Technical Specification of steel rolling mill

Technical Agreement For Syrian Profile Steel Project

【】〖

〗 !

1#1 $ame% Annual 1&'''' tons of hot roll steel production line 1#1

Purpose%

the

continuous

casting

square

"illet

of

1''(1'')1*'(1*' and &'(1&' +ith the length of ,''' is heated "y furnace and rolled "y roughing mill# Then the required products +ill "e made after rolled "y 1' units of tandem mill units#

*#1 The process chart is as follo+s% Thee Th

ra++ ra

mate ma teri rial al

-the -t he

cont co ntin inuo uous us

cast ca stin ingg

"ill "i llet ets. s.

+ill +i ll

"e

transferred to the hot transporting roll ta"le in heat condition "y the deportation chains from the continuous casting cold "eds# And then the hot "illets +ill "e transported to the feeding roll ta"le "efore the reheating furnace through the transporting roll ta"le and after the centering of the the centering roll ta"le the continuous casting "illets +ill "e sent to the reheating furnace for heating# 1


/or the cold continuous casting "illets from outside) they +ill "e hanged han ged to the the

feedin fee ding g roll ta"le ta"le "efor "efore e the reheat reheating ing furna furnace ce

through the transporting roll ta"le and after the centering of the the centering roll ta"le the continuous casting "illets +ill "e sent to the reheating furnace for heating# 

The

heating

furnac ace e

heat ats s

the

square

"ill lleet

to

the

temperature of 11&'01*&'2 as required "y the technology# 

The heating furnace is pusher heating furnace# furnace# The materi material al

feeding and discharging is one the ends# 

Thee pu Th push sher er +i +ill ll pu push sh th the e he heat ated ed squ quar aree "i "ill llet et on th thee

roller# 

The conformity square "illet goes through the former roller

and centered "y guide# Then it comes into &&' rolling mill for repeating milling# 

3hen 3h en mi mill llin ing) g) th ther ere e ar are e di diff ffer eren ent t ro roll ller er se sequ quen ence ce fo forr

diff di ffere erent nt pr prod oduc ucts ts# # /o /or r && &&' ' ro roll lling ing mi mill ll) ) it is &0 &044 se seque quenc nce# e# After cutting) it goes into roller for con5eying and then comes into 1' sets of rolling mill# The production of angle steel is made "y 11 sets of rolling mill# Among the 11 sets of rolling mill) there is 1 roughing mill) 6 sets of intermediate mill and 7 sets of fine mill# The production of channel is made "y &04 sets of machine) in +hich 1 is roughing mill) 6 intermediate mill and * fine mill# 

/or &&' rolling mill) there is entrance guide and steel

plate in the front of machine# Also there is lifting platform on thee "e th "ehi hind nd of ma mach chin ine) e) so as to en ensu sure re th thee fr free ee op oper erat atio ionn of milling# 2


/or the cold continuous casting "illets from outside) they +ill "e hanged han ged to the the

feedin fee ding g roll ta"le ta"le "efor "efore e the reheat reheating ing furna furnace ce

through the transporting roll ta"le and after the centering of the the centering roll ta"le the continuous casting "illets +ill "e sent to the reheating furnace for heating# 

The

heating

furnac ace e

heat ats s

the

square

"ill lleet

to

the

temperature of 11&'01*&'2 as required "y the technology# 

The heating furnace is pusher heating furnace# furnace# The materi material al

feeding and discharging is one the ends# 

Thee pu Th push sher er +i +ill ll pu push sh th the e he heat ated ed squ quar aree "i "ill llet et on th thee

roller# 

The conformity square "illet goes through the former roller

and centered "y guide# Then it comes into &&' rolling mill for repeating milling# 

3hen 3h en mi mill llin ing) g) th ther ere e ar are e di diff ffer eren ent t ro roll ller er se sequ quen ence ce fo forr

diff di ffere erent nt pr prod oduc ucts ts# # /o /or r && &&' ' ro roll lling ing mi mill ll) ) it is &0 &044 se seque quenc nce# e# After cutting) it goes into roller for con5eying and then comes into 1' sets of rolling mill# The production of angle steel is made "y 11 sets of rolling mill# Among the 11 sets of rolling mill) there is 1 roughing mill) 6 sets of intermediate mill and 7 sets of fine mill# The production of channel is made "y &04 sets of machine) in +hich 1 is roughing mill) 6 intermediate mill and * fine mill# 

/or &&' rolling mill) there is entrance guide and steel

plate in the front of machine# Also there is lifting platform on thee "e th "ehi hind nd of ma mach chin ine) e) so as to en ensu sure re th thee fr free ee op oper erat atio ionn of milling# 2




Bet+eenn roughin Bet+ee roughing g rollin rolling g and intermediate rolling) rolling) there is

a tracea"le head for mill# 

The hot shearin shearing g is instal installed led "et+een roughing rolling mill

and intermediate mill# The hot shearing is used for cutting# 

/or fine mill) stand looper is installed in order to ensure

the micro8tension rolling# 

Before entering the cold "ed) the rolled profile "ars need

to "e sa+ed into t+o pieces first and then "e sent to the cold "eds for cooling# After cooling) the straightening +ill "e made# And the straightened profile "ars +ill "e fi9ed8scale sa+ cut in the cold sa+ing group +ith 11 cold sa+s# After this process the prof pr ofil ilee "a "ars rs +i +ill ll "e de dete tect cted ed an and d th then en "u "und ndle led) d) +e +eig ighe hedd an andd pac:ed# 

Accordin ing g

to

the

si;e)

determin ine e

the

straig ighhtening

equi eq uipm pmen entt fo forr pr prof ofil ile e "a "ar# r# /o /or r sm smal all l si si;e ;e)) ,' ,''' st stra raig ight hten enin ingg machine is used# /or "ig si;e) &'' straightening machine is used# 

,#1 Annual output Angle Ang le ste steel el *#& *#&0=> 0=>) ) cha channe nnel l ste steel el &01 &017>) 7>) flat ste steel el 1'0 1'0*'( *'(1'0 1'06'# 6'# The total annual output of hot rolling is 1&''''T# ,#*
1*'@1*'@,'''

?quare "illet si;e allo+ed tolerance% Allo+ed tolerance of thic:ness &#'mm Allo+ed tolerance of +idth

&#'mm

Allo+ed tolerance of length

='mm 3

1&'@1&'@,'''


,#, /inished products ?i;e and +eight of finished products% Angle steel

Angle steel $o#

*#& , ,#& 6 6#& & 7 4 =

"

?i;e d

r

*& ,' ,& 6' 6& &' 7' 4' ='

, , ,#& 6 & & 7 4 =

,#& 6#& 6#& & & &#& 4 = G

2m* ?ection area 2m*

CgDm Theoretic quantity CgDm

1#6,* 1#46G

1#1*6 1#,4,

*Dm Futside surface area *Dm '#'G= '#114

,#'=7 6#*G* 6#=',

*#6** ,#,7G ,#44'

'#1&4 '#147 '#1G7

G#6*6 1*#,',

4#,G= G#7&=

'#*4& '#,16

Angle steel leg thic:ness tolerance -d.% HD8'#6&> angle steel HD8'#7 FG> angle steel Angle steel leg length tolerance -".% HD8'#=&> angle steel HD8 1#* FG> angle steel 4


Total length tolerance of angle steel% =''' H&'D' # I=''' H='D' 2hannel steel

odel

& 7 7#& = 1' 1* 16 17

?i;e h

"

d

t

r

r1

&' 7' 7& =' 1'' 1*' 16' 17'

,4 ,' 6* 6& &' && 7' 7&

& 7 7 7#& 4 4 = =

4 4#& 4#& = =#& G G#& 1'

4 4#& 4#& = =#& G G#& 1'

,#& ,#4& ,#4& 6 6#*& 6#& 6#4& &

2hannel height tolerance -h.% hJ1'' HD81#& 2hannel leg +idth tolerance -".% K"J1'' HD8* 1&'J"J*''

HD8*#& 5

2m* ?ection area 2m*

CgDm Theoretic quantity CgDm

=#666 1'#*6 1*#46

7#7, =#'6 1'

*1#,1 *&

17#4, 1G#46

1''JhJ*''

HD8*

HD81#& 1''J"J1&'


2hannel leg thic:ness tolerance -d.% dJ1'' HD8'#6 1''JdJ*'' HD8 '#& Total length tolerance of channel% =''' H&'D' # I='''

H='D'

/lat steel

3idth

Thic:ness

$ominal si;e 1'0*& *&06'

$ominal si;e H'#&D81#' H'#&D81#'

MNOQRK≤6'''

1' 1*0*'

H,'D' # 6'''07'''

H'#*D8'#6 H'#*D8'#6

H&'D'

7''' S

H4'D' Total length tolerance of flat steel% 6''' H&'D'

H,'D' # 6'''07'''

7''' a"o5e H4'D'

4.

