Project Group alongside Bay-Forge Private Limited in the revamping of a radial-axial rolling mill capable of producing rings up to 6 metres in diameter.
The development of the Rolling Cad software over recent years has allowed us to continuously deepen our know-how in rolling processes.
Bay-Forge of the FomasGroup group, a long-standing customer of ours, entrusted our team with the revamping of a key installation for its Indian facility: a radial-axial rolling mill capable of producing rings up to a diameter of 6 metres.
The objective was to modernise the installation, which was affected by component obsolescence issues, and to provide a new control and command system that, by interfacing with our Rolling Cad, would resolve the operational problems previously present.
The Project Group team therefore set off as a group for Asia.
The project was carried out in several phases. First, our team visited the facility and presented the work plan to the customer, who made available a working group that facilitated the smooth progress of the order.
Prior to the shipment of the electrical switchboards and control console, we received a visit at our Reggio Emilia headquarters from Bay-Forge technicians for approval of what had been developed.
The final phase saw our technicians working on site, first carrying out the electrical installation of the equipment and then proceeding with commissioning of the plant.
Eight months of work engaged our team; a speed of execution that becomes an important strength when it comes to revamping of rolling mill plants.
We asked some questions to our team members:
- What was the Customer’s initial request?
“The Customer required a renewal of the electrical, electronic, and control system parts, as they were no longer able to achieve the desired performance due to component obsolescence and operational issues.”
- How did we solve the customer’s problem?
“For this revamping, we renewed the mill by replacing electrical panels and control desk and by providing new control and command system that, combined with our software RollingCAD, addressed and resolved the operational issues.”
- What difficulties did you faced at the Customer’s site in India?
“One thing that should not be underestimated is the distance and time zone difference, which made it challenging to communicate with colleagues at our premises; therefore, we had to commit more time to preparing the details in the office in advance.
In addition, in order to be able to provide continuous and prompt support to the Customer, we placed great importance on remote connection of all devices, so that we could intervene promptly if needed.”
- What advantages has our solution brought to the production process?
“We studied and developed a turnkey solution to overcome all the obsolescence and operational problems, and to improve performances of the process and the rolling mill itself.
The revamping of such kind of plants ensures extended production life and allows to avoid downtime caused by the wear of old components.”
- Why choose Project Group over a competitor?
“Project Group offers a cutting-edge command and control system based on own proprietary software RollingCAD and a remote assistance service by attentive and helpful specialists; our system is then based on commercial and readily available hardware to facilitate regular maintenance activities.”
The revamping of such facilities ensures an extended productive life for the plant because old electrical and electronic parts are replaced with modern and more efficient components.
This also allows us to customize control systems and meet the needs of both the Customer and the mill.
There are four radial-axial rolling mill retrofits already scheduled by Project Group by the end of 2023, a sign that we are on the right path.
