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Ingeteam Industry Division

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Ingeteam Industry, S.A.

Ingeteam Metals Solutions, S.A.

Ingeteam, GmbH (Germany)

Ingeteam a.s. (Czech Republic)

Ingeteam, LTDA (Brazil)

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Introduction

We are passionate about creating practical solutions that deliver real business value to our customers

Ingeteam Industry Division integra-tes mechanical engineering, elec-trical and automation companies. With more than 30 years experience in the Industrial sector, especially Steelworks, it is in a position to pro-vide global (turnkey) or partial solu-tions customized to our customers’ demands and needs.

We implement new installations and modernize existing ones.

At Ingeteam Industry Division we help our customers to use electrical power effectively and to increase industrial productivity in a sustainable way.

Ingeteam Industry Division Engineers have been trained, audited and certi-fied to exacting standards, enabling them to provide fast and professional support where and when our custo-mers require it.

With branches in different countries our Engineering Solutions are fur-ther supported by experts from Inge-team Industry Division head offices in, Spain.

Product and system technical su-pport, commissioning, technical assistance services, 24/7 break-down response, maintenance spare parts management and workshop repairs, are all part of our services which are available to our custo-mers worldwide.

The different Ingeteam Industry Divi-sion training courses cover standard, certified and customized product and system training courses. These courses can be undertaken either at the offices of the different companies forming part of Ingeteam Industry Division or directly at the customer’s installations.

Turnkey engineering and moderniza-tion solutions include system design, integration, upgrade programs and revamps.

Process application and consulting includes optimization, condition mo-nitoring, trending analysis and engi-neering consultation.

Ingeteam Industry Division engi-neering services support industries, including steel and metals plants, industrial water treatments and mi-ning.

Our vast experience in the design of installations and equipment, our ca-pacity to integrate other manufactu-rers’ equipment and platforms, our proposals’ flexibility, and a permanent coordination between the mechani-cal and electric departments, enable us to achieve the optimal solution for our customers. We are well-known in the market for providing customi-zed solutions to meet the particular needs of each installation. Our inves-tments and projects in R&D+I, both

Count on us to assist you in making fast and more

successful decisions

mechanical and electric, allow us to maintain our leading technological position in the market.

Our activity is directed towards achie-ving a robust and easy to maintain product. this is why we direct much of our efforts to a continuous evalua-tion of our suppliers, and the care-ful preparation of our operation and maintenance manuals.

For us it is also important to work side by side with our customers in the fo-llow-up of the project, the supervision of manufacturing processes and the integral tests of the application and commissioning.

Portfolio of Ingeteam Industry Division Services

4 Mechanical and Electrical Engi-neering.

4 Commissioning.

4 Consulting and Optimization of Systems.

4 Engineering and modernization of existing plants.

4 After sales and system support.

4 Technical assistance and on line services.

4 Maintenance contracts.

4 Training courses.

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At Ingeteam Industry Division we focus on helping our customers to ensure results.

Ingeteam Industry Division exper-tise, technology and infrastructure are all used to create a solution our customers can profit from. Our refe-rences prove our competence.

We supply solutions for life-cycle services and support of equipment

Auxiliary Equipment for Steel Plants

We focus on ensuring results and our references prove our competence

and control systems for ladle meta-llurgy facilities (level 1 and 2), con-tinuous casters (level 1 and level 2), hot rolling mills, reheat furnaces, transportation and material han-dling, water treatments and pump stations.

Ingeteam Industry Division provi-des customers with mechanical, electrical and automation systems, software and services to run their operations productively and profi-tably. Ingeteam Industry Division continues to help create value for customers by delivering more than equipment - We deliver solutions.

Ingeteam Industry Division offers information technology solutions that address every one of the cus-tomers’ core assets, operations and processes:

Consulting Services for helping ste-el making companies find the best solutions for their assets, from a single drive system to a complete rolling mill, for both new and exis-ting plants.

Business Consulting Analysis and Solutions for value chain optimiza-tion, to allow steel plants to imple-ment real time order fulfilment for their customers.

Our solutions reduce loopholes in the establishment of supply limits

for ferrous and non-ferrous indus-tries along with the different compa-nies that are part of the Ingeteam In-dustry Division, we are able to focus on helping our customers to ensure results.

Ingeteam Industry Division is a su-pplier of industrial engineering so-lutions, mechanical and electrical equipment and control systems to optimize the melting, shaping and

finishing of ferrous and non-ferrous metals.

Ingeteam Industry Division supplies engineering, design, project ma-nagement, programming, supply, mechanical /electrical installation, commissioning, start up, training and contracting on a turnkey basis of main and auxiliary electric drives and automation systems for steel-making. We also handle automation

The points detailed above are used to assist steel making companies to achieve the following:

4 Increase productivity.

4 Increase material quality.

4 Reduce energy consumption and costs.

4 Achieve total integration between steel plant and the rest of the plants.

4 Achieve supply coordination.

4 Close the gap between the plant, customers and suppliers.

Ingeteam Industry Division continues to create value

for customers by delivering more than equipment.

We deliver solutions

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Always directed at optimizing the in-vestment we offer the highest stan-dards of safety, quality and service for all projects.

Complete Solutions

4 Ferroalloy dosage and transporta-tion systems.

4 Water treatment and refrigeration plants.

4 Pig iron and steel transportation systems.

4 Scrap yards, fusion and steelmaking furnaces.

4 Fume extraction and filtration.

4 De-dusting systems.

Mechanical equipment

4 Torpedo ladles.

4 Ladle heaters/dryers.

4 Tundish heaters/dryers.

4 Converter heaters/dryers.

4 Special vehicles. 4 Ladle, scrap bucket & tundish cars.

Over the years, the philosophy of the companies that form part of Ingeteam Industry Division has always been fo-cused on adding customer value. Im-proved productivity and quality, stability and simplicity in operation and flexibi-lity based on customer demands are key performance factors linked with our systems and services, all aimed at improving the profitability of the metals producing process.

The companies that form part of Inge-team Industry Division are long-term suppliers of ferrous and non-ferrous ste-el plant world-wide with a unique range of products. Virtually any need ranging from mechanical electrical equipment, market furnace transformers and rec-tifiers, electrode regulation systems, to automation solutions, can be handled through our engineering services. Our global team of engineers combines ex-perience from all facets of metal produ-cing. Our engineers always work closely with our customers in order to improve the performance of their steel plants with high-level management, process and application consulting services.

We implement projects integrating equipment and specific systems supplied by third parties as well as ser-vices (civil works, installations, etc.) ca-rried out by local companies. Ingeteam Industry Division offers financing for-mulas for its projects to meet our custo-mers requirements.

Our business model, as well as our competitive strategy, is based on thinking as a leader when providing and delivering industrial solutions to our customers

Auxiliary Equipment for Steel Plants

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Ingeteam Industry Division has a vast experience in the fields of mechani-cal, electrical, automation and pro-cess control as regards cold rolling mills. We pursue a surprisingly sim-ple strategy: We listen to our custo-mers intently because that’s the best way for Ingeteam Industry Division to select exactly what their needs are.

We offer a broad range of solutions for cold rolling mills, from individua-lized special functions to compre-hensive turnkey solutions.

In close cooperation with our cus-tomers, Ingeteam Industry Division develops production system confi-gurations that accommodate each of the required operational details and perfectly match the customer’s current requirements. In that way our customers have a single, dedi-cated point of contact for everything required. Personalized streamlined services to find the right solution for every challenge and every project.

Ingeteam Industry Division has equipped cold rolling mills with state-of-the-art mechanical/elec-trical and control system solutions worldwide. In close cooperation with our customer’s project engineers, Ingeteam Industry Division carries out plant modernizations, mana-ges new construction projects and stands ready to support our custo-mers around the world.

From consulting, planning, deliveries and installations, through optimi-zation and maintenance: Ingeteam Industry Division accompanies each phase of the project, throughout the entire lifespan of the plant. Be it reliable mensuration and control systems, advanced drive techno-logy, power management, efficient storing logistics or advanced control component solutions. With Ingeteam Industry Division our customers can get them all from a single source and in that way we both achieve the best results from our partnership:

Customer success

Ingeteam Industry Division designs and supplies all types of equipment and installations for reversible steel strip mills. The mechanical as well as drive and control electrical equi-pment is manufactured synergisti-cally using the extensive experience offered by the Ingeteam group. Thus we are able to deliver a highly reliable project at an optimised cost.

From its creation the companies that form part of Ingeteam Industry Divi-sion have developed complete equipment for cold rolling of carbon steel, stainless steel and non ferrous me-tals from 200.000 t/y to 600.000 t/y.

