Competence in metallurgical services

Operational support, plant upgrades and maintenance services from a single source your partner over the entire life-cycle of your plant

Metals Technologies

Strong competitive pressures force plant operators to keep production and maintenance costs at the lowest possible level. Continuous optimization and improvement of performance is the key challenge toward achieving this goal which is why plant operators are increasingly focusing on operational support, plant upgrades, and maintenance services.

You expect
 Customized solutions for decreasing operating and maintenance costs to offset growing cost pressures  State-of-the-art plant performance and highest plant availability and reliability through professional maintenance over the entire life-cycle of the plant  Extended plant lifetime achieved by regular technical updates  Consulting services to extend the product portfolio and increase the product quality  Excellent trained employees with outstanding problem-solving skills to respond to the challenging market requirements

Your challenge: To satisfy your customers while outperforming your competitors

Customized solutions To react to changing customer requirements such as product variety and price reductions means that you need the highest possible flexibility in your production which is feasible, by, for example, utilizing state-of-the-art process equipment. For the integration of modern equipment in your existing plant, you need a long-term partner that has detailed knowledge about your facility and the most experience in both plant construction and maintenance. Plant performance and availability In a rapidly changing market, almost no other factor determines success like a plants productivity. To keep the complex processes in a plant running efficiently, optimization on a continuous basis is essential. Performing periodic maintenance is mandatory to avoid breakdowns and expensive production losses. Operating at high temperatures involves the risk of unscheduled breakdown if a component fails. Fast and continuous availability of spare and wear parts minimizes production standstills. Effective cost-cutting Increasing competitive pressures together with fluctuating demand causes a serious impact on the price of all kinds of steel products. Permanently rising costs for energy, raw materials, and transport make it necessary to cut both operating and maintenance costs. The right equipment and the right combination

of external and internal maintenance activities make it possible to flexibly adapt your cost structure. Extended plant lifetime To save on major capital investments, to improve the quality of steel products, and to ensure permanent succeed in your market, it is essential to extend the lifetime of your existing plant and to keep it equipped with state-of-the-art technology as much as possible. With Siemens VAI, you will have a modernization or upgrade partner who will provide you with the latest plant technology, ensuring the necessary production quality and flexibility over your plants entire lifetime. Skilled personnel Highly skilled production and maintenance personnel are key success factors for maximum plant output and minimized costs. To achieve this goal, it is necessary to continuously train your production and maintenance personnel to keep them at the highest levels of knowledge and expertise. For this you need a trusted partner and advisor who can provide customized trainings that combine the latest technological trends and maintenance practices.

Our solution: Service and support from a single source fast, experienced, reliable.

Comprehensive operational support As one of the worlds leading plant manufacturers and service companies for iron and steel plants, we at Siemens VAI provide our customers with comprehensive operational support in operating their steelmaking, rolling, and processing facilities at the lowest possible cost. Our service portfolio includes the fast delivery of in-house produced original manufacturer components of the highest quality to ensure an extended service life along the entire process chain. In the case of an unexpected breakdown of a component, we promptly provide our customers with original spare and wear parts of highest quality. Because we are able to manufacture large quantities, we can offer parts at a competitive price. Warehouse storage of critical parts permanently guarantees their fast availability. The third important service listed in our portfolio is consulting and technical assistance, which is executed by highly skilled experts at every step of the process chain. By instructing and advising your operators on-site, Siemens VAI helps you find and realize potentials for performance improvement and reduction of costs. Customized training programs support the capability of your plant personnel and assure plant efficiency at highest possible levels. Efficient plant upgrades Decades of experience worldwide in design, consulting, and engineering of metallurgical facilities ensure that each client receives the most innovative

technological upgrades for their manufacturing plants and processes. Because of our comprehensive knowledge focused in the area of services, Siemens VAI can provide stateof-the-art solutions. Modernizations and mechatronic solutions for plant components result in, for example, increased plant performance, improved quality, easier handling, and increased safety. Relatively small investments to secure the latest equipment technology can yield large advances in plant functionality. Complete range of maintenance services Outsourcing of relevant services, such as online and offline maintenance, is a very efficient way to impact your cost structure. Siemens VAI offers you the full range of maintenance services across the processing chain and everything from a single source. Our worldwide experience in the iron, steel, and aluminum industries also enables us to identify and implement the necessary preventive measures at every stage of production, therefore avoiding downtimes and cutting unnecessary costs. To offer a fast and uncomplicated repair service to our customers, we run service workshops around the world held at our own manufacturing facilities. With Siemens VAI, you can be sure to get high-quality repair services using original manufacturer components performed by highly experienced teams at an attractive price.

