Tata Steel Limited has produced the first coil following the completion of an extensive upgrade of its compact strip production (CSP) plant at Jamshedpur in Jharkhand, marking the resumption of operations after a major modernisation programme. The revamp enables the facility to manufacture thinner strip gauges down to one millimetre, while improving dimensional accuracy, flatness and overall throughput.
The upgrade involved the integration of a new seventh finishing stand into the CSP rolling mill, alongside a comprehensive renewal of the plant’s automation systems. The modernisation was completed with a rapid ramp-up, supported by extensive pre-commissioning tests and close coordination between Tata Steel and SMS group teams.
The CSP plant, originally supplied and commissioned by SMS in 2011, has an annual production capacity of about 2.5 million tonnes. It produces hot-rolled strip in widths ranging from 900 millimetres to 1,680 millimetres and thicknesses from 16 millimetres down to one millimetre following the upgrade.
The addition of the seventh finishing stand allows for improved rolling load distribution, particularly for harder steel grades, wider strip widths and thinner gauges. SMS group said the new configuration reduces bottlenecks in the finishing mill, increases output for selected products and allows the casting process to operate at an optimised thickness, improving overall plant efficiency. The existing roll-changing equipment was also adapted to support the additional stand.
Further modernisation measures included upgrades to finishing stands F1 to F5 through the installation of a new hydraulically operated pass line adjustment system. Five laminar cooling sections were replaced with four reinforced cooling units equipped with edge masking. The exit area of the mill was fully upgraded, including a new measuring house, with provision made for the future installation of a second multifunction gauge.
Mechanical enhancements also included the installation of high-torque gear-type spindles with an internal oil return line. These are designed to transmit higher torque loads than conventional shafts while using continuous oil lubrication to improve cooling, reduce maintenance requirements and extend service life.
As part of the project, the level 1 and level 2 automation systems were fully renewed within the X-Pact ProBAS platform, using embedded controllers and an updated human-machine interface. The level 2 system includes process models for pass schedule calculation, automated cooling control and profile, contour and flatness control, aimed at improving process stability and product quality.
“Thanks to the excellent cooperation between Tata Steel and SMS group during the execution phase and especially during the shutdown and ramp-up, this complex revamp project was a success,” said Hendrik Trimborn, Project Manager at SMS. “The open and trusting communication made it possible to identify challenges early on and to find solutions together.”
During the initial ramp-up, fourteen coils were rolled from the first day without any cobbles, and within six days the mill processed strip down to 1.2 millimetres thickness. SMS group said this performance reflected detailed preparation and thorough pre-commissioning activities despite the complexity of the shutdown.
Tata Steel Limited is an integrated steel producer with operations spanning mining, steelmaking and downstream processing, with major manufacturing facilities in India and overseas.
