Mill Modernity & Meticulous Mechanisation Amidst Minimal Downtime

In a masterstroke of engineering orchestration, Germany’s SMS group has finalised a comprehensive automation upgrade at Jingye Steel’s renowned five-meter heavy plate mill in Yingkou, Liaoning Province. Originally installed by SMS in 2009, the mill was brought offline for only ten days, an impressively short window in metallurgical terms, for a high-stakes overhaul of its automation system. Leveraging their X‑Pact® Service contract, both partners achieved flawless synchronisation between upgrade and routine maintenance. The transformation took just eight days, averting extended outages & maintaining production continuity.

Process Perfection Through ProBAS & Predictive Precision Platforms

At the technological heart of the upgrade lies the X‑Pact® ProBAS level 1 automation system, now deployed across the roughing mill, finishing mill, and hot plate leveler. Designed for real-time process control in demanding industrial environments, this system replaces legacy automation hardware with a platform capable of fine-tuned responsiveness, intelligent diagnostics, and seamless process optimisation. This renewal not only prevents technological obsolescence but significantly improves uptime, mill efficiency, and precision in producing heavy plate steel.

EtherCAT Excellence & Embedded Electronics: The Digital Dynamo

An exceptional innovation embedded in this upgrade is the deployment of EtherCAT I/O architecture coupled with X‑Pact® Embedded controllers. EtherCAT, Ethernet for Control Automation Technology, enables ultrafast, deterministic data communication between industrial nodes, sensors, actuators & controllers. This high-speed protocol is pivotal in handling the vast sensor network and precision demands of plate rolling operations. The embedded systems, meanwhile, are robust industrial PCs designed for harsh environments, providing resilience, compactness, and remote monitoring capabilities, all hallmarks of a future-proof steel operation.

Safeguarded Steelwork & Sentinel Systems for Operator Security

Modernisation extended beyond operational efficacy to encompass comprehensive safety system reinforcement. SMS replaced outdated safety modules with next-generation safety hardware complying with international standards such as IEC 61508 and ISO 13849. These enhancements elevate both functional and occupational safety within the mill, offering improved interlocks, real-time safety diagnostics, and rapid emergency intervention protocols. As the mill handles colossal slabs of steel under high heat and pressure, such refinements are indispensable for protecting both personnel and infrastructure.

Protocol Plurality & Platform Plasticity: The Open Architecture Advantage

One of the most strategic elements of the project is the implementation of an open hardware & system platform, a pivotal deviation from traditional proprietary industrial automation. This architecture empowers Jingye Steel to integrate a diverse range of software, control systems, and third-party components in the future, without being constrained by brand-specific ecosystems. Conforming to global interoperability standards, this openness not only ensures modular upgradability but also aligns the mill for Industry 4.0 compatibility, including AI-driven process control, smart maintenance, and advanced analytics integration.

Commendable Coordination & Cross-Continental Collaboration

The collaboration between SMS and Jingye was marked by rapid coordination, multilingual technical teams, and 24/7 support during execution. Plant Director Wang Hailong lauded the project team, stating:

“We were supported in this automation project by an excellent team from the SMS Automation, Digital and Service Solutions unit, who worked diligently and efficiently in such a short time to ensure a successful outcome.”

SMS’s automation engineers executed the upgrade while minimising on-site impact and aligning every task with Jingye’s strict production timelines. This is a testament to years of cultivated trust and a proactive service model under their annual X‑Pact® Service contract.

Production Prowess & Plate Portfolio Expansion

The heavy plate mill at Jingye boasts an annual capacity of 2.3 million metric tons, serving critical applications such as shipbuilding, pipeline infrastructure, pressure vessels, boilers, and high-strength structural components. These use cases demand unyielding material integrity, consistent thickness, and fine-grain microstructure, all of which are contingent on meticulous automation and control. With the new upgrade, Jingye’s mill not only maintains its output volume but positions itself to handle more complex steel grades and customer-specific orders, enhancing its global competitiveness.

Strategic Sustainability & Scalable Solutions for the Steel Sector

This project is a beacon for sustainable industrial renewal. By modernising existing equipment rather than building new, SMS and Jingye reduce raw material consumption, embedded energy use, and capital expenditure. Furthermore, the adoption of EtherCAT-based energy metering and monitoring systems will enable Jingye to track electricity use in real time and adjust production dynamically to reduce CO₂ emissions.

SMS group’s Christoph Stappenbeck, Vice President for Automation, Digital and Service Solutions in China, summarised:

“Our goal is to maintain and expand the performance of our customers’ plants throughout their entire lifecycle. Through modernization and service, SMS ensures long-term viability, enhanced output, and greater flexibility.”

Key Takeaways

• Jingye Steel’s five-meter heavy plate mill was upgraded by SMS in just eight days during a ten-day scheduled shutdown, avoiding extended downtime.

• SMS installed the latest X‑Pact® ProBAS automation platform featuring EtherCAT I/O & embedded controllers, boosting system reliability, communication speed, and process control.

• The modernised open hardware system allows future scalability, integration of third-party software, and alignment with Industry 4.0 standards.