Ingeteam Industry Division also ca-rries out upgrading of existing equip-ment to achieve capacity increases and to improve the resultant pro-duct quality.

Solutions for Cold Rolling Mills

We listen to our customers so we can understand their needs, because our goal is our customer´s success

The kind of rolling mills and equip-ment developed are basically compri-sed of:

4 Rolling mills.

4 Skin Pass mills for hot rolled steel.

4 Temper mills for galvanized and annealed strip.

4 Entry and exit equipment for rolling mills.

4 Complete automation equi-pment for new and existing mills.

4 Technological packages for new and existing mills, AFC, AGC and AEC.

4 The main configurations of the rolling mills:

4 2 Hi.

4 4 Hi single and double stand.

4 6 Hi single and double stand.

For the benefit of our customers, Ingeteam Industry Division is cons-tantly working to develop pioneering concepts and future-oriented tech-nologies based on proven solutions and techniques.

Thanks to our comprehensive tech-nological know-how, we are ready and prepared to confront the ever growing requirements of the global market.

Ingeteam Industry Division ingenious plant concepts and designs guarantee high productivity and availability plus low maintenance requirements

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Processing Lines

Ingeteam Industry Division strip pro-cessing lines cover almost the enti-re spectrum of refining, processing and quality assurance. The produc-tion ranges of these lines vary widely depending on the requirements of our customers, achieving process speeds of up to 250 m/min for yearly productions up to 850.000 t/y.

That is one of many ways we ensu-re that our customers produce high quality strip with special properties.The end result is a refined strip that meets customer demands, provi-ding them with more added value. Due to the advanced automation of our plants and our resource-saving processes, Ingeteam Industry Divi-sion offers, above all, a high level of cost-effectiveness.Equally impressive is the versatility of our solutions.Ingeteam Industry Division has many references for Processing Lines ins-tallations in Europe and throughout the world, providing our customers the following different types of pro-cessing lines:

4 Complete Solutions

4 Mechanical Equipment

4 Electrical and Automation

Our solutions reduce loopholes in the establishmentof supply limits, as well as meet our customers’coordination requirements in subsequent phasesof engineering, manufacture, installation and commissioning

Complete Solutions

4 Pickling Lines (push-pull and continuous).

4 Galvanizing Lines (45,000 T/y up to 850,000 T/y).

4 Electro-galvanizing Lines. (40,000 T/y up to 400,000 T/y).

4 Continuous Annealing Lines.

4 Coil Coating Lines.

4 Cleaning and Degreasing Lines.

4 Tension Levelling Lines.

4 Recoiling and inspection lines.

4 Cut to length and slitting.

4 Coil packaging lines.

Mechanical Equipment

4 Coilers and un-coilers.

4 Coil cars.

4 Degreasing and Chromating Units.

4 On line Skin-Pass mill.

4 On line tension levelers.

4 Vertical and horizontal strip accumulators.

4 Tension bridles.

4 Side trimmers.

4 Scrap choppers / ballers.

Ingeteam Industry Division is in a position to provide the prerequisites for achieving the desired performance in terms of end product quality and tolerances as well as of plant output and availability. Ingeteam Industry Division supplies complete electrical solutions from power distribution, drives, automation system, technological control functions, instrumentation and sensors up to auxiliary equipment.Ingeteam Industry Division process control systems offer integrated solutions for a high degree of automation and an increase of yield, operator-friendly visualization systems and diagnostic systems which ensure easy handling and mo-nitoring and facilitate trouble shooting.Ingeteam Industry also has the know-how for the planning, erecting and commissioning of processing lines.When planning these installations, the following boundary conditions are always taken into consideration:

4 Optimization of capital and running costs.

4 Keeping erection and commissioning times down to a minimum.

4 High availability of all equipment.

4 Maintenance and technical assistance.

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Continuous Galvanizing Lines

Hot-dip galvanizing is one of the most important procedures for corrosion-proofing steel. Once the steel strip has been coated in the over 450°C zinc or zinc-aluminium bath, it is not only highly corrosion-proof, but also features exactly defined mechanical properties such as formability. At Ingeteam Industry Division we su-pply process-optimized hot-dip gal-vanizing lines that make the grade with high speeds and zinc coatings to ultra-close thickness tolerances. Included are air knives that auto-matically control and set the desired thickness of the zinc coating.

Depending on the surface quali-ty, air or nitrogen is used to remo-ve the liquid zinc. It is essential for the high precision of this process that the strip runs smoothly in the area of the air knives. Next in line is an exactly defined cooling process in the downstream air and water cooling section. At the end of the process, galvanized steel strip that meets the high quality demands of international markets leaves the production line.

4 Ingeteam Industry Division can supply hot-dip galvanizing lines designed to deposit a wide ran-ge of surface coatings onto steel strip.

Hot Dip Galvanizing Lines for both hot and cold rolled strip guarantee first-class product quality for construction, appliance and automotive applications

4 Coatings are specifically designed for subsequent application of paint and/or laminates.

4 Lines are available in capacities to handle strip in thicknesses from 0.15 mm up to 6.5 mm and in widths up to 1,850 mm.

4 Ingeteam Industry Division hot-dip lines offer a choice of horizontal or vertical non-oxidizing type furnaces. The furnaces can be sized just to provide a clean surface for optimum adhesion of the zinc coating, or, they can be designed to also anneal strip of various grades from full hard to deep drawing quality.

Technological Highlights

4 Optimized line concepts for all galvanizing products and all market segments

• CGL`s for highest qualities of cold rolled strip, for automotive body parts.

• CGL`s for high qualities of cold rolled strip and/or pickled hot rolled strip, for appliances and building industry.

• CGL`s for standard qualities of hot rolled un-pickled strip, for special applica-tions and building industry.

4 Technological competence for the overall process.

4 High efficient strip cleaning concept due to combination of spray and dip cells, electrolytic cleaning, brushing machines and cascade rinsing for highest surfa-ce qualities.

4 Chem. post treatment: chromate passivation, phosphate & anti-fingerprint with spray / roll coater for efficient surface protection.

4 Multifunctional skin pass and leveling technology for all surface qualities and flatness demands.

4 Turret head side trimmer with automatic scrap baler, scrap press or scrap chopper.

Skin passing and tension leveling are essential for the production of exposed auto-motive strip and other high-quality applications. Using an advanced control system, all skin passing, leveling and strip elongation requirements, specified mechanical properties and surface-roughness demands are met. Ingeteam Industry Division also offers solutions for wet skin passing mills, featuring flexible application of fluid onto the work and back-up rolls.

Main Benefits

4 Highest strip yields with exce-llent surface quality.

4 Extra deep drawing qualities remain unaffected due to ideal rolling conditions.

4 Fulfilment of strict strip flat-ness and roughness specifi-cations.

4 Low expenditures for work-roll maintenance.

4 Rapid skin pass adjustments.

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Pickling Lines

as well as a long service life complete the picture. But above all - they offer you the best possible scale removal without over-pickling your steel strip.

Effective turbulence. What makes the difference here is the interaction of our turbulence technology and our advanced process design. Scale breakers perform the purely mechani-cal preliminary work. Then, complete scale removal takes place in the acid bath of the turbulence pickling line. Our patented immersion cover opti-mally seals off the pickling channel to minimize acid vapour formation. The pickling tanks made of plastic or co-rrosion-resistant steel have a special bottom profile that largely prevents sludge deposits.

Continuous Pickling Lines

Continuous pickling line solutions supplied by Ingeteam Industry Division feature modular design, high pickling efficiency, economi-cal operation and the application of advanced technologies such as turbulence pickling. Selection and integration of all process equipment and components is accomplished on the basis of our own in-house operational know-how. This ensures that the demands of the producer as well as the environment will be met.

Push-Pull Pickling Lines

Push-pull pickling lines offer signi-ficant advantages with respect to investment costs and operational

Wastage in down-stream rolling and coating processes is reduced signifi-cantly if the metal surface is comple-tely free from surface impurities such as scale, oil and grease. The cleaner the material is at the beginning of the cold rolling process, the more relia-ble and cost-effective the production of the required finished quality. Fast, effective pickling is the prerequisite for achieving this goal. This, in turn, requires a stable process, exact strip tracking and accurate strip and pic-kling control.

Ingeteam Industry Division supplies the full range of technological solu-tions for the de-scaling of both strip and wire-rod. Pickling lines Solu-tions supplied by Ingeteam Industry Division are characterized by high pickling rates, low-cost pickling ope-rations, flexible production, a wide range of product sizes, qualities and coil weights, reliable plant operation and low maintenance requirements, in addition to the fulfilment of the highest standards for environmental safety.