6#1. The hot transporting chain8type con5eyor% 1 set /unction% The hot "illets from the continuous casting de5ice +ill "e directly transferred "y this set of chain8type con5eyor to the reheating furnace feeding roll ta"le# 6


The ma9imum +eight of the transferred pillets% &*7#&:g The ele5ation of the deportation chains% to "e determined "y the metallurgical furnace# Transporting speed% '#1 U'#,mDs# Vri5ing manner% single direction The space of the the chains% =''mm The quantity fo the chains% fi5e pieces Transmission mode% one group transmission Transmission motor% A2 **C3 6#*. /eeding roller ta"le

, sets

/unction% recei5e the "illet from the hot transporting and sent them to feeding port of furnace# a9# +eight for sending% 6(&*7#&CgDtime
nX*'

* sets

/unction% for dou"le8array feeding and pushing for heating furnace odel% hydraulic pushing type 7


Push force% G'@*TX1='T a9# stro:e% 17''mm [ydraulic station motor% A2 *@G'C3 6#&.
nX1*

nX1* 8


nX1*

in# diameter% &1'mm

a9# 71'mm\


/i9ing type of intermediate roller% angle ta"le `pper roller "alance type% pressure spring "alance `ni5ersal direction a9is "alance "rac:et% adopting or refer to currently used 7&' rolling mill "alance "rac:et# /ly+heel de5ice% 1 set /ly +heel distance% ]V*X*6'C$8m* ?peed reducer% 1 set odel% ZV16' AX16''mm nX*' iX7#==4 reference 5alueb Lo+ speed a9is a9# output moment% &&'C$#m AX*9&&'mm n_*& iX1 ]ear machine seat% 1 set AX*9&&'mm n_*& iX1 Allo+ed handing8o5er8moment% &&'C$#m 2onnection de5ice% 1 set $ylon "ar pin coupling and uni5ersal a9is and "rac:et ain motor% 1 set odel% Y<1*&'81'D16,' Po+er% 1*&':+
face

ele5ation%

a"out

=''mm

-according

to

aperture

conditions.

nX1*'

Vri5en mode% separating 1 set of dri5en Vri5en motor% YZ<**&8=

**C3 4*'rDmin

&#*. 3or:ing roller ta"le "efore the roughing mill and the tilting plate% 1 set /unction% used to recei5e and send "illet for roughing role process a9# +eight for rolling "illet% *@16&'Cg
face

ele5ation%

a"out

=''mm

-according

to

aperture

conditions.
nX&

nX1'

Vri5en motor% YZ<*&'18= ,'C3 4*&rDmin &#,. Lifting ta"le "ehind the roughing mill

1 set

/unction%The rolling mill +ith three rollers has the upper and the lo+er rolling line# The lo+er rolling line is transported the rolled pieces "y the roll ta"les) +hile the upper rolling line is transported the rolled pieces "y this lifting ta"le "ehind the roughing mill# And the rise8and8fall and the rotation of the lifting ta"le are all carried out "y the machinery#

1 set

/unction% used to recei5e and send the rolled "illets in the roughing milling process a9# +eight for sending "illet% *@&*7#&Cg
face

ele5ation%

a"out

=''mm

-according

to

aperture

conditions.
nX1'

a9# 6G' mm\


[olding8do+n de5ice% * sets for each Type% manual regulation [olding8do+n stro:e% a"out1''mm -reference 5alue. oint speed reducer% 6 sets 2onnection de5ice% 6 sets $ylon "ar pin coupling and uni5ersal a9is and "rac:et ain motor% Z500-3A 4#1.

/ront

roller

7''C3 of

&''81*''rDmin 6 sets

C7

intermediate rolling mill

machineDThe

roll

ta"le

"ehind

the

1 set

/unction% used to recei5e finishing milling parts and send them into C7 machine a9# +eight for sending "illet% &*7#&Cg
face

ele5ation%

a"out

=''mm

-according

conditions.
nX1=

4*'rDmin

a9# ,G'mm\

to

aperture


Type% manual regulation [olding8do+n stro:e% a"out ='mm -reference 5alue. A9ial regulation% according to a9ial regulation de5ice of "ar rolling mill of same specification of company
7''C3

&''81*''rDmin

7 sets

=#1. The roller ta"le "ehind the fine rolling /unction% used to recei5e the rolling parts from C1 and send them into cold "ed# a9# +eight of sending "illet% &*7#&Cg
face

ele5ation%

a"out

=''mm

-according

to

aperture

conditions.
nX&4

/unction%Voing segmenting sa+ cutting to the hot8milled profiled "ars# Because of the temperature of the final hot mill is "et+een =&'UG&'2) the hot sa+ is needed#

1 Processing condition and parameter 2on5eying and cooling of rolling parts% channel &>817> steel *#&>8=> flat steel 14

angle


a9# +eight of rolling part% &*7#&:gDpcs

/unction% fi9ed on the side of front roller of cold "ed) used for pulling the rolling part to cold "ed quic:ly to a5oid "loc:ing# Type% multi8cla+ pusher -or adopt companys hori;ontal carrier organ type. ?tro:e of pusher cla+% 4''mm Vistance of pusher cla+% 7'''mm Pusher cla+ higher than roller% 1*'mm a9# transferring time% ,' timesDmin Vri5en mode% motor dri5e 1'#6. The output roller ta"le "ehind the cold "ed% 1 set /unction% for transferring the cold8rolled part to straightening machine for straightening
11#1 The roller ta"le "ehind the &'' straightening machine% 1 group /unction% used to recei5e the rolling parts from &'' straightening machine and send them into ,'' straightening machine#
nX*

1*#1. The roller ta"le "ehind the ,'' straightening machine % 1 16


group /unction%

used

to

recei5e

the

rolling

parts

from

the

,''

straightening machine and send them into the length8scaled roller ta"le
nX*

/unction\ used to recei5e the rolling parts from the straightening machine and cutting them into ruler material after cooling#
nX6,

11C3

?tructure requirement% a# /or structure design roller) the installation "et+een cold sa+ing units and hori;ontal mo5a"le machine shall "e considered# "# The upper of roller shall "e equipped +ith pneumatic lifting pressing positioning de5ice to ensure the sta"le sa+ing# c# The end of roller shall "e set +ith positioning "affle#

 Voing segmenting sa+ cutting to the profiled "ars after cooled from the cold "ed# 17


/unction% is equipped on the end of front roller of cold "ed for positioning of roller part# Type% spring "uffer type a9# +eight of rolling part% &*7#&:gDpcs Fperation speed of rolling part% ma9# 7mDs Baffle si;e% +idth (height 7''@*&'mm -"affle is 1&'mm higher than roller.

/unction% used to tra5erse the scaled material after sa+ing from the sa+ing roller ta"le to the pac:ing and transporting roller ta"le# And the chec:ing process +ill "e carried out during the transporting process# Tra5erse material si;e% U17>) angle steel% *#&> U =>
nX61 18


Pac:ing the sa+ed short8length profile "ars "y this pac:ing machine# G'''@1*'''mm b# And the pac:ing process is doing "y the +or:ers#

Pac:ing the sa+ed fi9ed8length profile "ars "y this pac:ing machine# G'''@1*'''mm b# And the pac:ing process is doing "y the +or:ers#

/unction% used for positioning of "illet at the end of the pac:ing rac: Type% spring "uffer type Buffering "illet +eight% 1*,':g Billet speed% 1#& mmDs Baffle face si;e% 7''@,''mm -*''mm higher than the upper surface of roller.

19


!

The equipments for profiled "ar production line mainly include% &&' roughing mill) 6&' intermediate mill and ,&' finishing mill\ ingot pusher) furnace deli5ery ta"le) front roller ta"le of roughing mill) rear lifting platform of roughing mill) rear roller ta"le of roughing mill\ rear roller ta"le of intermediate mill\ rear roller ta"le of finishing mill\ front roller ta"le of cooling "ed)

cooling

"ed)

cooling

"ed

flat

carrier\

cooing

"ed

transferring steel) rear roller ta"le of cooing "ed\ front) middle and rear roller ta"le of straightening\ sa+ cutting length roller ta"le\ pusher\ off8si;e run8out roller ta"le\ "unch run8out roller ta"le\ 1> thin oil station) *> thin oil station) +ater treatment system) etc## ain equipments supplied "y the equipment plant% hot sa+ing equipment) &'' straightening machine) ,'' straightening machine) pac:ing machine and air compressor station) etc#

Total installed capacity of &&' roughing mill) 6&' intermediate mill and ,&' finishing mill is 4*&' :3# *#1 &&' roughing mill uses high pressure motor of 1*&' :3 1''''^) of +hich the soft start is reali;ed "y liquid soft8start ca"inet# *#*

ain dri5e of 6&' intermediate mill and ,&' finishing mill

rolling

line

is

"y

V2

motor)

installed

capacity

of

6&'

intermediate mill is 6@7''X*6'' :3) "y use of controlled silicon V2 po+er supply# *#, nstalled capacity of ,&' finishing mill is 7@7''X,7'' :3) "y use of controlled silicon V2 po+er supply# 2


