• Upgrade of the outdated level 2 automation secures the long-term operational stability and ongoing production efficiency of the medium section mill
• State-of-the-art X-Pact^® Vision webHMI improved productivity and decision-making processes by consolidating information from each section onto a single screen
• The entire modernization of the level 2 automation system was successfully carried out while production was underway

For CELSA Barcelona’s medium section mill, located in Castellbisbal, Spain, SMS group has successfully upgraded the process automation system, executing the project without interrupting ongoing production. The upgrade, culminating in the awarding of the final acceptance certificate (FAC), involved a crucial overhaul of the automation systems to maintain the mill’s competitive edge and improve its operational efficiency. Since its original design and commissioning by SMS group in 2001 and modernization in 2020, the mill, which has an annual capacity of approximately 900,000 tons, has played a crucial role in the production of high-quality long rolled products such as beams, angles, and channels for the construction industry. 

The goal of this modernization was to replace the previous level 2 automation system, which had become a security risk due to outdated operating systems and development tools. By implementing state-of-the-art automation technologies, CELSA Barcelona aimed to secure long-term operational stability and maintain continuous production efficiency. The new X-Pact^® level 2 system features an open software architecture, ensuring ease of maintenance and extensibility, while allowing for seamless integration of additional functionalities and digitalization with minimal effort. The enhanced visualization capabilities, achieved through cutting-edge web technologies based on the proven X-Pact^® Vision design, utilize 4K screen resolution. With the tandem mill in particular, the implementation of X-Pact^® Vision webHMI plays a crucial role by consolidating information from each section onto a single screen. This significantly streamlines operations compared to the previous setup, which required two to four screens, thereby markedly improving productivity and decision-making processes.

This modernization reflects the enduring partnership between CELSA and SMS, leveraging over two decades of collaborative experience. SMS’s intimate knowledge of the mill’s original systems and its continuous relationship with CELSA were instrumental in executing the project without interrupting ongoing production. 

Eduardo Prieto Fernández, Rolling Technology and Process Engineer at CELSA Medium Section Mill, commented, “The successful commissioning of this project, carried out simultaneously with ongoing production and without any interruptions, underscores the effective collaboration between our teams. The extensive knowledge of our processes facilitated a smooth and efficient renovation, making the entire procedure notably straightforward.”

This project demonstrates SMS’s ability to deliver standardized automation systems tailored to diverse industrial needs. It ensures CELSA remains at the forefront of technological advancements, reinforcing their competitive edge in the European and US markets.