Pickling Technology for strip includes Push-Pull Pickling and Continuous li-nes, either stand alone or coupled to a tandem cold mill. Our comprehensive modernization packages include sca-le breakers as well as full acid mana-gement in the process section.

Ingeteam Industry Division´s Conti-nuous Pickling Lines give high tur-

bulence pickling and smoothest handling of strip inside the process section at highest throughput ra-tes. Our Pickling lines feature high pickling efficiency, a minimum of ope-rating costs and a maximum of envi-ronmental compatibility in making first-class products.

Mechanical equipment, process sec-tion, electrical equipment and auto-mation including mathematical model all from a single source.

Good reasons for the best technology:

4 High turbulence generation by the kinetic energy of the strip.

4 Automatic turbulence control a- ccording to strip speed.

4 Hydrodynamic support of the strip in the Ingeteam´s module to avoid bottom contact of strip.

4 Mathematical model for plant pa-rameters to guarantee optimum economic plant operation.

4 Both polypropylene and steel ru-bber-lined pickling tank design available.

Scale-free quality. To produce per-fect steel strip with clean, scale-free surfaces, pickling is essential. Our pickling lines with turbulence techno-logy come with the added advantage of low energy and acid consumption. Low maintenance and operating costs

flexibility, particularly for frequently changing strip dimensions and steel grades. Ingeteam Industry Division offers a uniquely designed V-shaped flat pickling tank, which increases the strip stiffness during its passa-ge through the tank. Strip buckling and flattering is avoided and reliable threading is assured. In order to pre-vent strip staining in the rinsing sec-tion. The energy-efficient design of the fume-extraction and sealing system significantly reduces energy costs and acid losses.

The focus of the automation solutions is to assure an

optimum metallurgical and process-technological

performance with respect to steel quality and

operational costs

Ingeteam Industry’s comprehensive modernization packages include scale breakers as well as full acid management in the process section

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Coating Lines

Ingeteam Industry Division coating lines incorporate the most advan-ced techniques of application and drying of all types of paints and var-nishes. These are mainly directed at the civil construction and household appliance markets (brown line and white line).These lines are custo-mized to meet the requirements of each individual client, ranging from the most simple to the most sophisti-cated application control systems. In addition to imparting an aesthetically pleasing and decorative appearance to the strip, organic coatings must also have good forming properties and improve corrosion resistance, especially for outside applications. We provide standardized types of li-nes to meet the different production capacities, in compliance with each clients specifications.

The integration of paint sections in new or existing galvanizing lines may, in certain situations, entail the optimization of operating costs. The complete automation of all processes integrated in these lines with state-of-the-art open control sys-tems, provided by our company, enable us to be positioned as a lead supplier for this type of market. Always directed at optimizing the investment, our projects offer the highest standards of safety, quality and service. Ingeteam Industry Divi-sion organic coating lines stand for reliable operation, high throughput

Basic automation plays a key role for smooth plant operations. Requirements in this area include standardized platforms, open communications, easy expansion and reliable diagnostics

We provide standardized types of lines to meet the different

production capacities, in compliance with each clients

specifications

rates and top product quality. The highest degree of flexibility is assured for different steel strip grades, various coating compositions and colours, as well as strip dimensions for a wide range of product applications.

Strip protection. Ingeteam Industry Division precision coating lines apply liquid insulation substances, chemicals or varnishes to steel strip. The resulting pre-treated strip offers the further processing industry perfect properties and sur-faces, removing the need for extra, expensive process stages. That’s why coated strip is highly attractive on the market.Organic coating lines are capable of imparting the following coating:

4 Prime and second organic layers with solution application as Polyesters, Epoxy, Polyurethane, PVDF, Acrylic, Plas-tisol.

4 Coating for topside and backside.

Key features include:

4 Mashed lap and laser welders.

4 Strip cleaning sections (for treating cold ro-lled as well as metal coated strip).

4 Chemical roll coater.

4 Catenaries or flotation oven types.

4 Prime and finish roll coaters with latest state of the technology including two or three rolls with hydraulic roll position control.

4 Enclosed coater room with environment con-trol.

4 Strip surface inspection.

4 Post-painting process options include lami-nation, embossing and PVC film applica-tion.

4 Possible integration as a process section in our galvanising lines.

4 Modern drive and automation solutions.

Main benefits:

4 Optimized pre-treatment for ideal coating adhesion and corro-sion resistance.

4 Computer-controlled line settings based on coating program and strip characteristics.

4 Reliable strip threading and strip tracking through weld quality and drive controls.

4 Application of coater control for uniform coating thickness with low lacquer consumption.

4 Special furnace design for fast and homogeneous heat transfer to the strip.

4 Fully automated furnace pre-settings and program change for increased yield and throughput capacity.

4 Integrated quality control system.

4 Integrated environmental solutions which reduce energy, chemical and process water requirements.

4 Highly compact plant layout and design.

4 Safety issues for line operation and maintenance.

4 Low operation and environmental expenditures.

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Machines for processing lines

Steel strip must always feature the right combination of strength and formability. Frequently, the chemical com-position of the steel strip is modified by selecting the fur-nace atmosphere accordingly. Take, for instance, annea-ling lines for producing electric strip. Ingeteam Industry Division annealing lines ensure the correct properties. Depending on the temperature-time model, annealing alters the microstructure inside the strip and/or the strip surfaces. The upstream strip cleaning processes and the exactly coordinated processes in our annealing furnaces, as well as in the cooling sections, produce steel strip that meets precisely defined requirements.

Tailor-made annealing lines.

Low energy consumption, high production rates and gentle strip treatment, along with top quality, are the main features of our annealing lines. Based on your ma-terial and production range, we supply the right solution for you:

4 Continuous annealing lines for carbon steel and tin plate strip.

4 Annealing and pickling lines for stainless steel and electric strip.

4 Bright annealing lines for stainless steel.

4 Annealing and decarburization lines for electric strip.

Electrolytic de-greasing lines

Ingeteam Industry Division electrolytic de-greasing lines are ideal for removing oil and iron residues from steel strip. The strip is immersed in a hot alkaline solution, where the surface is treated by transporting the strip through direct-current electrodes in a so-called inner conductor process. Electrolytic de-greasing works with a circulation system for the alkaline solution.

As a rule, our electrolytic de-greasing lines are combined with pre-cleaning systems. Our Customers options here

include spray cleaning with brushes, brush rinsing and cascade rinsing. These are supplemented with dryers and ventilation systems. Treated in this way, the strip meets even the highest surface demands for all types of further refining.

Tension levellers.

Ingeteam Industry Division tension levellers are available for hot and cold strip. Either way, they achieve surface flatness that meets extremely exacting demands. The flying changeover of the bending cassettes results in a high yield. And that’s not all: our customers also benefit from energy-saving operation and precise tension con-trol.

Trimming shear.

This innovative machine design enables our customers to change the knife head and scrap chopper in just 60 seconds - without switching off or decelerating the plant. And there’s no need for any adjustments after changing the knives. It’s obvious that this substantial reduction in stoppages results in significant cost advantages. Ne-edless to say, the Ingeteam trimming shear provides ex-cellent and reliable cutting quality whether used for thin or thick strip.

Double cross-cutting shear.

The double cross-cutting shear features a free-of-play cutting system with swivel joints. The machine is robust and easy to maintain, and what’s more its special design means it works quickly yet at low cost. Large openings facilitate strip feeding and the integrated pinch roll auto-matically ejects scrap consisting of short strip ends.

Stitching machines.

To run strip processing lines in a continuous process, one must feed them with practically endless strip. That’s where Ingeteam´s stitchers are used. Their special tech-nique ensures flat yet secure stitched joins - at record speed.

Our customers benefit because all the elements - energy supply and distribution, drive technology, instrumentation and automation, including production planning - come from a single source Our control system can automatically adjust the strip

to ensure constant flatness

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of process equipment & chemicals, aftermarket service, and ongoing technical support. Our technologies can be applied in process segment requiring robust metal cleaning processes.

Ingeteam Industry Division is committed to leveraging core technologies for new and enhanced applications and processes. Ongoing activities include:

4 Process R & D - chemical supply.

4 Application development - engineering & design.

4 Field service - ongoing technical support.

4 Process equipment.

Chemical Treatment

Ingeteam Industry Division offers a broad range of processes for descaling and cleaning metals. Whether the material is strip, sheet, bar, wire, plate, or fabrications, our process equipment can be designed to accommodate bath or continuous production requirements.

Ingeteam Industry Division know-how and experience can help you produce superior metal products with our process-based technology approach: equipment, chemistry, and ongoing support.