*#6 T+o8le5el automation control system is composed of PL2 and industrial computer) to complete the automatic control of full line equipments# t is an open computer control system) ha5ing a space for adding a three8le5el production management system#

,#1 F5erall performance and characteristics of control system% ,#1#1 Each operating "oard is operated "y uni5ersal touch screen) connected "y P
on full consideration

of the

functions) to reduce equipment as +ell as faults# ,#* 2ontrol functions in rolling mill area% ,#*#1 manual control of all equipments in this area ,#*#* segmental emergency stop function 21

reali;ation

of


,#*#, automatic and manual operation function ,#*#6 cascade control of frame speed ,#*#&

minimum

tension

control

of intermediate and

finishing

rolling ,#*#7 logic control of rolling mill startDstop ,#*#4 human8computer interface% a. equipment operating status parameter display ". setting of rolling parameter c. faults) display and alarm of e5ents d. dynamic

simulation display

of

rolling

lines

and

5arious

equipments ,#, Technical functions of intermediate mill and finishing mill dri5e system ,#,#1 ]eneral requirements of intermediate mill and finishing mill dri5e system /or the equipment supplied) it shall ensure reali;ation of 5arious control functions and satisfaction of the performances required "y production) and sta"le as +ell as sta"le and relia"le operating in a 5ariety of en5ironments) +ith con5enient maintenance) lo+ fault rate and simple operation# ,#,#* 2haracteristics of intermediate mill and finishing mill dri5e ca"inet ,#,#*#1 dri5e ca"inet is re5ersi"le e9citation system\ ,#,#*#* static property satisfies '#1k) and dynamic property satisfies '#&k# ,#,#*#,

protection

requirement%

dri5e

fan)

po+er

components

temperature protection# ,#,#*#6 insulation of incoming line ;one# ,#,#*#&

+ith

such hard+are

+ith

0**'^

for

Profi"us8VP

communication

as

required ,#,#*#7

soc:et in the

lighting# 22

ca"inet

and

self8pro5ided


,#,# ,# ,#*# *#44 ea eart rthi hing ng fo for r co comp mput uter er an and d in inst stru rume ment nt an andd ca ca"i "ine nett is designed separately# -details can "e determined "y the user#. ,#,#, Electrical dri5e of V2 main dri5e Thee ma Th main in dr dri5 i5ee of in inte term rmed edia iate te mi mill ll an and d fi fini nish shin ingg mi mill ll is V2 dri5e) and +ill ta:e ?iemens all8digital 7
de55ic de ice e

or

E`
comp co mpan anyys

??V& ?? V&G' G'

re5e re 5ers rsi" i"le le

e9pansion de5ice) `C as control system# ,#,#6 Vri5e de5ice has the follo+ing functions% 888 o5erload protection for motor\ 888 o5ercurrentDcurrent limiting protection for e9citation\ 888 o5ercurrent protection for thyristor\ 888 instantaneous o5er8current protection for motor\ 888 A2 o5er5oltageDunder85oltage protection\ 888 lac: phase protection\ 888 phase sequence protection\ 888 o5er5oltage protection for motor\ 888 function of communication +ith PL2\

 start) stop and emergency stop control of rolling line\  cascade speed setting of rolling line\  automatic cascade control\  minimum tension control\  adapti5e control of speed setting\  self8diagnosis of system\  fault alarm and e5ent record\  print report -such as shift report) daily report.\  net+or: communication#

otor parameters of roughing) intermediate and finishing mill 23


$o#

1 *

,

Equipment name

Electrical equipment

ty#

&&'
ain motor

1

Y<1*&'

1*&'

&=&

1''''

A2

ain motor

6

Z&''8 ,A

697''X*6''

&,*81*''

77'

V2

ain motor

7

Z&''8 ,A

797''X,7''

&,*81*''

77'

V2

?u"total

11

od odel el

ain technical data Po Po+e +err -: -:+. +.
ôltage -^.

Po+er supply

4*&'

2onfiguration for V2 dri5ing de5ice of intermediate and finishing mill system 7#1 V2 dri5e po+er part Adop Ad optt ?i ?iem emens ens 7< 7

control of all lo+ 5oltage dri5ing equipments from the discharging roller ta"le "ehind the finish rolling mill to the "unch run8out roller ta"le) from hot sa+ing equipment to air compressor station equipment\ 7#, Program of automation system 7#,#1 ]eneral description Esta"lishing an automatic control system) not only shall meet the technology requirement in site production) "ut also shall pro5ide a fle9i"le) con5enient human8computer interface for the user# n terms of the reali;ation) or of the relia"ility) easy operation and

continuous

ser5ice)

it

is

a

comprehens nsii5e

test

to

the

auto au toma mati tion on sy syst stem em# # ?u ?umm mmin ing g up th the e pr pro oec ects ts +e ha ha5e 5e ma made de)) an andd ta:i ta :ing ng in into to ac acco coun unt t th the e ad ad5a 5anc nced ed co cont ntro rol l pr prog ogra ramm of fo fore reig ignn similar enterprises) +e adopt a distri"uted control system program made

up

"y

computer

net+or:)

+hich

fully

reflects

the

decentrali;ed control) centrali;ed management of modern computer8 controlled concept# The lo+er computer in this system is responsi"le for acquisition and preliminary processing of data in the site) and the upper computer is to complete other management tas:s in the system# 3e pro5ide the program of automation control +ith t+o8le5el net+or: control as follo+s%  on8site dri5e) remote control net+or: 8 P

as reference speed) in front of +hich) the speed of frame is set in proportion automatically

according

to

the

principle

that

metallic flo+ is equal# Vuring rolling process) +ith manual inter5ention of adustment quantity) increase and reduce the speed of all frames in front of it in re5erse rolling direction in order# 3hen rolling different si;es of steel) o"tain the specified end frame no# and corresponding highest rolling linear speed ^La9 from rolling ta"le) as +ell as total percentage of current selected rolling ^Lk) so it can calculate the frame speed ^L?# 7#,#*#* inimum tension control inimum tension control adopts current memory method# t indicates the period that +hen the steel head is gripped "y the no# n rolling mill) after the dynamic speed drop of motor is restored) "efore this steel is gripped "y no# nH1 rolling mill# /or no# n rolling mill) in relation to free rolling +ithout "ac: tension) after filtering) the rolling current sampled at this time is that of no# n rolling mill) and is memori;ed# 3hen this steel is gripped "y no# nH 1 rolling mill and the dynamic speed drop of motor is restored) after filtering) the current of no# n mill is sampled again) and is compared +ith the memori;ed one) from +hich the de5iation can "e used for adusting the rolling speed of no# nH1 mill so that the de5iation is ;ero# 7#,#*#, 2ompensation control of dynamic speed drop 3hen the head of rolled piece is entered the rolling mill) the speed +ill reduce suddenly# To ensure to maintain the second flo+ "alancing

"et+een

frames

for

an

instant

of

"iting) and

to

successfully complete looping among frames +ith loopers) set a dynamic

compensation

5alue

-'#G=01#'*.)

multiplied

"y

speed

setting 5alue of this frame) as the speed 5alue +hen "iting) after completion

of

dynamic

speed

drop

compensation 5alue# 26

of

"iting)

+ithdra+

the


7#,#*#6 2rop end control of hot shearing /or flying shear control) there are t+o detection circuits% one is cutting edge position detection circuit) composed of coded disc on cutting edge shaft and high8speed counter of PL2# Another one is the detection circuit of rolled piece head) end from [V to hot shear) composed of coded disc mounted on the upstream frame) [V and high8speed counter of PL2# The speed setting of hot shear is gi5en "y follo+ing formula%

^rX^cCs

n +hich% ^r% set 5alue of hot shear position ^c% speed of upstream frame Cs% ad5ance coefficient of speed -&01&k.
2[`X21H2[L82*82,

n +hich% 2[`% accumulated pulse count required "y starting of crop end 21% pulse count from [V to cut point 2*% pulse count corresponding to system response time 2,% pulse count corresponding to shutdo+n position to cut point 7#,#*#& ?peed and motion control of pinch roll t is "etter that the speed of pinch roll is generally set 10&k ahead of the linear speed of front frame# There are three types of motion for pinch roll% 27