Siemens VAI strives to be a long-term life-cycle partner dedicated to our customers success. We offer our experience, our technical expertise, and our customized service and maintenance solutions to reduce your costs, increase productivity, and improve product quality and operational safety.

Advantages of Siemens VAI metallurgical services:

 Technological leadership in metallurgical plants, implementing the latest state-of-the-art services  High-quality service from more than 2,500 service specialists worldwide  Cost reduction in both operation and maintenance  Increase in plant availability and productivity through powerful modernization packages  High quality and fast delivery of spares / components manufactured in-house  Single point of contact resulting in short response times and simple interfacing  Decades of experience in life-cycle service

Experience and expertise in all aspects of the processing chain

Full line of services As one of the worlds leading plant-building companies and plant service providers for the iron and steel industry, Siemens VAI has extensive knowledge spanning the entire process chain of iron and steel production and processing. This expertise, combined with our decades of experience in maintaining iron and steel works, enables us to provide a complete range of services along the entire process chain, from the delivery of spare and wear parts to online and offline maintenance. Only comprehensive services from a competent partner throughout your plants entire life-cycle can ensure a trouble-free operation and optimal functionality.

From raw materials

to finished products.

Single-source solutions for the entire metallurgical process chain including original manufacturer components, third-party spare parts, modernization and mechatronic solutions, technical assistance and training, online and offline maintenance, and much more.

Over 2,500 service specialists around the world

Global presence for local support Siemens VAI customers can rely on a unique service network throughout the world. We place our service and expertise in more than 25 service locations worldwide at your disposal comprehensive support, close at hand.

U.S.: Baltimore, Benton Harbor, Blytheville, Columbus, Decatur, Huger, Milan, New London, North East, Reading, Worcester Mexico: Monterrey Brazil: Cubatao, Itagua, So Paulo, Vitria, Volta Redonda UK: Sheffield Germany: Legelshurst Austria: Linz Italy: Marnate France: Montbrison China: Minhang, Taicang Bahrain: Al Hidd India: Kolkata, Mumbai Headquarters Center of competence/manufacturing/maintenance

Comprehensive services, complete support perfect for plant optimization

Operational support
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Plant upgrades
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Maintenance services
Page 18

Siemens VAI provides comprehensive services throughout the entire life-cycle of your plant to improve your plants operation.

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Original manufacturer components Spare and wear parts Consulting and technical assistance Training

Modernizations Mechatronic solutions

Online and offline maintenance Repair service of original manufacturer components

Erection

Commissioning

Operational phase TIME

Lifetime extension

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Operational support
Original manufacturer components, spare and wear parts equipment for superior plant performance

Electric arc furnace panel

SIMETAL EcoStar strand guide roller

We optimize service intervals and provide our clients with the parts, components, and expertise that will support the operation of their iron and steelmaking, rolling, and processing facilities at the lowest possible cost and the highest levels of productivity. With Siemens VAI as your partner, you gain access to the expertise of experienced service specialists. We help you improve your plant and system efficiency, extend component and plant life-cycles, minimize plant downtime, and lower your spare part inventory. Overall, this adds up to a sustainable reduction of your costs.

Spare and wear parts Being able to count on having spare and wear parts available is extremely important to plant operators. Thanks to our global production sites and our global procurement network, we can ensure that the right spare parts are delivered at the right time. We realize the shortest possible delivery times, especially in emergencies. We deliver either original manufacturer components or, if these are no longer available, appropriate replacement parts. If necessary, we develop a migration strategy together with the plant operator.