Ingeteam Industry Division benefits from having experience in a wide variety of applications in the metals industries. By combining unique chemistries with purpose-specific equipment, Ingeteam Industry Divi-sion can provide our customers with optimized processes and solutions for their plant.

Ingeteam Industry Division is well established and provides surface cleaning and treatment technologies for components and materials. Dri-ven by its markets, Ingeteam Indus-try Division makes problem solving its first priority. Ingeteam Industry Division is a single-source supplier

Ingeteam Industry Division is committed to leveraging core technologies for new and enhanced applications and processes

Driven by its markets, Ingeteam Industry Division makes problem solving its

first priority

Ingeteam Industry Division can provide customers with robust, industry-proven processes that solve their most difficult metal cleaning problems. Single-source responsibility for all process aspects from initial proof of concept to field commi-ssioning helps assure consistent, repro-ducible results.

From small, unitized process systems to large, fully automated process lines, Ingeteam Industry Division can provide you with the appropriate process solution to your cleaning problems.

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Modernization of Existing Installations

Upgrading of existing systems can often represent a real alternative to making long-term investments in expensive new equipment. In many cases, improvements in product quality (strip thickness, flatness) and productivity will open new mar-kets or market niches for our cus-tomers in which quantity is not the primary consideration.

Over the past few years, Ingeteam Industry Division has revamped many rolling mills and processing lines of almost any age and from all major manufacturers, by providing tailor-made solutions.

The various projects have involved a wide range of different tasks, from replacing all electrical equipment to partial upgrading measures, such as installation of new converters to drive control systems.

Thanks to the wide variety of inter-faces available, Ingeteam Industry Division systems can be integrated into plants from any manufacturer. Product quality in term of strip thic-kness and flatness can be dramati-cally improved by replacing existing technological control equipment.

As part of the comprehensive ran-ge of services offered by Ingeteam Industry Division, we will also pre-pare a study covering the entire plant, which is an essential aid for the client in his decision-making process.

The upgrading of process lines re-quires specific solutions, capable of improving the installation’s produc-tivity or the quality of the products obtained. This is one of the most important activities of Ingeteam In-dustry Division.

The solutions presented to custo-mers are aimed at optimizing their investment return. These may invol-ve mechanical, electrical and con-trol revamping measures for each specific application.

Depending on the specific needs for each situation, Ingeteam Industry Divi-sion can supply individual equipment to be installed into existing installations in order to solve prior design problems or to simply improve their performan-ce, such as:

4 Trimming sections, including automatically adjustable shears and equip-ment to evacuate steel scrap.

4 Chromating roller sections ideal for galvanised lines.

4 Uncoiling and coiling sections in process lines and rolling mills.

4 Strip guiding solutions.

4 Remotoring of existing equipment.

Based on a comprehensive engi-neering study of the rolling mill or processing line to be upgraded, this study allows the effects of possible modernization measures (installa-tion of new technological control systems, drives, etc.) to be predic-ted in deep detail.

In modernization projects the time needed to carry out the necessary upgrading measures, i.e. the down-time involved, is just as important as the cost of the upgrading activities themselves.

For this reason, together with our customers, we work out the imple-mentation strategy optimally suited to each project.

Typical targets for a modernization:

More flexibility, increased availabi-lity of rolling power, enabling new products.

4 Improved tolerances.

4 Higher thickness accuracy.

4 Reduced length of head/tail out of tolerance.

4 Increased availability.

4 Better availability of components.

4 Improve features for diagnosis.

4 Minimized time.

4 Short time to come back to 100% production.

Upgrading of process lines that require specificsolutions, capable of improving the installations’productivity or the quality of the products obtained,is one of our strongest activities

The experience and know-how of our engineers over the last 30 years in the

international steel industry has been applied in the development of products

that exceed each of our customers’ expectations and specific needs.

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Other Plants Industrial Water Treatment Plants

Ingeteam Industry Division’s main objective, from bench-top high purity lab watersystems to industrial water reuses, is tohelp industrial users find the mostsuitable techniques for the application

Mining sector, paper and pulp, cement and sugar factories

Streamlining in, sub-processes out. At Ingeteam Industry Division we never lose sight of this fact when optimizing all areas of our customer’s infrastructure, from raw material, intermediate and finished product storage, to transport, administration facilities and communications systems. Our priority is to ensure that your core process is always supplied and supported effectively and reliably, and all resources receive maximum leverage to enhance proce-sses.

Numerous factors, such as increasing environmental concerns, the need to optimize energy consumption, and exacting demands on the quality of the end product, ne-cessitate an increasing level of automation in the mining sector, paper and pulp, cement and sugar factories.

Ingeteam Industry Division solutions encompass appli-cation standards for coordinated drives and automation control technology, as well as quality control and energy

management. Profitable solutions must cover all areas, from the individual production island to the entire factory or mine. Ingeteam Industry Division provides automation solutions that features own and market process control systems, field communications systems, standard BUS devices, and numerous add-ons for boosting performan-ce and transparency.

Our comprehensive solutions offer a high level of plant availability and transparency. Automated mining systems, paper, cement and sugar manufacturing required data to be exchanged with different systems at different levels, whether top down from the production control level to the field level, or bottom up to the Internet via office commu-nications systems.

Not only is the acquired data used to optimize the product to be manufactured, but it is also increasingly being inte-grated in higher-level management systems.

Across the entire water cycle, from drinking water, industrial water, was-tewater and water transport, Ingeteam Industry Division has the answer for water treatment, plant automation, electrical systems and building techno-logy, as well as the requisite services from design, planning, commissioning and maintenance.Water and wastewater treatment are critical to every industry. Each indus-try has its own set of requirements which determine treatment needs, from process water to wastewater. Ingeteam Industry Division is ready to help you meet these requirements.Through high-purity water technology and related services, Ingeteam Indus-try Division helps industry and manufacturers meet specific water quality requirements to ensure consistent processes and production. Ingeteam In-dustry Division also helps industry meet ever increasing industrial wastewater regulations, while improving efficiency and reducing waste disposal costs.For certain processing lines (continuous or batch mode) where high quantities of fluids are used, Ingeteam Industry Division provides effluents treatment plants:

4 ROASTER type acid Treatment and regeneration plants for flows from 2000 l/h onwards.

4 Batch systems for acid baths.

4 Industrial residual water treatment plants.

Ingeteam Industry Division water treatment process includes both organic and inorganic chemicals formulated to meet the individual specifications of customers in the industrial sector:

4 Physical pre-treatment of water: settling, filtration, etc.

4 Physicochemical pre-treatment of water: reverse osmosis, resins, etc.

4 Treatment of energy carrying fluids: cooling towers, boilers, etc.

4 Drinking water production.

4 Process water production.

4 Effluent and sludge treatment, etc.

Ingeteam Industry Division is your ideal partner for finding a solution to your industrial water treatment problems.

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An optimized process control of coke-making operations is a deci-sive factor for a stable and disturbance free coking process and for producing coke of uniform and excellent quality.

These objectives are met while taking particular care to minimize energy costs as well as assuring a high level of productivity, a maxi-mum battery service life and minimized environmental emissions.

In the process of converting coal into coke using the by-product coke oven, the volatile matter in the coal is vaporized and driven off. This volatile matter leaves the coke oven chambers as hot, raw coke oven gas. After leaving the coke oven chambers, the raw coke oven gas is cooled, which results in a liquid condensate stream and a gas stream.

The functions of the by-product plant are to take these two streams from the coke ovens, to process them to recover by-product coal chemicals and to condition the gas so that it can be used as a fuel gas.

Ingeteam Industry Division undertakes complete consultancy and turnkey supply of the following:

4 Integrated coal preparation, beneficiation, handling and storage plants.

4 Coke oven batteries and machines.

4 Coke dry cooling plants.

4 Coke sorting and handling plants.

4 Charging emission control system.

4 Hot and cold repair of ovens to prolong the life of coke oven bat-teries and restore production.

4 Expert services for health check and upkeep of coke oven bat-teries.

4 Heat control and Post commissioning Services.

Coke making technologies

Technology Span

4 Coal beneficiation & coal preparation.

4 Coal carbonization through by-products recovery ovens.

4 Gas processing & coal chemicals reco-very plants.

4 Coke dry cooling plant.

4 Other chemicals, petrochemicals based on process licensor’s know-how.

4 Range of Services Offer Market Stu-dies.

4 Technology Selection, Feasibility Re-ports.

4 Basic Engineering.

4 Consultancy and Detailed Engineering.

4 Procurement Services.

4 Inspection Services.

4 Project Management.

4 Supervision of Construction & Installa-tion.

4 Heating up & Commissioning.

4 Health Study, Revamping/Repair.

4 Project Execution on Turnkey Basis.

Coke-making process

Dynamic scheduling of coke-oven machine operations and optimized heating control of the coke-oven battery are the key issues for producing coke with excellent quality

The main emphasis of a modern coke by-product plant is to treat the coke oven gas sufficiently so that it can be used as a clean, environmentally friendly fuel

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An important part of advanced facili-ties for the transfer of bulk materials are storage and transport systems that optimize throughput times. Forward-looking, future-oriented solutions are characterized by the smooth integration of these systems into an automation hierarchy and a simple, inexpensive operation. Un-relenting cost pressures are forcing the owners/operators of bulk han-dling facilities to identify and exploit rationalization potential. Significant savings can be achieved through unmanned operation of stackers, re-claimers, or combined machines.