/ull pinch [ead and tail pinch Tail pinch The selection of pinch method is completed "y the operation station# 7#,#*#7 nterloc:ing of rolling line and hydraulic) lu"rication station and +ater treatment system As an independent system of hydraulic station and lu"rication station and +ater treatment system) it must ha5e such signal as ready) fault and so on sending to PL2# As an integral part of ready for +hole line) if the +hole line is not ready) it cannot run# f the +hole line runs) "ut hydraulic station or lu"rication station or +ater treatment system fails% for light fault) stop tapping of heating furnace immediately\ send out alarm signal\ if the fault is still e9isted after three minutes -this period of time is +aiting for completion of rolling in current rolling line.) shut do+n in corresponding area# /or maor fault) the +hole production line should "e stopped# 7#,#*#4 Fperation of rolling line equipments There are normally t+o operating modes of automatic and manual for rolling line equipments# /or dri5e system) it is fitted +ith inching operation -generally) inching setting 5alue is & U1'k.# 3hen

selecting

automatic

mode)

all

equipments

automatically

complete rele5ant actions in order according to the function) interloc:ing

condition

and

process

control

requirement#

3hen

selecting manual method) all equipments are operated randomly "y operators according to safe interloc:ing conditions# The

speed8regulating

dri5e

equipments

are

operated

"y

corresponding set 5alues gi5en "y operation station) +ith speed and manual fine8adusting -com"ined adusting) single adusting. 28


compensating speed operation# nching operation for all dri5e equipments is set for local operation ca"inet# 2ontrol

of

the

operation +ith lo+

real8time

requirement

is

completed "y the operation station -such as% F$DF// operation of dri5e systems) startDstop operation) operation of equipments and selection of control mode) local operation allo+a"le) rising and dropping operation of looper rising de5ice) etc.# 2ontrol of the operation +ith high real8time requirement is completed

"y

appliances

on

the

operating

"oard

-such

as%

operations related to manual inter5ention of equipment speed) emergency stop) emergency fault handling) etc.# The maintenance operation for equipments and roller changing of rolling mill are carried out on the local operation ca"inet#

The system is totally set t+o8le5el net+or:) of +hich VP net+or: is di5ided into t+o lines# Fnly the regulation ca"inet of main rolling mill is lin:ed to this net+or:) +hich is to ensure that the regulation ca"inet has rapid response) so that it may adapt to a large num"er of computing upon closed8loop control of speed and minimum

tension

transmitting operating

control)

"et+een

"oard

and

there

regulation local

are

large

ca"inets#

operation

ca"inet

num"er The

of

control

+ill

carry

data for out

transmission through the second VP net+or:) +ith small data transmitted "et+een them# The data acquisition and monitoring of upper computer is transmitted "y industrial Ethernet) of +hich the control le5el is increased successi5ely# 4#1 ?ite transmission VP net+or: t comprise of ?486''PL2 and 1' sets of V2 speed8regulating de5ices through communication "oard# $amely) this net+or: completes the follo+ing control for V2 speed8 29


regulating de5ices%

PL2 → V2 speed8regulating de5ice%

?tartDstop signal nching command signal for+ard and re5erse signal ?pecified setting

signal

-including%

general

setting)

single

setting) cascade setting. V2 speed8regulating de5ice →

PL2

Vri5e system status
reali;ation

of

startDstop

control)

logic

control

and

interloc:ing protection of +hole line\ *. setting and cascade control of single machine of frames ,. minimum tension control of intermediate rolling\ 6b5ertical looper control 4#* The system is a distri"uted control system -V2?. made up "y L* net+or: +hich has the characteristic of handling field "us# The local signal is handled automatically "y intelligent electrical terminal -such as% V2 speed8regulating de5ice.) +ithout ha5ing to request the inter5ention of the master station) "ut is su"ect to the macro control of master station) so that the master station may sa5e lots of times to handle more and more critical tas:s -such as% calculation of closed8loop speed and minimum tension setting) etc.# 4#, ?486'' of PL2 is the fastest 2P` in ?4 series PL2 +ith VP port 3


series# As the field "us technology is applied) a lot of signals are handled in the site) and using a single 2P` can complete the proect +ith such a large computing tas:) so as to sa5e costs for the manufacturer# n addition) only the small frame structure of P
connection

"et+een

electrical

terminals

can

"e

su"stituted respecti5ely -such as% operating "oard to controlled silicon room) etc) large num"er) long distance) point8to8point connection.) +hich not only sa5es lead +ires) "ut also reduces the terminal nodes) and reduces the fault rate as +ell as the maintenance +or:load#  f some station in the net+or: fails or is maintained) it +ill not affect the operating of +hole net+or:#  A maor difference "et+een digital system and simulation system is that it +ill not ha5e null shift) +hich has gi5en a strong assurance for system relia"ility and reduces maintenance +or:load# 4#& 2on5enient commissioning and maintenance n the dri5e regulation ca"inet is set +ith necessary s+itching 5alue

and

signal)

so

it

can

complete

commissioning

of

the

regulation itself +ithout any inter5ention of other equipments# The digital system is not necessary to "e maintained) and the intermediate

relays)

contactors)

indicator

lamps

and

other

equipments can "e detected "y state ta"le of PL2 system and forced 5aria"le ta"le# 4#7 ndustrial Ethernet 4#7#1 ]eneral description t is a full protocol net+or: in accordance +ith ]erman V$1G*6& 31


standard) +hich has "een authori;ed "y Europe) e5en the +hole +orld# ts protocol is same as L*8VP net+or:s) "ut the function is stronger than L*8VP net+or:) and has +ide compati"ility) more suita"le for mass data e9change# 4#7#* $et+or: functions t completes the functions as follo+s% a. monitoring of operating conditions of +hole line equipments) real8time

simulation

of

such

process

as

startDstop)

steel

carrying) risingDdropping looper and so on\ ". real8time display of digital quantity of main parameters\ c. display of rod8shaped real8time diagram of analog quantity of main parameters\ d. real8time display of system single line diagram\ 4#7#, ain screen A# ain screen Po+er

on

and

self8chec:

the

system)

after

net+or:

contact

detection) enter into the first screen in the system) it +ill display 5ersion num"er and main menu) so +hen the user is operating) it is not necessary to return to the main screen) you can s+itch to other screens directly\ B# onitoring screen of host computer n order that the personnel not in the site can +atch the rolling process) it can real8time simulation startDstop) steel carrying) risingDdropping looper and other processes) and display of digital quantity

of

main

parameters)

total

setting)

single

machine

setting) actual linear speed) actual rotation speed) armature current) armature 5oltage) e9citing current) etc# 2# aintenance reference screen The screen displayed is the same as the monitoring screen of host computer) "ut adding digital display of linear speed setting) rotation speed setting) for maintenance personnel to de"ug\ 32


V# ?ystem single line diagram Visplay flat roll) main circuit situation) for operation personnel to monitor\ E#
quality

centrali;ed

of

the

monitoring

system)

management

+hich for

greatly

facilitates

operating

maintenance

personnel\ #
the

operation

situations

of

machine

unit

and

main

parameters in chronological order and print) to replace manual operation\ C# [istoric fault inquiry
the

operation

situations 33

of

machine

unit

and

main


parameters in chronological order and print) to facilitate inquiry and to pro5ide "asis for routine maintenance\

!

1#1 otor -Brand% ABB.) one open and one stand8"y odel% Y* 1,*86 Po+er% 4#&C+
,#1 The dilute oil tan: is "etter to "e installed in ground channel) thus the oil may flo+ smoothly and freely and the oil liquid of speed reducer +ill not o5erflo+#

-1. otor -Brand% ABB.) one open and one stand8"y odel% Y* 17'L86 Po+er% 11 C+
The dilute oil tan: is "etter to "e installed in ground channel) thus the oil may flo+ smoothly and freely and the oil liquid of speed reducer +ill not o5erflo+#

!

ndustrial ?er5ices 2orporation in ?yria is preparing a ne+ plate production line) +ith one *&tDh pusher8type heating furnace as a 36


complete set# This item is a turn:ey proect and +e are the general contractor for design) equipment supply) construction) installation) "a:er) commissioning and production#

 1 b
circuit

system)

+ater)

electricity)

nitrogen

and

compressed8air system) steam system#

-1.
37


-1. /uel and calorific 5alue% hea5y oil) G7''(6#1=CD:g -*. Billet "loom si;e% 1&'(1&'(7'''mmw1&'(1&'(,'''mm -,. ?teel species% car"on structural steel) lo+8alloy structural steel) etc# -6. 2harge and discharge temperatures of "illet% charge temperature of "illet% 4'' x='' x w the cold charged temperatureK*'x discharge temperature of "illet% 11&'x81*&'x -&.
-1. The top and "ottom of the furnace supply heat) +ith heath temperature uniformity in furnace area# ?etting partition in furnace to control furnace temperature and furnace press easily) and to reduce interference in segments# -*. The reheating furnace sets 6 5ertical +ater pipes to satisfy the request of