Main benefits:  Siemens VAIs technological and service leadership  Cost reduction in operation and maintenance  Increase in plant availability and productivity  Proven spares quality and logistics

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Rolling mill chocks with MORGOIL bearings

Original manufacturer components Original manufacturer components are the end product of our many years of coordinated efforts and experience in engineering, design, manufacturing, operations, and maintenance. Our welldefined test procedures in-house and before installation enable us to offer plugand-play applications. The components are manufactured in Siemens VAIs own facilities.

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Operational support
Consulting, technical assistance, and training the expertise available for our customers

On-site training

Consulting services

Consulting Changing market requirements and competition compel all producers of steel products to continuously evaluate, maintain, and improve their sales position. Funds for investments are not unlimited, and priorities must be defined. Managers need to know the plant areas where investments are most urgently needed, will yield the shortest return on investment, and contribute most to a sustainable and competitive operation. The bottlenecks in processing lines must be identified and decisions made on whether upgrading or replacement of equipment will be most effective. To resolve these issues, Siemens VAI offers a full range of consulting services for the

entire steel manufacturing and rolling process across the full plant life-cycle. The consulting services include audits of the technological and economic performance of operations and maintenance (facilities evaluation, feasibility studies, production logistics analysis by simulation) and recommendations for improvements. Siemens VAIs expertise can provide valuable information for your decisionmaking about facility investments: how to exploit the installed capacity, increase the material or product quality, extend the product mix, and introduce more highly valued products if the current product mix is not achieving a competitive sales position.

Furthermore, our experts can provide information on how to improve the experience and competence of your human resources, which ultimately determines the efficiency of your operation and the maintenance of your facility. We can also calculate how the envisioned measures would influence the cost and profitability of your operation. Main benefits:  Provision of facts and figures for efficient management decisions  Identification of equipment deficiencies, bottlenecks and investment priorities  Definition of performance improvement potentials

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Equipment maintenance training

Technical assistance Siemens VAIs experienced instructors can provide technical assistance and comprehensive support in the efficient and sustainable introduction of metallurgical and production processes for either improved product quality yields or new steel grades or more effective operation and maintenance procedures for the optimized use of your installed capacities as well as for the start-up of new facilities. Our services include up-to-date guidelines product processing and manufacturing to improve the operation and maintenance of the facility, and support from experts in implementing this information.

Training The capability of your human resources to maintain and extend their expertise determines the successful operation of your steel plant. Continuously maintaining and improving this capability is a major management issue, and requires ongoing attention. Siemens VAI can support your managements efforts by providing customized training services. The services may include the design of concepts for initial, basic, and continued training, effective programs for classroom training, training using simulators, on-the-job training, and the provision of the training itself.

Main benefits: Customized and efficient upgrading of human resources for:  a more efficient and profitable use of facilities, materials, and energy  an accelerated ROI and so more availability of funds for added investments and growth strategies

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Plant upgrades
Modernizations, mechatronic solutions extending your plants functionality

Minilap welder (Processing and finishing lines)

SIMETAL Vaicon Converter Drive

Siemens VAI: Where the most modern production technology meets the increased demand for product quality. Our decades of worldwide experience in the design and engineering of metallurgical facilities provide our clients with innovative technological upgrades for their manufacturing equipment.

Modernizations As part of an ongoing service offering, modernizations are your alternative to building an entirely new plant. This type of investment keeps your plant technologically advanced while preserving its value and extending its life-cycle. By making small, cost-effective upgrades or replacements, you can bring your components in line with the latest technology. These types of modifications typically require minimal plant downtime, or none at all and your plant will remain competitive in the marketplace.

Mechatronic solutions Mechatronic systems are essential for modern plants. The intelligent interaction of mechanics, drives, automated control, and media technology optimizes process control. Other advantages include: Improvements in performance, production quality, maintenance, and efficiency as well as a reduction in system failures and downtimes. Typical solutions in iron and steel works include electrode controllers, hydraulic oscillating units, segment controllers, sizing stands, shears, and levelers.