The current market for industrial systems is characterized by short innovation cycles, massive ratio-nalization pressures, and growing complexity of equipment. Distribu-ted systems and the great automa-tion depth required make special demands on communication and automation systems attempting to maintain clear, easy-to-follow struc-tures while guaranteeing maximum operation safety.

What is more, growing requirements placed on the interaction between material storage and handling sys-tems can only be met with logistics concepts that ensure both an effort-less exchange between information and material flows and convenient handling functions in later opera-tion.

Ingeteam Industry integrates auto-mation solutions for bulk material transport and storage:

4 Coal handling plant

4 Bucket Wheel Excavator

4 Conveyors

Material Handling Systems

We integrate material handling systems, automation system technologies, mechanical and electrical equipment to meet customers’ needs

Turnkey supply of electric and automation equipment, level 1 and 2. The supply includes:

4 Medium voltage electric substation.

4 Low voltage electric distribution equipment.

4 Electrical equipment for motor drives.

4 Motor control centre at fixed speed and variable speed in both d.c. and a.c.

4 Large-size drives in low and medium voltage.

4 Synchronisation and regulation of motors in drying and coiling process lines.

4 Basic Level 1 Automation, comprising control PLCs systems and opera-tion/display HMI in local or general network topologies.

4 Level 2 Process Automation, with advanced product follow-up control and quality evaluation.

4 Instrumentation.

Services:

4 Design and detailed engineering.

4 Planning, scheduling and monitoring.

4 Project management.

4 Supervision.

4 Start up services and commissioning.

4 Technical training.

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We are able to provide engineering services spanning the entire life cycle of the automation and control systems

Ingeteam Industry Division offers a complete range of electrical equipment and automation servi-ces related to process control and monitoring systems. These services are driven by modern trends in in-dustrial automation and by simple and effective concepts of totally integrated automation, integrating Ingeteam’s own product or third party platforms.

Ingeteam Industry Division is able to provide engineering services which span the entire life cycle of our cus-tomers automation and control in-vestment. Our engineers make up a team which can provide consultan-cy, project delivery and site services across a wide range of industrial installations. They are expert in the application and maintenance of our own product or third parties plat-forms. Ingeteam Industry Division projects department can deliver a solution which will ensure that our customer’s production systems are tightly integrated with their factory process computer systems, ensuring optimal productivity and efficiency.

The projects can be implemented both in Spain and throughout the world. All of Ingeteam Industry Di-vision project engineers speak En-glish fluently and have experience in international projects.

The most common services provided are:

4 Project estimation and management.

4 System design and documentation.

4 Software localization.

4 PLC programming.

4 SCADA-system programming.

4 Equipment assembly and installation.

4 System commissioning and startup.

4 Software modifications to PLC, HMI, SCADA.

4 Consultancy and technical support.

4 Training of personnel on site or at our different training centres.

4 System maintenance and troubleshooting.

Ingeteam Industry Division projects department has been offering con-trol systems equipment and advan-ced engineering solutions for over 30 years. Ingeteam Industry Division success has been founded on deli-vering our customers cost-effective, conceptually sound and innovative automation and control equipment.

Being an expert in systems integra-tion, Ingeteam Industry Division pro-ject department offers a “partner” approach to developing a solution. Highly qualified project engineers review all requests and make sure that the final specifications are con-sistent and that delivered products

will meet or exceed customer’s re-quirements.

Ingeteam Industry Division projects department provides complete au-tomation and control solutions from system concept to commissioning and onsite support. Ingeteam Indus-try Division maintenance and servi-ce department is able to provide the engineering support services which allow customers to maximize return on their control system investment.

Once the automation system is ins-talled, we are then able to provide a tailored service contract so that the customer can focus on managing

Solutions for Automation and Drives

his business, not his automation sys-tems. As the business environment changes, the automation and infor-mation systems must accommodate and take advantage of change. Inge-team Industry Division consultancy or embedded engineering services can ensure that your automation systems continue to give you the competitive edge.

In the last decade, companies be-longing to Ingeteam Industry Division have successfully completed a signi-ficant amount of projects around the world. Our expertise encompasses process and machine control, data acquisition and information mana-gement, and material handling con-trol systems.

Foreign suppliers of production li-nes may be particularly interested in planned maintenance programs that include testing and survey of electrical installations, refurbish-ment of hardware in situ and off site, power factor survey instrumentation, checkup and calibration, inspection of PLC and PC hardware, system performance analysis and process optimization, update of firmware and modification of application software.

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The right drive – with the right features – in the right place.

From a single motor to a complete drive system – in every industrial process, drives must meet the highest expectations with regard to power, torque, dyna-mic performance, availability, communications and diagnostics capabilities.

However, the top priority for our engineers is the cost-effectiveness of our custo-mers systems tailored to their specific needs in consulting, planning and com-missioning as well as in the processing of every inquiry. Our customers can also count on us whenever special technical competence is required.

What are the benefits our customers achieve from obtaining technology and ex-perience from a single source?

Ingeteam Industry Division application experts will recommend the correct drive system to fit as many applications as required by our customers.

Perfect integration – also in existing plants – is no problem for us. Ingeteam Industry Division handles the configuration – tailored to the required applica-tion, made to fit and last.

Through the combination of complete technology and extensive engineering know-how, Ingeteam Industry Division drive experts can solve even the most difficult drive task that may arise in the different areas of application.

Ingeteam has put a great deal of effort in R&D+I to offer technologically advanced solutions that suit the demands of automation and regulation processes for the industrial sectors

We integrate our own state-of-the art drive

technology or equivalent market products

Titular que corresponda

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The modules currently available are:

4 Installation Management Module.

4 Acquisition Module.

4 Historical Data Storage Module.

4 Alarms and Events Processing Module.

4 Operating Panels Editing Module.

4 Operating Panels Display Module.

4 Production Tables Module.

4 Report Generation Module.

4 Alarms Notification Module.

4 WEB Access Module.

Ingeteam Industry Division proposes solutions that meet the exact needs of our customers, by making use of the equipment and systems developed and manufactured within the Grupo Ingeteam or by other manufacturers.

Ingeteam Industry Division Engineers are vastly experienced in the fields of automation, process control and industrial information technology, In-geteam Industry Division pursues a surprisingly simple strategy: We listen to our customers intently, that is the best way for us to select exactly what they need from our broad range of solutions for steel plants, hot rolling mills, cold rolling mills and processing lines from individualized special functions through comprehensive turnkey solutions.

Its open architecture and high standardized level, with the exhaustive application of the OPC model (OLE for Process Control), enable it to incor-porate and support other manufacturers’ software components. Thanks to this factor, the integration of process information into other business spheres, like engineering, maintenance, etc., is easily carried out.

Ingeteam Industry Division offers automation and in-house

manufactured state-of-the-art SCADA System solutions or equivalent market products


Electrical and Automation

Ingeteam Industry Division has been designing systems and applying solutions for automation and control directed at the industrial sector, mainly in the steel making process. These solutions are directed towards reducing maintenance and operating costs and subsequently improving manufacturing outputs in order to obtain a better quality product. The following electrical and automation solutions are aimed at achieving those objectives:

4 Complete electrical equipment, medium voltage cells, transformers, motors, motor control centres, control desks and panels, field devices, etc.

4 Basic Level 1 Automation, comprising control PLCs and operation/display HMIs, in local or general (Ethernet) topologies.

4 Level 2 Process Automation, with advanced product follow-up control, quality evaluation, coil optimization, etc.

4 Execution of specific functions:

4 Automatic operation sequential for the various sections of the Line (loading of coils, centring of coils, shearing, etc.).

4 Calculation functions (coil width, coil diameter, radius, thickness, length, positions, welding-point follow-up, etc.).

