PCT Engineered 4-High 2000 HP Cold Mill User Manual

72” 4-High 2000 HP Cold Mill

The Application

Norandal USA, a manufacturer of light and
medium gauge aluminum foils used in the
packaging and automotive industry needed a
major retrofit on their breakdown cold rolling
mill.

Shape control for the continuous cast coils
needed improvement, and because of this,
production levels were limited. PCT
Engineered Systems, LLC was subcontracted
by Mannesmann Demag, an international mill
equipment manufacturer, to provide the PLC
control and operator stations, as well as the
mechanical and electrical installation for the project. Mannesmann Demag chose PCT
because of a past partnership providing turnkey reconstruction management of an
aluminum cold mill after a fire. Additionally, Norandal USA directly contracted with PCT to
provide a new digital drive system for the cold rolling mill.

The PCT Solution

PCT Engineered Systems worked with
Mannesmann Demag and Norandal USA to
increase the mill’s productivity by improving
shape control and reducing between-coil time.

© 2006 PCT Engineered Systems LLC. All Rights Reserved

Shape control, a major concern for Norandal
USA, was improved by providing the following:

• A new hydraulic gauge control system

• A new work roll bending scheme

• New entry bridle equipment

• Upgraded flatness and spray controls

• An ABB shape roll

Once improved shape control was established, the mill became less of a bottleneck in regard to
production throughput. New, electric drive controls that use a Eurotherm/SSD digital drive system to
improve speed control on the existing motors, reduced between-coil time were also added. By
improving speed control, PCT has helped Norandal USA increase the amount of useable product per
coil. PCT also provided a new control system including a GE 90-70 PLC system employing a fiber optic
link to the digital drives, and linked via Ethernet to the Mannesmann Demag Maras mill control system.

Other modifications provided by PCT included:

• Operator interface stations in the pulpit and on
the mill

• A new operator’s pulpit and control consoles

• A new trim removal system

• High- and low-pressure hydraulic piping routing

and installation

• Electrical conduit and cable installation planning
and labor

• Remanufacture of the hydraulic gap cylinders to
facilitate the improved gauge control

For a project of such magnitude, this complete
turnkey upgrade was completed with minimal
downtime. To date, the mill has outrun production
expectations, and Norandal USA has reported
significant improvements in product shape and
flatness.

5433 Tremont Ave.
Davenport, IA 52807

563.391.8011
FAX [phone]

The Solutions Team

© 2006 PCT Engineered Systems LLC. All Rights Reserved

www.teampct.com