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SIMETAL WDS Baumco (Wet dedusting system)

Main benefits:  Increase in plant availability and productivity  Cost reduction for operation and maintenance  Extended product portfolio  Extended plant life-cycle  Fulfill increasing demands of environmental, health, and safety regulations

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Maintenance services
Online and offline maintenance decades of experience for every type of plant

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Central maintenance of Siemens VAI at new steel plant of ThyssenKrupp CSA, Brazil

Siemens VAI-developed roll cladding center

For plant operators, it is important that maintenance is closely coordinated with operations and that repairs are executed quickly and reliably. That involves a maintenance partner who is embedded in the plant organization, direct contact between maintenance and operations, service performed on-site, local repairs, payment in local currency, and customer proximity. At Siemens VAI we offer our maintenance and repair services from a global network of service facilities, including general repair workshops in close proximity to customers and service centers specialized in specific repair tasks and parts.

A strong drive for continuous improvement of product quality, plant availability, and total cost of ownership can be found in Siemens VAIs win-win contract models:  Performance-based agreements  Menu pricing  Cost plus fee Online and offline maintenance As the only metallurgical plant builder with long-term experience in online and offline maintenance, we offer a wide range of services, from specialized component repair and field services to integral plant maintenance for entire steelmaking plants and rolling mills.

Our activities cover a broad spectrum, from routine unit change-outs to turnaround and repair programs to breakdown maintenance and repair to development and implementation of CMMS (computerized maintenance management systems) through condition monitoring and maintenance planning. Furthermore, we guarantee an improvement of components subject to maintenance (enhancement of function and better maintainability). All of our activities are based in a global supply chain and logistics management for material, spare parts, and repair processes.

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The worlds largest and most advanced HAGC cylinder-test stand

Main benefits:  Switching from fixed cost to variable cost for maintenance  Improved service intervals  Reduced inventory and assets  Global spares and components access

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Maintenance services
Repair service for original manufacturer components customized solutions

Refurbishment of copper-mold plates

Repair of coiler mandrels

Repair service of original manufacturer components Siemens VAIs repair service of original manufacturer components is focused on engineered core components for steel plants and rolling mills. We cover a wide variety of engineered components critical to your equipments performance, like HAGC (hydraulic automatic gauge control), chocks and bearings, MorgoilTM bearings, continuous casting oscillators, coiler mandrels, and hydraulic blocks. Our repair service is not limited to components engineered by Siemens VAI we also have extensive experience in the repair and upgrading of components designed by other plant builders.

Our scope of services includes condition monitoring, residual lifetime assessment, repair scheduling, manufacturing/ supply of spare parts, assembly, and testing, including performance testing of critical components like HAGC cylinders. In addition, we offer field services for on-site inspections, equipment auditing, and installation as well as equipment inspection and repair planning. Our diversified portfolio of repair services includes specialized repair activities like hard facing of components subject to wear. Depending upon the customers requirements, we can offer case-by-case repair services, comprehensive repair programs, and annually renewable or multi-annual service agreements.

Main benefits:  Improved reliability of critical components through in-house testing  Improved product quality, fewer product downgrades  Higher product yield due to tighter tolerances of production equipment  More uptime, higher productivity  Reduced overall maintenance costs due to longer component lifetime and longer mean time between repair  Increased equipment lifetime = lower cost for equipment replacement

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Automation solutions
Customized electrics and automation concepts to improve your competitive edge

In addition to engineering and technological expertise, Siemens VAI also provides a complete range of automation solutions ranging from process automation to sophisticated optimization packages and expert systems. Based on a long history of successful control and automation projects in the iron and steel industry, we offer both integrated and stand-alone solutions for all automation levels and types of power supply. We provide our customers with modularly designed, expandable, and upgradeable packages with integrated diagnostic tools to help them achieve continuously higher plant performance.

We offer:  Functional and detailed design specifications based on collaboration with customers  Hardware design, procurement, and supply  Automation software from concept to factory test, utilizing highly qualified and process-familiar engineers in locations worldwide  Full electric, instrumentation, and computer turnkey design, from procurement to commissioning Our automation solutions are designed to generate improvements throughout the entire value-added process by combining proven solutions for your power supply, drives, and automation systems with technology-specific solutions. Siemens VAIs electrical and automation concepts encompass the entire arena of production.