4 Closed loop regulation functions (elongation, position, temperatures, thickness, etc.).

4 Supervisory functions and automatic generation of alarms.

4 Connection with other levels and the operators of the plant.

Titular que corresponda

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In close cooperation with our cus-tomers, Ingeteam Industry Division develops production system confi-gurations that accommodate each operational detail and perfectly match the customers current requi-rements. In that way our customers have a single, dedicated point of contact for everything they need and personalized streamlined services to find the right solution for every cha-llenge and every project.

Ingeteam Industry Division has equipped a considerable amount of installations with state-of-the-art electrical system solutions. In close cooperation with our industrial en-gineers, Ingeteam Industry Division also conducts plant modernizations, manages new construction projects and stands ready to support our customers wherever it is required. From consulting and planning to deliveries and installations, through optimization and maintenance: In-geteam Industry accompanies each phase of the project, be it reliable mensuration and control systems,

advanced drive technology, power management, efficient warehouse logistics or advanced control com-ponent solutions, with Ingeteam industry Division our customers can get them all from a single source.

The following describes the essen-tial and basic level in the industrial process automation pyramid and includes the following control sys-tems:

4 System for the acquisition of data in real time (data logger).

4 Cabinets for auxiliary power supply and distribution.

4 Local control desks and boxes.

4 Field devices and sensors.

4 Logic and sequential control systems PLCs.

4 Remote I/Os units, for field data acquisition.

4 Local communication networks (Interbus S, Profibus DP, Can, etc.).

4 Industrial communication networks type Ethernet (cable, F.O., etc.).

4 Operation and display systems HMIs.

4 Engineering units.

Automation Solutions

Ingeteam Industry Division Automation Engineers specialize in the implementation of proven and cost-competitive solutions, customized to the requirements of steel producers. Ingeteam Industry Division provides integrated systems for all automation levels across the entire production chain for both Greenfield installations and modernizations or extensions.

A vast background of experience in drive systems, process control, process optimization, expert packages and plant logistics, combined with our permanent emphasis on research and development, is the foundation for decisive impro-vements in product quality, plant performance and profitability.

Highlights

4 Combined engineering, operational, metallurgical and automation know-how.

4 Comprehensive solutions covering the entire iron and steel production route.

4 Both integrated and stand-alone solutions for all automation levels.

4 Supply of modularly designed automation packages with standardized interfaces.

4 Application of latest knowledge-based and artificial intelligence software tools.

4 Solution-oriented services covering the entire life-cycle of supplied automation systems.

In order to ensure ongoing market success for your

plants, Ingeteteam Industry Division is continuously

pushing innovation forward in the field of automation


We integrate own and market products

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Ingeteam Industry Division is committed to ensuring that their customers receive the most cost-effective, tailor-made solutions for their industrial requirements

Turnkey Solutions

The demands for attractive, economical and environmentally compa-tible industrial solutions are stronger today than ever before. Most in-dustrial projects are extremely complex to realize and therefore usua-lly customers usually prefer them to be handled on a turnkey basis. Its great competence in project management, engineering and systems integration as well as in project processing and financing enables In-geteam Industry to not only provide customers with technically in-novative systems but to also make sure they receive solutions which offered are efficient, safe and tailored to customer requirements.

Engineering and Consulting

Before the idea of a new plant can be transformed into a real pro-ject and is mature enough for implementation, our customers require professional support. That is where Ingeteam industry competence comes in. We can be of assistance to our customers right from the start, during the pre-project phase, in choosing the right solution and ensuring its safe and efficient implementation. During the decision-making phase we advise our customers on all aspects and we con-duct feasibility studies and profitability calculations in order to place the project on a solid footing.

During the engineering phase, we adapt the entire system to the ope-rational needs taking account of our customers existing infrastruc-ture. After that, all technical components are oriented towards our customers’ individual project and we harmonize all the systems and components, i.e. mechanical, hydraulic, electrical, automation and power supply.

Services

Successful and efficient project management always means optimum use of potential for the given circumstances

With every project our aim is to provide complete mechanical and electrical solutions

Project Management

At Ingeteam industry Division we believe that successful and efficient project ma-nagement always means the optimum use of potential for the given circumstan-ces. Ingeteam Industry Division’s flexible concepts enable our engineers to propose the perfect solution for the most complex demands, as well as to provide the best possible transparency and to keep a tight rein on the time schedule and costs.

Ingeteam Industry Division provides the necessary transparency for a multi-face-ted complete project on several levels. The project manager is always at hand as our customers direct contact for the project right from the start.

The project manager takes overall res-ponsibility and, is aware of the customer’s needs and how far implementation of the project has progressed. That makes for direct communication.

During e very phase of the project we never lose sight of our aim of optimizing time, costs, and quality: any savings po-tentials are disclosed in advance and then realized flexibly and efficiently during the implementation phase.

Ingeteam Industry Division project struc-ture therefore provides the conditions to make efficient use of time through the in-telligent networking of all project phases right from the start.

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Services

Ingeteam Industry Division flexible concepts enable our engineers to propose the perfect solution even

for even the most complex demands

Electrical Erection Works

To implement our installations we normally rely on Ingeteam’s Service Division, which specializes in High and Low Voltage electrical installa-tions. The electrical installation su-pply includes mainly the following services:

4 Installation coordination and su-pervision.

4 Basic installation engineering, in-cluding user manual with analo-gy diagrams and drawings.

4 Detail engineering with develo-ped overview and cable routing layout drawings.

4 Supply and layout of power, con-trol and instrumentation cables.

4 Supply and layout of the main routes by means of trays and ac-cessories.

4 Supply and layout of secondary routes by means of conduit pi-pes, flexible steel pipes, em-bedded pipes, etc.

4 Cable connections.

4 Supply of the following installa-tion materials: terminal strips, terminals, cable labels, supports, clamps, field connection panels, etc.

4 Installation of electrical panels and equipment.

4 Supply of bases and supports for cabinets, panels and control desks (if required).

Installation Start-Up

Ingeteam Industry Division installa-tion and start-up services guarantee a professional and thorough start-up of the plant, while maintaining the contractual time schedule agreed with our customers. With compre-hensive expertise and dedication, our Commissioning Engineers will start up the systems supplied by In-geteam Industry, carrying out verifi-cation and functional testing of total system.

Commissioning

After the total system has been subjected to our comprehensive start-up phase, it is now ready for commissioning. Ingeteam Industry Division commissioning services are designed to protect the system and its applications, while ensuring that the equipment and system compo-nents are performing as designed.

The engineering definition, equip-ment construction, software ela-boration control, factory tests and

installation are the phases of an ins-tallation that have to be undertaken prior to commissioning.

The project team of Ingeteam In-dustry Division, who are well versed in all the installation’s details, exe-cutes the last phase of the project, using the most advanced supervi-sion and configuration tools. In this way the different parts that make up the process are tested and validated within an optimum time frame. The exhaustive tests carried out at the factory, together with its software va-lidation, guarantee optimum quality commissioning.

The close collaboration with the Client during the development pha-se of the project makes it possible to execute a smooth and fast handover of the installation to the owner.

Ingeteam Industry Division project structure therefore provides the conditions to make efficient use of time through the intelligent networking of all project phases right from the start Our vast experience in understanding the process requirements enables us to

supply our customers with the most advanced solutions

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Ingeteam Industry Division instructors are predo-minantly Project Engineers who have vast expe-rience in the various fields included in our training courses. With such knowledge at our disposal, we are able to tailor courses to the specific needs of our customers.

Experience is the best way to learn. Ingeteam´s training courses have a strong focus on practical, hands-on exercises replicating real scenarios. This enables the trainees to learn quickly and effectively on the different type of equipment they encounter at their plants.

Our dedicated training centres, which are distribu-ted amongst he companies that form part of Inge-team Industrial Division, are extensively equipped to handle training across a wide range of situa-tions and product types, from risk management and energy efficiency to product optimization and Mechanical/Electrical safety training.

Ingeteam Industry Division sees Training as one of its most important activities, and our training cour-ses are continually developed to reflect advances in product and technology. Training courses are designed to be flexible so that they can be deli-vered either from an Ingeteam Industry Division facility or on-site at our customers’ premises. De-pending on the number of students, courses can be run either on a standard basis or tailored to specific needs.

Many courses have a hands-on approach which gives safe exposure to real-plant situations

Our Training Centres use various platforms from across the competitive marketplace, not only our own products. This ensures that trainees learn how to work quickly and effectively on all types of products that they typically en-counter on a day to day basis.

Our instructors accompany the students for the duration of the training course. This allows them to build indivi-dual relationships with the students, understanding their strengths and suggesting how to overcome their weak-nesses.