"illet distri"ution# Across +ater pipe uses T

type support# To eliminate +ater pipe "lac: mar:ing a"solutely and to reduce cross8section temperature difference of "illet) the design lea5es certain length of true hearth in soa:ing ;one) and staggeres the soa:ing ;one slide and the furnace floor tu"e at the 38


same time# [eat resistant slider uses Z]2r*&$i*'# -,. The furance ta:es ad5antage of high8pressure fuel no;;le +ith steam atomi;ation) and +e decide to use saturation steam to atomi;e the fuel as considering that the steam press of furnace contact point is '#=pa# -6. [ea5y oil is heated "y the spiral8plate heater on the front furnace platform) the outlet temperature of hea5y oil is 16'x) and the heating medium of plate

heater is superheated steam +ith

the temperature of *&'x# -&. Air heat e9changer and steam superheater are set in the flue# Air

preheated

temperature

is

6&'x)

and

steam

o5erheated

temperature is *&'x# The chimney inside the furnace is structured "y the concrete and the refractory materials\ the chimney outside the furnace is ,'m high and constituted "y the

three parts% the

"ottom part +ith the height of 1'm and the diameter of 1#7m -+elded "y the steel plate of *'mm.\ the middle part +ith the height of 1*m and the diameter of 1#*m -+elded "y the steel plate of 1'mm.\ the top part +ith the height of 7m and the diameter of '#=m -+elded "y the steel plate of 7mm.# The connections of the three parts are connected "y the flanges and integrally assem"led to fit the condition of the 1&':mDh +ind speed# The outlet diameter of the outside chimney is '#=m and the natural discharge of the smo:e is ta:en use of for the furnace# The temperature of the flue inside the furnace is 7''04''x) and the temperature of the "ottom of the outside chimney is *''0,''x# -7. Fil supply system uses main pipe for returning oil-"efore heater. to sta"ili;e oil press) and does not set oil return de5ice in other segments# -4. Vesigning light oil system +hich imports from main pipe and only is used for starting and stoping the furnace# -=. 3ater girder in furnace adopt e5aporati5e cooling# 39


-G.
furnace pressure strictly to

minimi;e the heat loss#

1# Adopting a three8section consecuti5e pusher8type reheating furnace +ith "illet end charge and side out# The reheating furnace uses floor +ater pipes +ith o5erhead structure in preheating and heating segments) heating dou"le sides of "illet\ lea5e certain length of true floor in soa:ing ;one to "alance the cross8section difference in temperature of "illet and eliminate +ater pipe "lac: mar:ing# ?oa:ing ;one uses true floor +ith pin: fused alumina# The reheating furnace ta:es use of t+o8segment furance temperature control for the soa:ing segment and the heating segment# The roof of the furnace ta:es the scre+do+n structure) and all no;;les are installed on the +all of the upper

and lo+er sides of the

furnace# The com"ustion control system of the reheating furance has t+o 4


control segments) that is soa:ing segemnt and heating segment) +hich

can

satisfy

the

request

of

heating

temperature

and

difference in temperatureof "illet# The reheating furnace sets 6 5ertical +ater pipes to satisfy the request of

"illet distri"ution# Across +ater pipe uses T type

support# Ta:ing natural draft and do+n draught as the flue gas e9hausting method#

Total length of the reheating furnace masonry%

17,''mm

Effecti5e length of the reheating furnace

1&,''mm

nnerl +idth of the furnace

7=''mm

[eight of the upper hearth

1400mm

[eight of lo+er hearth

$o 1 *

, 6 & 7 4

= G

1800mm

$ame purpose of the furnace [eating steel species

`nit

Billet specification /urnace approach temperature of "illet [eating temperature

mm

/urnace output ?teel pressure intensity of furance floor /uel z lo+ calorific 5alue
tDh

Vata Billet heating "efore rolling 2ar"on construction steel) car"on construction quality steel) lo+8 alloy high8tensile structural steel 1&'(1&'(7''' 1&'(1&'(,''' *'x as cold installed 700x-800xas hot installed 11&'x81*&'x

°2 °2

mP*P#h CDmP, ]Dt { 41

[ea5y oilKG7''(6#1= 2old installed

1#*G7]Dt


1' 11 1* 1, 16 1& 17 14

consumption
1=

2ooling +ater consumption

1G

Pressure of the e5aporation cooling system ?team output

*' *1

ain equipment of the e5aporation cooling system

:gDh mP ,PDh mP ,PDh k

='' G''' G,'' 1#' 450

°2

E5aporation cooling |4'''Pa |'#,Pa 2lean circulating +ater 1''tDh) tur"id circulating +ater ,'tDh) soft +ater 4tDh '#4=pa

*#&8&#'tDh adia"atic 1''k8G'kb }

~1*''(&''' "oiler drum one piece

Locating the qualified "illets from charging stage on the roll ta"le out of furnace) pushing the "illets into the furnace "y the steel pusher) through the heating of preheating) heating and soa:ing segments) arri5ing at the tapping platform) pushing them out from the side of the furnace "y the steel pusher

and entering

into the rolling line# T+o pushers not only can run seperately) "ut also can run together#

The roof +all of the reheating furnace adopts the comple9 masonry +or: structure +ith monolithic cast) and the furance floor ta:es the comple9 masonry construction\ the furnace "ody has good performance on heat insulation and good air tightness# 42


According to the temperature) structure and other factors of 5arious parts of the furnace) ma:ing a reasona"le com"ination of the refractory materials to ensure that the ma9imum temperature of e9ternal surfaces for e5ery masonry +or: can reach the national standards# n regular conditions) the furnace +all and the roof can +or: for more than fi5e years# The compositions of refractory materials of the 5arious parts are as follo+s% The composition of materials for the furnace roof%

[igh alumina anchoring "ric:s for the furance roof-L;8&&. Lo+ cement casting material

*,'mm

Perlite insulation material

1''mm

Total thic:ness

,,'mm

The composition of the furnace +all% Lo+ cement casting material

*76mm

Light8+eight insulating "ric:-rX1#'.

117mm

Aluminum silicate fire8proof fi"er felt Total thic:ness

1*'mm &''mm

The composition of fire8proof materials for the floor at heating segment% [igh alumina "ric:

117mm

2lay "ric:

*4*mm

Light "ric:rX1#'b

1,7mm

Viatomite "ric:

1,7mm

Total thic:ness

77'mm

The composition of materials for floor +ater pipe% 5ertical and cross +ater pipes and uprise pipes are all used# /ire8proof fi"er felt

*'mm

?elf8flo+ing casta"le

7'mm 43


Thic:ness

='mm

/urnace shell steel strucrure is +elded +ith profile steel and steel plate) to install and support refractory lining) fi9ed "eam) 5arious pipes of com"ustion system) operation and maintenance platform) installation of furnace door and no;;les) etc#

Fperating

platforms

are

set around

the

furnace and

in

the

operation areas of no;;les) control 5al5es) thermal detection de5ices) etc# And all the platforms are connected +ith passages and ladders) +ith safety railings for the platforms) passages and ladders# The platforms and the passages are made of profile steel and chec:ered steel plates according to the different parts#

•F5erhaul manhole door There is a o5erhaul manhole door on each side +all of the charge end) totally t+o o5erhaul manhole doors) +hich are used for the +or:ers€ in and out of the furnace) material deli5ery and the floor slag remo5al) etc## F5erhaul manhole door specification% &='(1','mm •Vrossing furnace door ?eting up 6 drossing furnace doors on the end +all of the charge end for the slag remo5al# Vrossing furnace door specification% ,&'(*G'mm •Peephole 44


There are many peepholes on the +all of the charge end and the discharge end of the furnace) +hich are used to o"ser5e the furnace condition in the daily producting operation# Peephole specification% φ 1,&mm

The 5ertical and cross +ater pipes of the furnace adopt the e5aporation

cooling) and

the

furance

floor

+ater pipes

are

optimally designed +ith 6 5ertical +ater pipes supporting the "illets and four uprights supporting the cross +ater pipe# The furance floor cross +ater pipe is ~1&G(*& seamless thic:8+all steel pipe) +hile the 5ertical +ater pipes ~1*4(*' and upright +ater pipes ~16'(1=# The semi8hot +ater pipe slide+ay adopts 12r*&$i*'?i*

heat resistant

steel

slider)

and

the

adia"atic

pac:ing of the +ater pipes uses the structure of dou"le8adia"atic self8flo+ casta"le material#As the furnace needs a great amount of +ater for cooling) the t+o 16C3 motors are ta:en for the +ater pump to dra+ +ater- one motor is ta:en for using and the other for spare.# 3hen the electricity is "ro:en) the adopted emergency plan is using the diesel engine +ith ,' horse po+er for the pump +ith the 2AL of *''mm to supply +ater for the furnace# All these three plans can guarantee the safety of the furnace#

The

com"ustion

system

adopts

t+o8segment

furance

temperature

control of soa:ing segment and heating segment# These t+o segments are "oth ta:ing use of high pressure steam atomi;ing hea5y oil no;;les# The heat load is outfitted 1*'k of the reheating furnace *&tDh output# 45


Futfit quantity% hea5y oil is rated at ='':gDh) and the ma9imum is G7':gDh\ The upper and the lo+er heat supply rate% 6&&&# T+o segments heat supply rate% 6'7'#

