1. Vítkovice STEEL, Czech Customer Success Story
Presented by
Zdenek Zadak, ICONICS East European Sales Manager
Introduction – me, Mr. Listak and Mr. Kunz

2. Company name and location:
Owned by Evraz
Evraz Group S.A. (LSE: EVR)
One of the Worldwide Leaders In Vertically Integrated Steel Production and Mining
Operations Mainly In Russia
- Ostrava region – heavy industry, Iron-mill, roll mills
Evraz owned, operations in Eastern Europe from mining to steel plants
Recent merge with Strategic Minerals Corporation (US) – one of world leading vanadium products producers

3. 1600 employees in some x plants.

4. VÍTKOVICE STEEL, a.s - Products
VÍTKOVICE STEEL, a. s. is a leading European manufacturer of rolled steel products
The main product mix consists of:
Plates, sections
sheet piles
flame-cut shapes
Steel plant Production of steel is done in converter steel plant.
Equipment: Secondary metallurgy with vacuum station
Continuous casting of slabs follows the steel plant
Rolling mills Plates are manufactured on 3.5 m Four-High rolling mill from continuously cast slabs
Flame-cut shapes manufactured by flame-cutting machines equipped with oxygen – NG burners with CNC
Production center Production capacity/year
Steel plant kt
Plate mills kt
Section mill kt
Flame-cut shapes center 30 kt

5. Overview of application
VÍTKOVICE STEEL, a.s. ROLLING MILLS
3.5 m Four-High Rolling Mill
Founded in 1971, Large modernization in >
improvement of the rolled material geometry, surface quality and extension of the assortment.
Plates are manufactured of concast slabs.
Plates are rolled in the thickness range from 5 to 70 mm, and in the width range from to mm.
The plate quality assortment is designed for:
Steel and bridge structures,
Ship construction,
Transport machines and vehicles,
Abrasion resistant plates,
Pressure vessels used in normal, or higher temperatures,
Special military engineering,
Plates resistant against atmospheric corrosion,
Special use (e.g. clad plates, longitudinally profiled plates),
Plates for welded pipes,
Flame cut shapes.

6. Business Value of the Project…
Legacy System Replacement
Siemens Sicomp and PPC4 – 1980’s
Realtime production flow management system
With Process Alarming And Monitoring
ICONICS Selected
Free Development
Czech Localization
Oracle Connectivity
Data Mining Customer Order Information
Data Logging Realtime data to TrendWorX32 History File
Realtime Reporting Integrated with Planning Systems
Evaluated Several Other Vendors
Especially Siemens WinCC
Strong Visualization
Thin Clients
GEN32 openness&standardization – seamlessly connect with any PLC-based control system via OPC interface – Simatic S7

7. Heart of the Roll Mill – 3.5 four high mill
- Cast slabs gets pressed here up to 10 times before they get it’s correct thickness within 5 and 70 mm and width up to 3,3 meters.

8. Rolling Mill Coordination Level
Application Topology
Rolling Mill Coordination Level
Primary Control Level
Oracle DB running Real-time Application Cluster (2x Alpha, 8 CPU and 16GB machines)
PC layer – both visualization & material management one the same screens = unique. StratusFT 4600 with 2 CPU, 2GB – now at 10%
S7-400 PLCs – each per aggregate

9. ICONICS Products Deployed
VÍTKOVICE STEEL, a.s. ROLLING MILLS
GENESIS32-FT
on Stratus FT 4600
GEN32-DB Connector to ORACLE
GENESIS32-Browser
25 Networked GenBrowser Stations
WebHMI Server + 5 clients
DataWorX32 Standard Edition
SupportWorX
Quality Professional Services
Czech Office Application Consultancy to System Integrator
GEN32 – operators in cabins
DWX32 – data concentrator, unifier
QPS – project fine tuning during it’s second phase

10. Detailed Description Of The Project
Siemens S7 PLC's with Kepware OPC Server
Over 8,000 Real Time I/O Tags
50 GraphWorX32 Displays
Real-time Data Visualization
Oracle Production Planning System Interaction
Central Oracle DB
Alpha Server With Cluster Topology
TrendWorX32 Data Logging to Oracle
ICONICS Database OPC Server Mining Used Extensively
Providing Interface To Production Control System
Stratus FT 4600 Fault-Tolerant PC
Microsoft Windows Server 2003
NT Domain Security Integration
150+ users

11. Photos Whole Rolling Mill process.
Left bottom – Push furnace producing cast slabs
Performance tracing – see # of processed sheets/slabs
#s in the path = # sheets on that section
Operator names

12. GDF files or screen captures
1, Right top, blue numbers: cutting plan for coming sheet = green moving rectangle – to understand how to cut it
2, below it: order list to understand # of cut pieces = goes to a pile
3, green arrow “down” is the cutting machine, changes to red when in action.
4, then blue rectangles with identification move to piles or scrap.

13. GDF files or screen captures
Top event window: messages per cabin on aggregate operation issues – downtime, alarms, warnings….
Black background – cabins use dim light conditions, while process is well illuminated.
Testing Aggregate
1, Bottom: SSL cutting machine to cut pieces for test (up to 500kg)
2, goes up to a magnetic crane (Manipulator) operated via GWX screens
3, Then it’s cut into small pieces (up to 20kg) and shipped to a testing center

14. End-user quotes
The ICONICS platform allowed creation of a common platform for human and machine interface to ORACLE and SCADA, resulting in substantial increase in the efficiency of operations.
It is now easier to create extensions of the project to other applications, such as our Water Treatment and Secondary Metallurgy Systems.
ICONICS proved that it is possible and beneficial to develop a single interface to real-time and IT database systems. It was relatively easy with ICONICS’ out of the box connectivity and visualization software.

15. Partners Systems Integrator – R.T.S. cs (Ostrava)
Provides Production Flow Management engine
Direct ICONICS Relationship With Vitkovice Steel
Project specification created in 2004, implementation started 2005
Other Projects
Water Treatment
Secondary Metallurgy

16. Q&A
Questions & Answers

17. Further Information Thank You! Zdenek Zadak Bretislav Listak
Sales Manager for Eastern Europe, ICONICS
Bretislav Listak
CIO, Vítkovice Steel a.s.
Jaroslav Kunz
Project Manager, Vítkovice Steel a.s.
Thank You!