Our instructors are highly experienced engineers with many years’ exposure to multiple industry sectors; we are able to adapt the course content to apply case stu-dies and real plant examples relevant to the student’s sector.

Our hands-on, performance-based technical training programs and educational training simulation equipment have been designed to meet the highest requirements in terms of accuracy, durability, reliability and user safety.

Every training course provides our customers with a detai-led student guide and exercises containing several hours of technical training sessions designed by Ingeteam’s training specialists. In addition, detailed troubleshooting procedure job aids and quick reference guides have been developed to enhance each trainee’s skills-building process.

Training

In today’s pressurized market, maintaining one’s competitive edge is more importantthan ever. Our dedicated training centre will improve our client’s skills, system reliability and risk management Practical courses with lots of exercise units on specially developed

training devices

Ingeteam Industry Division strategy aims at a continuous development towards achieving excellence in the quality we provide, always in the maximum respect of the environ-ment. To this end we are actively involved in: Internal development of the EFQM model. Improving the satisfaction of our internal and ex-ternal. customers, suppliers and the social environm environment.

The integration of Quality, Environ-mental Impact and Work Safety Ma-nagement, conforming to the ISO 9001:2000, ISO 14001 and OHSAS 18001:1999 standards.

Reduction of CO2 emissions and dangerous waste disposals, in strict compliance with the ROHS stan-dard.

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After-Sales

Technological support

After the installation’s guarantee expires, we provide the resources required to solve pro-blems that might occur.

IngeRAS™ Land

A system that enables on-line connec-tions to be established between our support centres and the installations’ control, supervision and diagnosis systems, using state-of-the-art telecommunication solutions.

T.A.S. – Technical Assistance Service

We have technical personnel on standby, con-tactable by telephone, 24 hours a day, 365 days a year.

Training

We have the resources required to train our customers’ personnel. Training can be carried out at our offices or at the client’s premises.

Repairs

Furthermore we control all the repairs carried out on materials and/or equipment supplied by Ingeteam Industry Division within the scope of the project. All material supplied and repaired by other suppliers must comply with Ingeteam Quality Standards for both service and product reliability.

Spare parts

Ingeteam Industry Division offers spare parts for all systems supplied. It is recommended that customers purchase and maintain a stock of spare parts so replacement devices are available when required.

Ingeteam Industry Division After-Sales Services is specially designed to meet the requirements of our customers with mechanical/electrical equipment solu-tions. Ingeteam Industry Division core competence, and thus our main focus, lies in the field of mechanical/electrical engineering services. Customers specify which services they want us to provide and on what scale, depending on the assessment of the after-sales service requirements and problem areas.

Service Agreements

Ingeteam Industry Division has service agreements available for our customer’s different plants, always ensuring the best support of their long-term goals. We can assist in proactively improving the perfor-mance of our customers’ plants through various service options.

From operating plant service agreements to full-scope operation, maintenance contracts and remote monitoring utilizing IngeRAS™ Land, Ingeteam Industry Di-vision service solutions can be adapted to our customers exact needs: scheduled inspections, preventive maintenance, re-mote monitoring, replacement parts pro-grams and incentives.

Maintenance

We provide corrective and preventive ser-vices with personnel providing assistance based at the customer’s installations.

We provide the after-sale service best suited to our customers’ direct assistance needs

Our customer-based business model has led to the creation of special departments. These departments incorporate personnel and tools especially selected for this purpose, which form an integral part of the activities developed. Our customers’ satisfaction is

one of the key aspects of our business




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Ingeteam Industry Division believes in and is fully committed to:

4 New technologies, innovation, productivity and competitive-ness.

4 Information and Communications Technologies (ICT).

4 Knowledge and knowledge management systems.

Using state-of-the-art telecommuni-cation resources, directly from our offices or anywhere in the world , we are able to connect, directly with our customer’s installations, accessing the installation’s control, supervision and diagnosis systems (Automation units, HMI, Register,...). Remote technical assistance carried out through telematic communications channels and IngeRAS™ Land. With this tool we can provide a faster

service, avoiding the need of having technical personnel travel to the lo-cations where assistance is requi-red. This saves costs since travelling expenses are eliminated.

What is IngeRAS™ LAND?

4 An indispensable tool for any company that wishes to have fast and efficient solutions to problems that may arise.

Integration of Services for Remote Control, Supervision and Maintenance of Systems directed at the Industrial Sector

We have the right stuff to do it

4 Powerful set of software and hardware tools directed at the industry sector.

4 Enables technical personnel, in-dependent of where they may be, to provide technical assis-tance to any installation that in-corporates this solution.

4 Offers fast and safe assistance via VPN and Tokens.

4 Includes a main server that cen-tralises the data of all associated installations.

4 Integrates all types of connec-tions: Satellite, RDSI, ADSL, UMTS, GPRS, GSM…

4 Service based, so it is easily up-datable and expandable.

4 IngeRAS™ can be customised to the client’s requirements.

Services

4 AAS (Access to Automation Systems Service).

4 PDCS (Data Capture Services).

4 MS (Messaging Services).

4 MAVS (Multimedia Added-Value Services).

4 EDCR (Document Consultation Services).

INGEDAT is a tool used for process maintenances such as adjustments, pro-blem solving, optimisation, diagnostics, etc... It includes a compatible PC, a data acquisition card and two software modules: SW IngeDAQ for the acquisi-tion, monitoring and filing of data and SW IngeDAT for subsequent treatment and analysis of data on disk.

SISTEAM MONITOR is a software product that complements the functions of the Scada System. It uses a powerful object orientated graph interface. The different modules that make up the SISTEAM MONITOR have been develo-ped to function with the System´s operating system.

Tools

THE ARGUS BOP

(Breakout Prevention) system allows customers to gain control over the mould area of their continuous casting machines. The Argus prevents sticker type breakouts. It also warns of any ab-normal situations in the mould area related to heat transfer, os-cillations, friction, inclination and more. Argus is the most effec-tive and unrivalled BOP system with more than 15 installations worldwide.

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R&D+i

One of the Ingeteam Group’s commitments is its pledge and dedicated efforts to R&D+I activities. Ingeteam’s Industry Division promotes this commitment and in this sense carries out R&D+I actions and projects related with innovation and optimization of industrial processes, mainly for the Iron & Steel Making Industry, by equipping installations with state-of-the-art Automation and Control Solu-tions. In this section we outline some of the most outstanding projects carried out, in recent years, in collaboration with Universities, Technological Centres and final Users in this sector of activity.

Development of an Automatic Inspection System capable

of detecting defects in rolled steel products

Development of an Automatic Inspection System capable of detecting defects in rolled steel products (currently being detected visually). This system was designed to operate in a reversible cold roll mill and to inspect 100% of the pro-duction. It identifies defects at a range of 1 mm in a strip 1m wide moving at a speed of 900 m/min in an environment of vapour and vibrations.

Competitive advantages:

4 Capable of inspecting both sides of the strip throughout 100% of the process.

4 Modular architecture and low cost.

4 Installation without additional construction works.

4 Software for detection, classification and control of surface quality.

4 Generation of reports and production data registers and production tracking.

Scientific-Technological Contribution:

4 Design of very high speed image capturing and lighting systems. Advanced lighting and image capturing Techno-logies.

4 Mechanical design of modular structure. Easy to install and offers the possibility of being removed to a remote area.

4 Light-optical-sensor set, capable of resolving distance, position and vibration.

4 Real-time, low level image processing software able to localize areas which are candidates for defects.

4 Low level image processing software able to localize defects throughout all the stages of the rolling process.

4 Learning process supervised by specialists.

Partners and Participants in the Project:

4 ARCELOR MITTAL (End User).

4 ROBOTIKER-TECNALIA. (Artificial Vision Unit, image processing, inspection of defects).

4 INGETEAM INDUSTRY S.A. (Electrical Engineering, Automation and Solution Control).

4 INGETEAM METAL SOLUTIONS S.A. (Mechanical Solutions Engineering).

- 100% coil inspection – Record of production data and defects + trac-king of coils.

– Classification of defects + Self-learning.

- Coiler/Coil-rewinding machine diameter calculation.- Control of position lights= f (diam.).- Strip Tracking. Sending to PC inspection.- Trigger camera elaboration.- PC inspection communication.- Manual movements, adjustment of lights and remo-

val of lights and cameras supports.

Project installed in the Mill. nº 4 - ARCELORMITTAL

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R&D+i

Development of an Integrated Surface Inspection System, automatic control and optimization of the pickling process

Development of an Integrated Surface Inspection System. Automation, Control and Optimization of the pickling pro-cess.