Air heat e9changer has plug8in "oard) and the air and the flue gas flo+ upstream and staggeringly) dou"le lines and dou"le iourneys# The high temperature pipe unit +hich meets the flue gas uses heat8 resistant steel pipes) and lo+ temperature pipe unit uses "oiler pipes# 3hen the temperature of hot +ind is o5er) the hot +ind +ill escape automatically# Performance of the air heat e9changer% Air preheating temperature% 6&'x a9imum quantity of the preheating air% =4&'mP ,PDh a9imum quantity of the flue gas% G,&' mP ,PDh nlet temperature of the flue gas% 4&'x The com"ustion air is pro5ided "y a fan) preheated "y the air heat e9changer

and deli5ered to the furnace) through pipes in 5arious

segments) flo+ orifice plate) electric control 5al5e to reach the no;;les at corresponding control segments# The hot +ind pipeline is pac:ed outside of the pipe "y the 1''mm roc: +ool and there are some "ello+ e9pansion oints# n lo+ pressure) the air system is easy to form the gas +ith e9plosion concentration in the pipeline) so the light8minded aluminum pressure8relief e9plosion8proof plates are designed to use at the end of e5ery air pipeline) to reduce the harm caused "y the e9plosion# Parameters of the com"ustion fan% uantity% one set /an type% G81G$o1*#&V 46


/ull pressure% G**GUG,1'Pa /lu9% 1*&4481=664 mP ,PDh Electrical machine% Y*='?86
filtering) metering and adusting in the platform) the hea5y oil +ill "e deli5ered to the heat supply segments of the furnace# /urnace hea5y oil pipeline ta:es the main pipe return oil method and the steam ac:et to preser5e heat# The no;;le fogging agent uses the superheated steam) the process is that the steam from the +or:shop through the superheater +ill "e preheated to *&'x U*='x and then sent to the no;;les in the segments# According to the requirements of the com"ustion control) the pipelines of hea5y oil) air and atomi;e are all equipped +ith necessary the flo+ metering and aasusting de5ices#

The furnace adopts the do+ndraught method# The furnace con"ustion 47


products flo+ from the flue located at the "ottom of the charging end to the flue at the "ac: of the furance) then through the steam superheater) the air preheater and the flue adusting 5al5e to the chimney +ith the height of &'m and the e9it dia# of *#*m) and then +ill "e deli5ered outside of the +or:shop# The flue has the cold +ind mi9ed de5ice to pretect the heat e9changer# To recycle the heat from the fume) the air preheater is installed at the discharge to preheat the com"ustion air to 6&'x# The preheater is the t+o8cycle metal8tu"e shape type +ith t+ist plug8 in piece) +ith the steam superheater in the fume entrance side# Pluging t+ist metal sheet in the inside of the metal pipes) on one hand) can increase the air speed and ourney in pipes# on the other hand) "ecause of producing continuous "ac:set and on the effection of centrifugal force) the air in the center of pipes +ill "e mi9ed sufficiently +ith the gas at the "oundary layer of the +all surface to reduce the "ottom of laminar flo+) strengthen the con5ecti5e heat transfer and reduce the pipe +all temperature# To protect the heat e9changer) the hot "last automatic e9hale de5ice is set at the main pipe# The steam superheater is the `8type psse preheater) +hich can superheat the atomi;ing steam heat around *&'x U*='x# The reheating furnace ta:es use of the furnace end do+ndraught# The

fume

passes

through the

air

heat

e9changer)

the

steam

superheater and the flue pressure adusting 5al5e to the chimney +ith the height of ,'m and the e9it dia# of '#=m The rehearting furnace floor pipes and end +all of furnace cooling pipes are all using the e5aporatiom cooling natural circulation system# The design pressure of the drum-steam header. for the e5aporation 48


cooling system is '#4=pa) and it is put in the main rolling span side of the reheating furnace# The standard height of the steam header center is 4#7''m\ the platform of the steam header is 7#&''m high +ith steel structure) and has ,#&''m platform "elo+ it +ith '#''' floor# ?oftened +ater for e5aporation cooling is pro5ided "y the soft +ater station of the factory# The main equipment for e5aporation cooling% one ~1*''(&''' steam header# E5aporation cooling de5ice including% +ater le5el autocontrol) steam pressure autocontrol) +ater le5el and pressure protection signal) etc# The saturation steam from the e5aporation cooling de5ice is piped to the out net of the factory# [eat preser5ation for the pipeline of e5aporati5e cooling system adopts the mineral cotton shell#

Automatic control system includes the process detect and control of the main and assistant installations for the reheating furnace# Fperation mode for this system% hand :ey"oard) PL2 autocontrol# PL2 autocontrol is used in general condition# ?+itch input and output usually use 5oltage of A2**'^ or V2*6^) and

analog input and output use 6 U*'mAV2# The signal of
resistence and T2 thermocouple enter the corresponding analog module directly# The

main

principle

of

design 49

is

that

according

to

the


technological conditions and requests) designing the automatic control system managing the request of

technology and the

consumer# The signals of instrument system are all e9pressed on the computer# To "e con5enient for the operator to directly get the temperature conditions a"out different areas of the furnace out of the operating room) a large display screen is put on the outer +all of the furnace -connected to the control system in the operating

room

"y

the

method

of

communication.)

and

the

temperatures of the different area of the furnace can "e displayed on the screen# This screen can ma:e the operator easily get the furnace +or:ing conditions# According to technology condition) the reheating furnace uses PL2 system) and the system uses puried A2 uninterrupti"le po+er supply-`P?.# Automati;ation control system carry out the follo+ing function% -1. operation station technology process and control menu display control and inter5ention production process affair and alarm display technology parameter current diaplay data communication -*. control station 5arious of temperature)pressure) flu9 measure and alarm collection and disposal of system data -1.system composition According to current technology condition and request) and to increase the system dependa"ility) Automatic control system choose the programma"le controller products from the ?EE$? company for the process detect and control of the reheating furnace# 5


-*. equipments slection /oundation Automati;ation is planned to use ?486'' as the main station of the process detect and control for the reheating furnace) and ET*'' as assistant station of the process detect and control for the reheating furnace# ain items of the heat engineering control and measurement are as follo+s% ‚detect

and

record

t+o8segment

furnace

temperature)

autocontrol of t+o8segment furnace temperature ‚asustion and control of t+o8segment hea5y oil) atomi;ing dose and air ratio ‚indication) record and autocontrol of the furnace pressure ‚indication and control of the main pipe pressure of hea5y oil ‚indication and control of the main pipe pressure of air ‚air temperature alarm and auto8spread ‚atomi;ing steam temperature alarm and auto8spread ‚emergency +ater input control ‚indication and record of the flo+ of t+o8segment hea5y oil) air and atomi;ing dose ‚indication) record and count8up of main pipe flo+ of hea5y oil ‚indication) record and count8up of main pipe flo+ of the steam for atomi;ing and heat preser5ation ‚record and indication of the fume temperature of front and "ac: of the preheater ‚record and indicationof the air preheated temperature ‚record

and

indicationof

the

atomi;ing

temperature ‚cooling +ater main pipe pressure indication 51

air

preheated


‚cooling +ater pumping and drainage temperature indication ‚the current indication for the pressure of hea5y oil and atomi;ing dose "efore the no;;le ‚the current indication for the temperature of hea5y oil) atomi;ing dose and hot "last "efore the no;;le -*.ain control items ‚/urnace temperature autocontrol in the soa:ing segment and the heating segment ‚Adopting the +ind and hea5y oil matching cross limiting autocontrol# 3hen the temperature is on the high side) reduce hea5y oil then reduce +ind\ +hen temperature is on the lo+ side) add +ind first) then add hea5y oil# Temperature lag time compensation# ‚Automatically

cutting

do+n

hea5y

oil

systems

of

each

segments +hen the the pressure of hea5y oil and air is lo+ ‚The fuenace pressure automatically controls the flue 5al5e ‚Emergency +ater automatically input -,.E5oporstion cooling system detection and autocontrol items% ‚anual and automatic control of the pressure of the steam header and the +ater le5el ‚Pressure detection for soft +ater supply ‚/lo+

indication

and

autocontrol

of

the

steam

header

feed+ater ‚F5er high and lo+ +ater le5el alarm for the steam header ‚F5er high and lo+ pressure for the steam header ‚3ater supply 5al5e automatically pumping +ater ‚anual and automatic control of the steam pressure

The main function of the automatic instrument is the logic control a"out processing equipment action and 52

the detection

a"out


technical process

parameters +ith electric) including the setting

for the part technical parameters to ensure manufacture on the rails under the computer system operating condition# The main instrument selecting% the gas flo+ detection commonly chooses orifice "oard\ the +ater flo+ detection chooses electrical flo+meter\ the control 5al5e e9ecuting afency carry out national ad5anced

manufacture\ the transmitter choose 11&1 series pressure

transmitter#

Adopting hea5y oil hea5y oil thermal 5alue% G7''(6#1=:DmP , contact pressure% '#=Pa rating +astage% ='' CgDh contact flo+% G7'Cg Dh adopting large "ac: oil) and the "ac: oil rate is not less than 1#& K1#

