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"NORANDAL SIX HIGH
MILL UPGRADE" Abstract: In September
2003 Industrial Automation Services (IAS) successfully completed a multiphased project for the
Norandal six high cold mill in Huntingdon, Tennessee. This project identified opportunities, and
then implemented automation and equipment solutions which cost effectively improved the productivity
of the mill. This paper describes the project scope with specific technical detail on key elements
responsible for the productivity improvements. The end goal of this project was to achieve sustainable
maximum mill design speed and throughput whilst maintaining acceptable guaranteed gauge and shape
performance.
Phase I consisted of a mill audit to identity areas of improvement. An IAS audit team consisting of
process, mechanical, control and modeling disciplines, together with Norandal personnel, conducted a
general investigation of the mill operation and produced a comprehensive report identifying areas of
potential improvement and specific recommendations to achieve them. Norandal's management reviewed
the findings and focused efforts in three principle areas. First, to improve mill speed and shape
quality by implementing a hot edge spray shape control system to reduce the tight edge conditions
prevalent in high reduction, high speed, light gauge rolling. Second, to reduce threading time,
reduce strip breaks, and improve head end shape quality by implementing a new adaptive setup model
that predicts optimal speed dependent roll gap, tension, and shape actuator setup references. Lastly,
a series of upgrades and additions to the existing software code was implemented to improve off-line
shape on a set of critical products such that a predictable and repeatable flatness was presented to
downstream processes and end customers.
Phase II of the IAS project consisted of the hardware and software implementation of the three
principal areas of interest.
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