In-depth technological process-modeling expertise combined with in-house experience in software and hardware engineering ensure the fastest possible project implementation and start-up. From feasibility studies to client training, we offer solution-oriented services for all stages of your project. Siemens VAI automation: your guarantee of highperformance plant operation at the lowest cost. Main benefits:  Energy and cost savings  Maximum reliability  Highest product quality  Customer and service orientation throughout the entire life-cycle of the electrical and automation systems

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Competence writes success stories Selected references

General maintenance all over the steel mill Customer: Scope: ThyssenKrupp CSA Siderrgica do Atlantico, Brazil Siemens VAI has signed a 15-year service contract for mechanical and E&A maintenance. Siemens VAI managed to set up the maintenance facilities to be ready for service on time. Training of 600 maintenance employees was also conducted. Today on- and offline- maintenance is done for all machinery and equipment for all steel production facilities all over the metallurgical processing chain.

Substantial improvement of lifetime of bender-roller Customer: Scope: Companhia Siderrgica Nacional, Brazil Since 1999 Siemens VAI is responsible for maintenance service of the slab casters designed by various manufacturers. Due to the experience and know how of Siemens VAI the lifetime of the bender rolls could be tripled within five years. Beside maintenance Siemens VAI is also responsible for the spare parts procurement.

Modernization of conventional hot strip mill-bearings Customer: Scope: Ternium Siderar, Argentina The customer was interested in upgrading a hot strip mill, in order to produce tougher materials. The solution was to convert the mill to new MORGOIL KLX bearings, which would extend load capacity by around 25% and increase also mill stiffness. In addition, the customer benefited by the conversion to state-of-the-art bearing technology, with less number of parts and less maintenance cost. With increasing load capacity in all bearings in the mill the requirements of the customer could be fulfilled.

Slab caster maintenance services Customer: Scope: Severstal Sparrows Point, USA Siemens VAI has been responsible for offline slab caster maintenance since 1985. The contract of this first Siemens VAI caster workshop ever has been extended four times.

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Roller lifetime improvement Customer: Scope: Nanjing Iron & Steel Company, China Nanjing Iron & Steel Company awarded Siemens VAI a contract for the reconditioning of caster rolls for two continuous slab casters. The 3-years contract became effective in 2009. Meanwhile, a significant increase of lifetime of caster rolls was achieved.

Training slab caster maintenance Customer: Scope: Hyundai Steel Company, Korea Hyundai Steel Company awarded a continuous slab caster to Siemens VAI in 2006. As part of the contract Siemens VAI had to train the maintenance personnel of Hyundai Steel Company theoretically as well as practically. The training was organized in a Siemens VAI owned workshop at CSN and at production sites of CSN and Usiminas in Brazil. The know-how transfer to the maintenance people of Hyundai Steel Company ran successfully.

Reduction of operational costs and environmental solution for rolling stands Customer: Scope: Hennigsdorfer Elektrostahlwerke, Germany In 2008 Siemens VAI carried out an upgrade on existing rolling mill stands, originally not supplied by Siemens VAI. Due to strict environmental restrictions grease disposal is no more accepted. The upgrade comprises the design and supply of the modification of the existing rolling stands from grease to air/ oil mist lubrication. Reduced cost of lubricant, extended life time of bearings, pay back time less than 2 years and a minimum impact on the equipment and minimum downtime of the plant was the result.

Replacement and upgrade of VOD- cover Customer: Scope: Saarschmiede GmbH Freiformschmiede, Germany The aim of the client was to increase reliability, improve plant availability and upgrade the process measurement under vacuum. Due to a new VOD-car and cover system temperature and sample measurements under vacuum are now possible, the high quality levels during VD and VOD process can be kept. The average time for vacuumtreatment could be shortened by approx. 20%. The vacuum level could be reached without replacing the initial installed vacuum pump capacity.

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For further information, please contact: Siemens VAI Metals Technologies GmbH P.O. Box 4, Turmstr. 44 4031 Linz, Austria Phone: +43 732 6592-0 E-mail: metallurgical-services.metals@siemens.com

The information provided in this brochure contains merely general descriptions 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-M2-A2-V3-7600 Printed in Austria Dispo No.: 21661 K-No.: 28102. SPS SVAI-09-00185 WS 12101. Subject to change without prior notice

Siemens AG 2010. All rights reserved. SIMETAL and SIROLL are registered trademarks of Siemens AG

www.siemens-vai.com
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