Three phase A2% &'[Z ôltage% A2,='^) A2**'^ Po+er% a"out ,':3 There +ill "e one '#*t oil "uring steam "oiler) and the dra+ing of the "oiler +ill "e supplied "y the seller# /or the discharge furnace door) hydraulic station) etc# ƒ3ater quality% clean circulating +ater ƒ3ater temperature% inleting,*x) yielding 6&x ƒ2ontact pressure%„'#,Pa ƒ2ontact flo+% ,'tDh ƒEmergency +ater% according to t+o electrical sources s+itch time '#&h\2onsumption% &'tDh 53


! Pressure% '#7Pa /lo+% *'m,Dh 

b

The quantity should satisfy the continuous 1' hours comsuption for the reheating furnace# 2omsuption% 1''':gDh Pressure %'#=pa Electric motor for the com"ustion fan of the reheating furnace% 1 piece (4& :3) ,=' ^ Po+er supply meter% A2 **'^ !&'[;) capa"iity% U1'C3

1#1 3hen the equipment installation proect has the condition for the stand8alone no8load test run) the seller should organi;e the test run and inform the "uyer a"out the test content) the precept) time and place of the test in *6 hours "efore the test run) mean+hile) the seller should ma:e the test record# The "uyer and the super5ising engineer ma:e the super5ision and chec: of the test running# 1#* 3hen the equipment installation proect has the condition for the lin:age

no8load test run) the seller should organi;e the test

run and inform the "uyer a"out the test content) the precept) time and place of the test) and the requirement for the "uyer a"out the test preparations in 6= hours "efore the test run The "uyer should ma:e preparations according to the requirement of the seller and send

representati5e

to

ta:e

part 54

in

the

test

andchec:

and


super5ise it# The seller should ma:e the test run record# Fnly after the test run is passed and "oth sides sign on the test recoed) the proect can "e put into the head load test run stage# 1#, f it is the seller matter that causes the failure of the test run) the seller should afresh the test run after amending the equipment and afford the e9panse of amending and afreshing# f it is the seller matter that affects the test running process) the proect duration +ill "e postponed# 1#6 Vuring de"ug and test run period) the seller ta:es charge of turno5er pieces and +earing pieces\ the "uyer ta:se charge of the e9panse of medium-oil) fuel.) fuel used for "a:er) human and tool#

*#1

The

proect

final

detection

is the

production8qualified

detection# The seller ma:es the precept for the heat load test run and the "oth sides confirm the

process after negotiation# The

"uyer ta:es charge of organi;ation) and the

seller arranges the

technical personnel to instruct) super5ise and deal +ith the pro"lems a"out the equipments# Passing the head load test run and the seller finished dealing +ith the pro"lems during it and through the "uyer s appro"ation) all equipments +ill "e handed o5er to the "uyer) then the detection period-try8manufacture period. +ill start) +hich +ill continue , months#

responsi"ility and economic loss# The "uyer ta:es charge of comsuptions +hich trial manufacture needs) and the seller ma:es cooperation# The seller ta:es charge of +earing parts##

!

1#1 3or:ing scope includes% Vesign of continuous caster\ Production and supply of contractual equipment\ ]uidance of installation)commissioning and trial operation\ ]uidance of equipment maintenance\ Buyers staff training -including technology transfer. `nder the condition that the in5estment control and product outline are relati5ely determined) "illet continuous caster shall "e designed "ased on mature technology) relia"le operation and reasona"le configuration#ts technical feature is to select high8 efficiency

de5ices

and

lo+

energy

consumption

to

o"tain

e9traordinary economic operating effects) +hich ma:es factories possess higher competiti5eness# Basic technical parameters of caster% 2aster radius Pass

7m * passes

Pass distance

1#,'m

Ladle turret

?traight arm type

Tundish car

/our

+heel

type

+ith

tra5erse

function Pouring mode

etering no;;le casting) mold po+der lu"rication 56


?econdary cooling

3ater

cooling)

*

auto

adusting

circuits for each pass 3ithdra+al straightening de5ice

Total & rollers for gradual

straightening
2hain group centrali;ed dri5e
Billet cutting

/lame cutting

Billet con5eying

]roup centrali;ed li5e roller

2ooling "ed type

?imple cooling "ed

ta"le The set pouring speed and correct pouring process can guarantee high8quality products# The automatic control system can ensure the correct and safe equipment running# The o5erall technical characteristics of the machine are guaranteed "y the design of seller) especially the e9perience in production of equipment# The type slection of equipment is closely related to the follo+ing high target 5alues%  Limited in5estment costs\  [igh8quality products\  [igh producti5ity\  Fperation as simple as possi"le\ 

$ote% The seller retains all of its right to modify +hile continuously updating

its

products in order

to impro5e

the

performance of casters# These modifications +ill "e completed during the detailed design) +hile retaining the "asic layout and functionality#

*#1 Product mi9 /or product mi9) please see the ta"le "elo+% ?$#

tem

1

?traight car"on steel

*

Lo+ alloy steel

Proportion

&'k

Tentati5e

&'k

Tentati5e

Billet section% 1&'@1&'mm)1*'(1*'mm)1''(1''mm Equipment is equipped +ith 1&'@1&'mm Vummy "ar head and crystalli;er) then the 1*'(1*'mm ) 1''(1''mm Vummy "ar head and crystalli;er should reorder# /i9ed length% ,m) 7m# *#* Technical process description and production capacity *#*#1 Technical process description ntermediate frequency furnace% $ominal capacity

1'T

elting cycle

G'min

ntermediate frequency furnace quantity * sets A5erage daily heats -*68hour production. 3or:ing days per year

,' heatsDday

,,' daysDyear

n such a case that the molten steel meets the quality requirements required for continuous caster) the "illet +ill meet the pro5isions of YB*'118=,# 58


*. Production capacity 3or:ing days

,,' daysDyear

A5erage daily heats

,'heatsDday

$ominal capacity

1'Dfurnace

Production capacity

GG'''tDyear

*#*#* Pouring speed) producti5ity and passes /or casting steel of different specifications and different steel groups) the pouring speeds of the <7m caster are as the follo+ing ta"le% Pouring section -mm. 2asting speed -mDmin.

1''@1''

1*'@1*'

1#=

1#*

1&'@1&' Pass 1 1#=

*#*#, 2ontinuous casting yield The follo+ing ta"le sho+s the calculated yield from molten steel -including the residual molten steel in the ladle after pouring. to the "illets in consideration of the follo+ing factors% Ladle capacity

1't

Passes

* stand

2utting length

Automatic ,mD7m

2ontinuous casting times 1&'@1&'
Pass 1

1& times Pass 1

Total -:g. ,'' ,''

1' 1&7 1&7

*' ,1* ,1*

*' ,1* ,1* G4* 1&'''' GGk

*#*#6

"ar# This time is measured from the end of last pass to the "eginning of the first pass of the ne9t pouring cycle# achine radius Angle Bending length form the meniscus to the 5ertical

m  m

7#' 4G#G G#&7

a9is of +ithdra+al straightener Vistance from the 5ertical point to the starting

m

7#&

point of cutting Vistance from the starting point of cutting to the

m

final "affle of dummy "ar Futput roller speed Vummy "ar feeding speed Billet si;e
mDmin mDmin mm mDmin m min m mm mDmin mm tD?tand mm mDmin min min min min min min min

*=#' &#' 6 *#* 1#4 1#*= G#6* 6&'#' 1#& ,''#' & ,#' '#' '#= 1' *#=& *#' 1#' '#& *#' 17#'&

*#*#& Pouring radius and straightening n order to optimi;e the casting conditions and "illet quality) pouring speed) steel grade and cross8section shall "e considered for the selection of pouring radius# n the present and future production process) the adaptation of caster to users requirements +ill also affect the selection 6


of pouring radius# Therefore) the main pouring radius is determined to "e 7m and +ith gradual straightening function# n the design of straightening ;one) the straightening +ith liquid core shall "e completed to reduce the pressure on the "illets -internal and surface.# E5en if the pouring speed further increases) no crac:s +ill occur# ]radual straightening ensures that the continuous deformation of "illets) and the elongation percentage of each straightening point is maintained "elo+ the critical 5alue at +hich crac: occurs# The

factors

influencing

steel

crac:s

are

the

initial

solidification structure -austenite or ferrite. and the tend to form lo+8melting sulfides -due to nD? ratio.# ?teel of different grades has different trends of crac: formation in straightening process# 2rac: tend depends on the chemical composition of steel grade and the "illet temperature +hen straightening# /ollo+ing is the main situations to form internal and e9ternal crac:s% 

f

the

straightening

force

on

the

solid

liquid

interphase is stronger than dra+ing force at critical temperature) the

product

crac:s

+ill

"e

formed

during

liquid8core

straightening) therefore) it is required to maintain the critical temperature +ithin the range of high8temperature "rittleness#  ?urface crac:s can occur +hen "rittleness range is 4''0=&' x# To resol5e such pro"lem) the secondary cooling shall "e precisely

adusted to ensure the

surface temperature is

G&'D1'&'x +hen straightening# The follo+ing factors shall "e ta:en into account in the design of straightening system% 61


