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Member News
tube documentation is making a signi cant contribution to total quality assurance.
To this end, SMS group has equipped the new PQF® seamless tube plant with a wide range of automated, state-of-the-art tech- nology. Norbert Theelen from SMS group: “Our advanced level of digitization allows Tenaris to make substantial time savings and achieve optimum transpar- ency as regards the current plant and production status. This is further enhanced by a host of other added value sources that boost ef ciency levels. Tenaris is a trailblazer for modern plant and equipment that combine the ben- e ts of digitization. For example, we have installed a secure WiFi network throughout the whole plant. This gives the operating crew access to information they need via mobile panels and to completely new ways of working.”
The basis for the automation used at TenarisBayCity is pro- vided by the CARTA® (Comput- er-Aided Rolling Technology Application) technology system, which is used as a technological production planning and process
control system for the entire hot rolling section of the seamless tube mill. CARTA® consists of three modules. The process-plan- ning module prepares the rolling mill settings and the tool design. The process management module controls the rolling process in real time, and saves and analyzes the process data. The tool manage- ment module is responsible for the precise and timely use of the tools. So the bene ts of CARTA® are numerous. This technology system offers not only increased output but enhanced tube quality and optimized mill utilization, too.
The measuring data used by CARTA® to monitor the quality are provided by systems such as Cal- iView®, which is supplied by SMS group. This is a newly developed inline system of measuring rolls and passes which are installed in the mill. A camera is used to take fast, precise and non-con- tact measurements of the stands inline, and to align them per- fectly. Time-consuming, manual measurements are no longer required. CaliView® ensures there is direct feedback to a mobile
control device, meaning the rolls can be precisely adjusted during the measurement. What’s more, the system detects wear on the work rolls and logs the data for producing informative statistics.
SMS group also implemented a holistic tracking solution for material and individual tube tracking. Production and quali- ty-related tube parameters are measured at every machine during this process. The Identi cation Database software tool uses data gathering terminals (DGT) to collect the relevant information at each speci ed station and assigns this automatically to the tube number.
The system provides produc- tion and quality reports in real time, statistical reports for iden- tifying quality-related prob- lems or production bottlenecks, and a comprehensive database for developing production and process know-how.
It is not just the tubes and pro- duction processes that are contin- uously tracked, the tools are too, especially the mill stands and mandrels, and for this they are equipped with around 850 chips and are monitored throughout with a fully automatic tool track- ing system with RFID technology. In addition to this, Tenaris also has a comprehensive condition monitoring system for the main drives, gears, motors, and saws. This online monitoring system is used in particular for monitoring parts that optimize preventive maintenance, increase the plant’s availability, and reduce operating costs.
ITAtube Journal No2/July 2018
75