ThyssenKrupp Companhia Siderúrgica do Atlântico, Brazil. Outsourced workshop and maintenance services for integrated steel plant. Metals Technologies

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1 ThyssenKrupp Companhia Siderúrgica do Atlântico, Brazil Outsourced workshop and maintenance services for integrated steel plant Metals Technologies 1

2 Professional maintenance services for entire steel plant The challenge: Based on the experience of Siemens VAI, which was already successfully operating offline maintenance workshops in Brazil, the challenge was to design and construct a central workshop capable to fulfill the needs of an integrated steel plant with five million tons in annual production. To accomplish this task the entire design concept had to be created jointly with the customer in order to tailor the scope of services to the plant design and the needs of ThyssenKrupp Companhia Siderúrgica do Atlântico (TK CSA) as well as to reduce the volume of the investment. The required scope of services had to include the operation of the central workshop, full-scope caster maintenance and online maintenance services for the entire plant, which are carried out as preventive and corrective maintenance activities during normal repair shifts as well as planned repairs executed during defined shutdowns. Additionally, qualified personnel must be kept on stand-by to assist in emergencies. Our solution: Based on its experience in performing maintenance operations in a variety of steel plants built by different manufacturers, Siemens VAI planned a full-scale maintenance organization and workshop on-site for this integrated steel plant, which were based on the requirements of the customer ThyssenKrupp Companhia Siderúrgica do Atlântico. Service activities cover all plant areas from raw-material handling to continuous casting and include mechanical as well as electrical services. In order to reduce the financial burden on the customer, the entire investment was done off-balance, arranged by Siemens VAI. The workshop anchored a 15-year ongoing service agreement managed and operated by Siemens VAI, in close cooperation with the plant s maintenance department and the individual plant areas. Achieved results: Fast erection of an 18,000 square meter workshop From planning to start-up in just 24 months Development of experienced staff Qualified staff of more than 800 service personnel Fully functioning workshop on-schedule with the steel plant s needs 2

3 The customer Name: ThyssenKrupp Companhia Siderúrgica do Atlântico Location: Sepetiba Bay, state of Rio de Janeiro, Brazil Annual output of steel slabs: 5 million tons Services: This ThyssenKrupp plant is near to ironore deposits and produces steel slabs for export. Around sixty percent of the slabs produced in Brazil will be used to supply the North American market with highquality steel. Forty percent of the steel from Brazil will be processed at ThyssenKrupp plants in Germany. Bild in besserer Auflösung vorhanden? 3

4 Highly qualified and experienced manpower througho Repair work done for all steel plant areas Professional outsourced maintenance enables plant operators to concentrate on their core business the production of steel and steel products. The highest level of maintenance support offered assumes full responsibility for all maintenance on site. This is Siemens VAI s agreement at the new steel plant operated by Thyssen- Krupp Companhia Siderúrgica do Atlântico in Brazil. The workshop was designed and built under Siemens VAI s supervision in order to guarantee its timely completion and also the fulfillment of the highest quality standards. A key factor for success has been the internal training of the maintenance staff to ensure services according to European and North American quality standards. These efforts are guided by international service experts who support the local staff with Siemens VAI key expertise. Central workshop and online maintenance The central workshop offers general maintenance and specialized mechanical and electrical services. All requests for repair or manufacturing of new components are submitted via an electronic interface (ERP-enterprise resource planning) between the customer s systems and the service provider. For online maintenance, TK CSA and Siemens VAI agreed on a particular number of personnel per plant area on each regular repair shift. The planning of daily repair jobs is performed by the customer s maintenance department. During times of peak demand, personnel are shifted between plant areas; and workshop personnel can be flexibly allocated as well. In the case of a shutdown, Siemens VAI is in charge of providing and supervising the necessary personnel. Main benefits: Customer can focus on the core business the production of steel High transparency of costs ensured by proposals for all work performed High flexibility thanks to the ability to shift personnel between plant areas based on actual needs During peak demand, backup personnel provide services in the required plant areas Lower costs due to flexible distribution of personnel, which allows for the reduction of the overall personnel requirement High-quality service based on international experience and expertise Integration of ERP systems 4

