and the classification of sheet products are discussed.

Rolling Theory - Development and interpretation of models for the prediction of roll force, torque and slip in rolling. The use of the friction hill model for explaining rollgap phenomena. The derivation of simplified models for solving a wide range of rolling problems and algorithms for solving model equations.

Rollgap Modelling for Hot Rolling - Developments in yield stress, friction, slip and strip temperature models for hot rolling. The influence of temperature, recrystallisation, precipitation and phase transformations on yield stress.

Rollgap Sensitivity Coefficients - Introduction to the concept of sensitivity coefficients and their use in control systems. Application of force, torque and slip sensitivity coefficients in mill problem solving.

Thin Strip, Foil and Temper Rolling Models - Examination of the limitation of circular arc models and development and application of non-circular arc rolling models. The effect of rolling speed and roll texture on the roll strip interface is considered along with the consequences for thin strip, foil and temper rolling. Closed gap rolling is also discussed.

Lubrication and Cooling - Discussion of the principal features for an integrated roll bite lubrication and cooling system.

Mill Thermal Analysis - Identification of heat flows in rolling, derivation of strip temperature models in the rollgap and between stands.

Roll Thermal Camber Analysis - Solution of temperature fields within rolls and approximate calculation of the roll surface expansion. Dynamic response of thermal camber to rolling conditions and individual cooling sprays and the application of hot edge sprays in rolling.

Introduction to Strip Profile, Shape and Flatness Concepts - Introduction to definitions and causes of manifest and latent shape. Parametric representation of measured flatness and thickness profile.

A Model for Flatness and Profile Analysis - Physical modelling of profile and flatness development in hot and cold rolling and a discussion of the various mechanisms for profile change and tension stress feedback.

Mill Vibration Phenomena - A review of the different forms of mill vibration phenomena, known as ‘chatter’ and ‘rumble’, the conditions which contribute to their occurrence, and possible means of minimising or avoiding the problems.

To reserve your accommodation and receive the discounted rate, please contact the hotel via telephone or email and advise that you are an 'IRTC36' delegate.

We suggest you do not delay in contacting the hotel in order to guarantee your reservation.

Hotel Reservations will happily assist you with any enquiries you may have regarding your booking.

This five and a half day course will commence on the Sunday afternoon with registration (approximately 3.30pm), followed by an introduction to PC operation and the rolling mill simulation software. It is important that delegates attend this session.

The course program will run from approximately 8.30am to 5.30pm, Monday to Friday. The course will conclude on Friday at approximately 4pm.

Tutorials and practical application studies, including hands-on exposure to a suite of advanced mill simulation and design programs, will support the theoretical concepts and model derivations discussed in the lectures. Facilities for private study and informal discussion sessions will be available and delegates are invited to simulate problems of their own choosing outside the formal course timetable.

The official course language is English.

Course Venue and Accommodation

Glen Wallace - Glen is the Global Director - Hatch IAS. His activities with the company started in 1991 with the design and implementation of shape, thickness and coating control systems. This work progressed into research and development activities contributing to patents in thickness control, mill vibration suppression and coating control. He has consulted to companies around the world on thin strip casting, rolling, annealing and galvanizing. In 1999 Glen established the North American operation of IAS and in 2003 he returned to Australia to lead IAS globally.

Hotel Londra

Via J. Da Diacceto 18, 50123 Firenze

Tel : + 39 055 27390

Fax : + 39 055 210682

Email: booking@hotellondra.com

OR : info@hotellondra.com

Web: www.hotellondra.com

Course Documentation

THE WORLD’S LEADING COURSE FOR THE FLAT ROLLING PROCESS

Argentina: Aluar Siderar S.A.I.C. Australia & New Zealand: BHP Comalco Aluminium Ltd Industrial Systems Pty LtdReal Time Consultants Pty LtdAustria: AMAG Rolling GmbHBahrain: GARMCO Belgium: Cockerill-Sambre Sidmar N.V. Brazil: C S NC S T Canada: Dofasco Inc. Lake Erie Steel ReycanChile: Medeco S.A. Colombia: Aluminium Nacional S.A.Aluminio Reynolds Finland:Rautaruukki Steel France: ArcelorCLECIM D M S IRSID Ugine SA USINOR Germany: AG DillingerAlunorfBFM GmbHBWG Bergwerk und Walzwerk D.A. Stuart GmbH Hille & Müller Krupp StahlStahlwerke BremenUngerer Messtechnik Greece: ELVAL Hungary: Dunaferr Hungalu Köfém Ltd India: Bralco Metal Industries Ltd Digi Drives (P) LtdFlat Products Equipments Ltd Ispat IndustriesLarsen & Toubro Ltd M.N. Dastur & Company LtdPP Engineering WorksSteel Authority of India TATA Iron & Steel Company The Tinplate Company of India Tube Investments of India Indonesia: PT Krakatau Steel Italy: Ansaldo CEDA SpA FATA Hunter EngineeringINNSE Japan: Hitachi Ltd I H I Pohang Iron & SteelSumitomo Metal Industries Kenya: Mabati Rolling Mills Ltd Korea: Dongbu Steel Company Ltd Pohang Iron & Steel Luxembourg: Eurofoil Mexico: A.M.I. Altos Hornos APM SA DE DV