Scientific Contribution:

The object of the project is to develop a system capable of operating in real-time and of validating 100% of the produc-tion which will enable, in a joint and integrated manner:

4 The detection and automatic classification of surface defects (mill scale, slivers, marks, etc.) and acting directly on the variable speed of the pickling process, halting and/or warning of serious defects if necessary.

4 Automatic measurement of the real width of the strip.

4 Automatic correction of the centring of the edge cuts.

It is important to mention that there is currently no comprehensive system of detection, measurement and classifica-tion which provides indications of the recommended speed of the pickling process. Nor does any system or application exist which integrates into one single place the three objectives which are being pursued.

Line needs:

4 Reduction of stoppages and increase in output.

4 Improvement in quality and security of the line.

Modelling and optimization of the production process.


4 ARCELOR MITTAL (End User).

4 ROBOTIKER -TECNALIA. (Artificial Vision Unit, image processing, inspection of defects).

4 INGETEAM INDUSTRY S.A. (Electrical Engineering, Automation and Solution Control).

4 INGETEAM METAL SOLUTIONS S.A. (Mechanical Solutions Engineering).

This project is part of Arcelor’s strategy of innovation and quality which commits them to promoting innovation in order to create value for their clients, while fostering Sustainable Development. It is also focused on optimizing the processes of production, through continuous improvement and qualitative technological advances.

This project enables Ingeteam Industry to offer comprehensive automation systems for the purpose of contributing an added value to their solutions for automation and control of sheet processing lines, as well as an improvement in information management and in the optimization of the pickling processes.

- Performance with strip centring unit

- Interface with edge cutters

Send speed set-points to the kinematics PLC - Receives welding point from the Kinematics PLCStrip tracking Communicating with PC HMI and DECOI2- Manual movements, adjustment of lights and with-

drawal of lights and cameras- Control of centring unit- Regulation of the line’s exit speed

- Artificial Vision Control /Artificial View Control

- Measurement of sheet width- Inspection of defects

Project installed in the Pickling Line-ARCELOR

MITTAL ETXEBARRI

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R&D+i

Optimization of the thickness control of a cold rolling reversible four-stand mill

Optimization of the thickness control of a cold rolling reversible four-stand mill.

Mathematical modelling of the process and development of a functional hardware/software model, whose parameters can be established via the HMI.

Scientific contribution:

The development of a rolling mill model that allows for the acquisition of a hardware/software system with a performan-ce similar to that which a real rolling mill would have.

All the significant physical entrance/exit signals are reproduced, resulting in a very useful tool when carrying out tests and controls, allowing one to work on the model, requiring the real rolling mill only for the final adjustments.

In this way it is possible to test all kinds of control strategies in the office, reducing the number of displacements, work and time required to commission system.

Characteristics of the model:

4 Modelling of a cold rolling reversible four-stand mill.

4 Implementation of the physical equations which define the process.

4 Reproduction of the physical entrance/exit signals which define the process.

4 Establishment of parameters and general control of functioning from a dedicated HMI.

4 System available for simulations and tests, through a physical interface which is similar to the real rolling mill.

4 Allows for a reduction in the time spent with development and commissioning of the mill’s control, so a large part of the work can be done in office.


4 INGETEAM INDUSTRY S.A. (Electrical and automation engineering and solution control): System Developer.

4 ARANÍA: Technological partner. Has allowed the use of its rolling mill in order to collect data. ARANÍA was also the first beneficiary to use the model and system for improvements tests on the rolling mill.

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Ingeteam Industry Division seeks to provide a healthy and safe working en-vironment at all sites and facilities and to take adequate steps to prevent acci-dents and injury to health arising from the course of work by minimizing, so far as is reasonable and practicable, the causes of hazards inherent in the wor-king environment.

Thanks to tough and innovative health and safety requirements in our plants and offices, we have a good workplace safety record and low accident figures. We engage in a wide range of initiatives to continue implementing our global occupational health and safety guide-lines.

The traditional work safety measures employed by Ingeteam Industry Division have been very successful in reducing work accidents and preventing the oc-currence of occupational diseases. But there is considerable potential still to be realized when it comes to promoting health in the work place as a means of reducing illness-related costs and en-hancing productivity.

4 The entire work force needs to be involved (participation).

4 Employee Health Promotion is con-sulted on all important decisions affecting healthy and safety in every organizational unit of the company.

Occupational Health & Safety

A systematic reporting system enables management to evaluate the overall direction and efficacy of the health and safety system and to develop strategies for improving it

4 All related measures and pro-grams are conducted systema-tically: requirements analysis, definition of priorities, planning, execution, continuous monito-ring and evaluation of results (project management).

4 Behaviour-related and relation-ship oriented measures are con-ducted.

4 It combines risk reduction with the strengthening of protective factors and health potentials (holistic approach).

Beyond that, our employees receive the necessary knowledge, training and equipment to fulfil their res-ponsibilities with regard to health and safety and to take the neces-sary precautions to prevent risks and perils. Personal responsibilities have been clearly defined. Periodic audits are conducted through all companies forming part of Inge-team Industry Division to ensure that the external and internal regu-lations are properly implemented and continuously observed.

Company executives, health and safety specialists, safety officers, safety experts, and employee re-presentatives work together to intro-duce additional improvements. The

work safety and health protection guidelines bind minimum standards for the entire Division. According to these guidelines, preserving the health and safety of every person who works for or with a company belonging to Ingeteam Industry Di-vision is fundamental to our various activities. The promotion of health and safety is an integral aspect of Ingeteam corporate culture, indica-tive of the group’s sense of respon-sibility for people and for its busi-ness. Ingeteam Industry Division intends to achieve and maintain a leadership position in this regard, by means of continuous learning and improvement, comparison and experience sharing.

The active and visible commitment of the company’s top managers is a critically important element of successful health and safety ma-nagement. Thus, managers on all levels are responsible for ensuring that the legal requirements and standards for health, safety and emergency planning are implemen-ted in accordance with the Ingeteam Industry Division guidelines and the applicable laws and regulations of every country where we have com-panies implemented.

Occupational health and safety is an important success factor for our

Division. Workplace accident prevention and protection

initiatives are a major priority

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Ingeteam Industry Division strategy is directed towards continually working to achieve excellence in the quality we pro-vide, always with the maximum respect for the environment. To this end we are actively involved in:

Internal development of the EFQM mo-del, improving the satisfaction of our in-ternal and external customers, suppliers and the social environment.

The integration of Quality, Environmen-tal and Occupational health and safety management systems conforming to (according to) the ISO 9001:2000, ISO 14001:2004 and OHSAS 18001:2007 standards.

Reduction of CO2 emissions and dange-rous waste disposals in strict compliance with the ROHS standards.

Ingeteam Industry Division is integra-ting the protection and preservation of global resources into our everyday busi-ness practices. Its part of doing what is right, and it means we’re committed to sustainable, responsible and thoughtful environmental behaviour. Managing the natural resources entrusted to our care is an integral component of our commitment to environment protection. We believe effective management begins with the thoughtful procurement of su-pplies, equipment and merchandise.

Quality & Environment

The quality of our products and services is an essential part of our corporate strategy, furthermore, our quality responsibility includes being proactive in protecting our environment and natural resources

Committed to the Environment

Reducing of CO2 emissions and dangerous waste disposals

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Committed to the EnvironmentIngeteam Industry Division

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Branches

Ingeteam Industry S.A. Spain

Parque Tecnológico - Edificio 10648170 Zamudio • BizkaiaTel: +34 944 039 699Fax: +34 944 039 688

E-mail: [email protected]

Ingeteam, GmbH Germany

Stielerstrasse 380336 München

Tel.: 49 89 99 65 38 55Fax: 49 89 99 65 38 99

e-mail: [email protected] www.ingeteam.com

Ingeteam Metals Solutions S.A.Spain

Parque Tecnológico - Ibaizabal bidea 70248160 Derio • BizkaiaTel: +34 946 569 500Fax: +34 946 569 501

E-mail:[email protected]

Ingeteam, LTDA

Brazil

Rua Luiz Carlos Brunello, nº 286Chácara São Bento

13278-074 - Valinhos-SPTel.: 55 11 3101 3777Fax: 55 11 3101 2530

e-mail: [email protected] www.ingeteam.com

Ingeteam a.s. Czech Republic

Technologická 371/170800 OSTRAVA - PUSTKOVEC

Tel.: 420 59 732 68 00Fax: 420 59 732 68 99

e-mail: [email protected]

Ingeteam, LTDA

Ingeteam a.s.

Ingeteam, GmbH

Ingeteam Industry S.A.Ingeteam Metals Solutions S.A.

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