5 ut the process chain Highly experienced service personnel Manufacturing with state-of-the-art machinery Offering Central maintenance services: Machining services to repair parts and to manufacture spare parts Mechanical and electrical repair services Motor repair up to 2.5 MW Servicing of hydraulic and pneumatic components like pumps and safety valves Balancing rotating devices Maintenance of heat exchanger Air-conditioner maintenance Condition-monitoring systems for vibration, thermovision checks Calibration service for measuring devices, including weighting systems Crane and conveying system maintenance Online maintenance services: Provision of qualified personnel for inplant maintenance services Backup for emergency repairs Management of workforce during plant shutdowns Capabilities Machining equipment: Horizontal CNC lathe up to 1 m x 8 m Vertical CNC lathe up to Ø5.5 m x 2.5m Drilling and milling machines Overlay welding machines Machines in mechanical workshop: Torch-cutting machine Shears Plate-rolling and pipe-bending machine Furnace for heat treatment Machines in electrical workshop: Siemens motor test stand for lowand medium-voltage motor (up to 2,500 kw) Electrical testing and calibration equipment Balancing machines Drying furnaces With this comprehensive machinery and highly skilled and experienced staff, Siemens VAI provides all maintenance and repair services required across the entire process chain of this integrated steel plant operated by ThyssenKrupp Companhia Siderúrgica do Atlântico. 5

6 Maintenance outsourcing: refocus on your core busine Checking the strand guide roller bodies Caster maintenance Maintaining casting equipment at the most up-to-date state of technology reduces downtimes and increases the availability of the slab casters. Siemens VAI has full responsibility for caster maintenance at ThyssenKrupp Companhia Siderúrgica do Atlântico s plant. The maintenance personnel offers caster services including changing caster units, quality-controlled component repairs, roll refurbishment and mold copper-plating, improvement of component design, and supply of custom-made spare parts together with spare-parts management for all caster units. Caster maintenance is provided based on a price-per-ton concept in order to perfectly align the goals of the steel plant with Siemens VAI s expertise. This creates a partnership with the objective of providing the customer with an efficient 6 service that includes permanent, sustainable improvements in the maintenance of the continuous casting machine and workshop. This significantly improves performance in the production of quality slabs and increased equipment availability and reliability. Services Caster maintenance services: Segment maintenance and repair Mold copper refurbishment including nickel plating Roll refurbishment including hardfacing through overlay welding Main benefits: Fixed costs for maintenance are converted to variable costs Payment model pushes constant improvement of equipment availability Use of state-of-the-art casting technology Short component turnaround times Spare part management included

7 ss Caster maintenance workshop Test and assembly stands for caster components Maintenance services offered by Siemens VAI Outsourcing of maintenance services, both online and offline, allows producers to focus on their core business activities. Operating and inventory costs can be reduced at the same time. Siemens VAI service workshops are located throughout the world in close proximity to leading producers. This ensures dedicated maintenance services and the fast repair or replacement of equipment with high-quality original manufacturer components. These include customized win-win payment models based on standard costplus-fee, menu pricing, or performancebased payments that allow fixed costs to be converted to variable costs. Manufacturing of original components Roll cladding center developed by Siemens VAI 7

8 For further information, please contact: Siemens VAI Metals Services Ltda. Avenida João XXIII, S/Nº, Santa Cruz CEP: Rio de Janeiro / RJ - Brazil Phone: +55 (21) Headquarters: Siemens VAI Metals Technologies GmbH P.O. Box 4, Turmstrasse Linz, Austria Phone: +43 (732) metallurgical-services.metals@ siemens.com The information provided in this brochure contains merely general descriptions or characteristics of performance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. Order No.: E10001-M2-A18-V Printed in Austria Dispo No.: K-No.: SVAI Subject to change without prior notice Siemens AG All rights reserved.