I M S AVillacero Group Netherlands: Hunter DouglasNedzink Nigeria: First AluminiumPortugal: Lusosider Acos Planos S.A. Qatar: Qatar Steel Company Ltd Russia: Joint Stock CompanySiberian Aluminium CompanyMikhalum JSCNovolipetsk Iron & Steel Company Saudi Arabia: Saudi Iron & Steel (SABIC) South Africa: Columbus StainlessHighveld Steel & Vanadium Corp. Hulett AluminiumKentz Automation & DrivesMittal (ISCOR Saldanha & Vanderbijlpark)Spain: Arcelor SaguntoIndustria Navarra del Aluminio INESPAL SA Instalaciones Siderurgicas SA Sidmed S.A. Sweden: Aluminium Teknik, Granges Eurofoil SkultunaMefos Metal Working Research PlantSandvik Materials TechnologySSAB-Oxelösund Switzerland: Lauener Engineering LtdTaiwan: An Mau Steel Company Ltd China Steel Corp.Chung Hung Steel Corp. Thailand:Sahabiriya Steel IndustriesUnited Kingdom: Bridgnorth AluminiumBritish Steel Cardiff Bar & Section Mills Croda Application Chemicals Ltd Davy McKeeLawson Mardon Star LtdThe Broner Group United States of America: AK Steel Corp. Allegheny Ludlum Steel Corp. Alstom Drives & Controls Alumax Mill ProductsAnsaldo Ross Hill Armco Inc.Automation Systems Int. Benchmark Automation Bethlehem Steel Corp. Bliss-Salem Inc. Brush Wellman Inc.Butech Bliss California Steel Industries Carpenter Technology Corp Chaparral Steel Company Chicago Cold RollingCommonwealth AluminumCSN LLC CSM Industries Elf North AmericaFluor Daniel Inc General Electric Company Golden Aluminum H.C. Starck Inc.Hess Engineering Heyco Metals Inc.Hussey Copper Inc. I B A I/N Tek Ispat Inland Steel Company Intergrated Industrial Systems J & L Specialty Steel J.W. Aluminum

COVERING THE MAJOR ASPECTS OF HOT & COLD FLAT ROLLING:

• Thickness & Flatness Performance Benchmarks

• Modelling for Hot, Cold & Foil Rolling Process

• Control of Thickness, Width, Profile & Flatness

• Hot & Cold Tandem Mill Control Design

• Design of Integrated Control Systems

• Scheduling of Reductions & Tensions

• Metallurgy of Sheet Products

• Flatness & Profile Analysis

• Mill Vibration Phenomena

• Online Models & Adaption

• Mill Automation Concepts

• Lubrication & Cooling

• Mill Thermal Analysis

• Rolling Mill Actuators and Instrumentation

• Early Bird Discount

• Half price for previous delegates

• Online access to IRTC Simulation Software after the course

• 30% Software Discount

IRTC36Florence, Italy

8th – 13th May 2011

PRESENTED BY:Hatch Associates Pty Limited7 Warabrook Boulevard, Warabrook NSW 2304 AUSTRALIAPh: +61 2 4968 6868 Fax: +61 2 4968 6800 irtc@hatch.com.auwww.indauto.com/irtc

Vanessa EckfordIRTC Co-ordinator

"It seems to me that the Hatch IAS team is a group of the most intelligent and experienced professionals in their field. They are a dedicated team that propagates the 'work hard / play hard' mentality, which made the course more than just for learning, but also fun."

Alex Acciacca – ArcelorMittal USA

“The IRTC provided me with an understanding of rolling fundamentals. Such understanding allows us to move away from ‘trial and error’ approaches and can greatly increase the effectiveness of developments in our process.”

Carel Anthonissen – Hulamin South Africa

36th International Rolling Technology Course

FLORENCE, ITALY

8TH - 13TH MAY 2011

REGISTER NOW

James HardieKaiser Aluminum Lukens Steel Company Measurex Corp. Mittal Steel USA (LTV and ISG)Morgan Construction Corp. National Rolling MillsNichols Aluminum Norandal USA Inc. North Star BHP Steel LtdNucor Steel Olin CorporationOregon Steel Mills Ormet Corp. PCT Inc.Quest Engineering Inc. Revere Copper Products Reynolds Metals RMI Titanium Corp. Rockwell Automation Rouge Steel Company Star AluminumSteelscape Inc. Taurus Group Thomas Steel Strip Corp. Tippins Inc. United Aluminum US Steel USS Posco Industries Vollmer America Inc. Warren Consolidated WCI Steel Weirton Steel Wheeling Pittsburgh Steel Corp.Wise Alloys, LLC Worthington Steel Company Venezuela: Alucasa Alumino Laminacion Vizcava SidorW O R L D W I D E : ABBGermany/Italy/NZ/Spain/Sweden/USAAEGGermany/USAAlcanCanada/France/UK/USAAlcoaBrazil/Hungary/Netherlands/UK/USA AlusuisseGermany/SwitzerlandAvestaPolaritFinland/SwedenCegelecAustralia/Germany/UK/USACorusBelgium/Canada/Germany/Netherlands/Norway/UKDanieliItaly/USADufercoBelgium/Sth Africa/USAHoogovensMexico/NetherlandsHydro AluminiumGermany/Italy/Norway/USANovelisBrazil/UKOutokumpuFinland/Netherlands/Sweden/USAPechineyFrance/Luxembourg/USAQuaker ChemicalsAustralia/ChinaSAPAChina/SwedenSiemensGermany/Singapore/USASMSGermany/ItalyTeich AGAustria/GermanyVAW AluminiumGermany/SpainVoest AlpineAustria/Brazil/USA