 Billet section\  Basic radius of continuous caster\  Pouring speed\  2ritical elongation percentage decided "y steel grade# The actual "illet straightening deformation rates are calculated as the ta"le "elo+% ?teel grade

?traight car"on steel Lo+ alloy steel

-mDmin. Pouring speed -mDmin. 1#'U*#* '#=U*#'

Efficient deformation rate -†.
Allo+a"le deformation rate -†
*#*#7 Tundish design The design of tundish shall reach the follo+ing targets% 

a9#

life

of

refractory

materials

for

long8time

continuous casting\  Lo+ temperature drop during pouring process\  ?afe pouring of multi8pass caster  $o no;;le eddy flo+ during the replacement of ladle# Tundish design of ‡shape can pre5ent refractory materials from peeling from tundish due to heat elongation percentage# t is recommended to use high8quality insulating "oards and co5ering agents to reduce temperature drop and ensure the steel quality# 2haracteristics of refractory materials recommended%  3or:ing lining material% insulting "oards 3or:ing lining thic:ness% 6'mm# t is recommended to use synthetic co5ering agents for tundish# The compositions shall "e a"le to adsor" slag inclusion and reduce o9ygen acti5ity# Basic features of co5ering agent% 2ompositions

?iF< *

Al<*
Al:alinity elting point

Almost half of the reo9ides are generated due to the poor protection of pouring passes from ladle to tundish) therefore) in order to pre5ent reo9idation) it is recommended to ta:e effecti5e protection to the passes from ladle to tundish# ?pecial $ote% n case that user use steel grade *,&) *'n?i for the production of 1&'@1&' and the molten steel of the intermediate frequency furnace can only meet the need of *6 heats of continuous casting) "ased

on the

cost and

organi;ation of

production)

insulating "oards shall "e selected as the tundish refractory material# etering no;;le casting +ill "e a good choice# *#*#4 old technology The predominant idea of the design of mold copper tu"e and tu"e +all thic:ness lies +ith the a5oidance of permanent deformation under the high8temperature +or:ing condition# The deformation of mold copper tu"e +ill seriously reduce the ser5ice life of mold) and cause deeper oscillation mar:s and shape defects on "illet surface# n order to a5oid deformation) the copper tu"e shall "e a"le to freely e9pand along the longitudinal a9is under temperature action# The taper of copper tu"e shall comply +ith the "illet shrin:age shape and maintain "illet and mold surface in contact# A proper taper can :eep good contact form "illet to mold outlet) reduce possi"le crac: and surface defects) such as off square and conca5e scars# The taper of copper tu"e is calculated according to the gi5en solidification shrin:age parameters of main steel grades# /or "illets) para"olic continuous taper is +idely used) +hich can "asically adapt to different steel grades and pouring conditions# 63


old +ater slit design is for high +ater speed to :eep lo+ tu"e temperature and a5oid +ater "oiling) especially near the meniscus of molten steel in the mold# The discontinuous changes in the temperature of copper tu"e +all and unsta"le heat transmission +ill lead to cooling +ater "oiling) causing

permanent

tu"e

deformation)

furthermore)

high

+all

temperature also increase the precipitation of dissol5ed salts# nhi"ition of +ater "oiling +ater does not only rely to +ater speed) "ut also +ater pressure# n fact) the "oiling temperature and pressure has a +ell8:no+n interrelationship) thus it is also a"le to a5oid "oiling "y increasing pressure# The typical 5alue of mode +ater slit design is 6mm) +hich is the optimi;ed

result +hen

mold has

high +ater

speed

and

lo+er

pressure# n order to ensure the +ater slit si;e) the +ater ac:et has stringent tolerance limits to ensure that the +ater slit is constant in all cases# ain cooling parameters% ?teel grade 3ater flo+ 5elocity a9# inlet pressure 3ater speed

]roup *'''LminDpass Bar mDsec

1!* „7#' „1'

ain parameters of corresponding mold% old material 3all thic:ness 2oating material 2oating thic:ness

2uAg 1'mm 2r '#1mm

*#*#= old oscillator The design of mold oscillator achie5es the follo+ing results% To ensure the surface quality and reduce the depth of oscillation mar:s  To ensure the sufficient lu"rication of solidified shells 64


The

"asic

factor

ta:en

into

account

for

the

selection

of

oscillation parameters is negati5e strip time) that is the time inter5al in the case that mold speed is faster than "illet speed +hen the mold and "illet mo5e in the same direction# t has the relationship +ith the oscillation parameters as "elo+% $?TX7'Dˆfarccos-^2(1'''Dˆfs. 3here% f Fscillation frequency per minute -1Dmin. ^2  Pouring speed -mDmin. ?  ?tro:e -mm. The negati5e strip time is directly related to the depth of oscillation mar:s# f the mold oscillates at higher frequency and relati5ely small amplitude) the negati5e strip time is short and oscillation mar:s are light# Practice

has

pro5ed

that

the

"est

negati5e

strip

time

is

'#1'0'#1*s# Vepending on different pouring speed) the frequency shall "e changed to ensure constant negati5e strip time# The results of changes are automatically controlled "y continuous casting and recorded "y the computer# Fscillation frequency and amplitude are determined "y the negati5e strip time and pouring speed# Pouring parameters are controlled "y the "asic automatic system# *#*#G Billet support ?eller recommends the mold +ith foot rollers# The purpose of foot rollers is to guide the "illet after getting out of mold and guide the introduction of dummy "ar head +hen resetting the dummy "ar# f the "illetDdummy head is +ithout guidance) it may scratch the "ottom copper tu"e +all of mold) shorten the ser5ice life of mode and result "illet surface defects# Practice has pro5ed that the proper use of foot rollers can reduce 65


mold +ear) and reduce the impact on the "illet surface under different pouring conditions# /oot roller num"er and distance considered in design% ?ection

$um"er of ro+s

 1

each ro+  *

mm 7'

mm 1&'(1&'

*#*#1' ?econdary cooling To ensure rapid solidification and eliminate the generation of metallurgical defects through the follo+ing conditions%  2ontrol the temperature reco5ery of the "illet surface +hich is on the spray cooling end\ A suita"le form of +ater cooling to a5oid the different cooling rates of "illet center) edges and corners\ Automatic control a suita"le "illet temperature to pro5ide good +or:ing conditions for steel rolling# The spray cooling system is "ro:en do+n into se5eral cooling ;ones according to the "illet si;e and steel grade# The distri"ution of cooling intensity effecti5ely determines the liquid core length and the a5erage temperature of "illet surface# The design of spray cooling system is "ased on the mathematical models of solidification and thermal conducti5ity# The program estimates the "est configuration of +ater cooling system +ith the calculated theoretical thermal conducti5ity distri"ution# n this case) there are three secondary cooling ;ones# ?$# 1 *

tem /oot roller /i9ed section

Length -m. '#*' *#6

1 /i9ed section *

*#, 2ommon facilities 66

$o;;le num"er 17 &7

2ooling mode +ater cooling


*#,#1 Po+er supply -e9cluding +ater treatment) air po+er. Lo+ 5oltage /requency  2ontinuous caster au9iliary motor) rated

,=' &' *''

^ [; C+

po+er

*#,#* 3ater 1. 2ooling +ater classification ndirect cooling +ater% the cooling +ater that does not directly contact the cooled o"ects) such as the +ater for the primary cooling circuit of a continuous caster# Virect cooling +ater% the cooling +ater that directly contacts the cooled o"ects) such as the +ater for the secondary cooling circuit of a continuous caster# Emergency +ater% the cooling +ater for protecting de5ices from the ha;ards of po+er do+n# Virect and indirect cooling +ater has o+n independent systems# The recirculation is in t+o +ays% closed circuit and open circuit# 3hen the equipment is running) it shall al+ays guarantee the quality characteristics of +ater to a5oid the impact of de"ris and corrosion# Technical requirements for +ater are sho+n in the follo+ing ta"le% 2ooling system

Ve5ice

?oft

?econdary

Emergency

3ater type P[ 2a hardness -mgD12a22F< ,<. g hardness -mgD12a22F< ,<. Al:alinity -mgD12a22F< ,<. a9# chloride -mgD122l. a9# sulfide -mgD1?F< 6<. a9# iron -mgD1/e. a9# silicon o9ide

+ater ab 4UG ,'U*6' 'U=' &'U*'' *'' 1&' '#& &'

+ater aab 4UG 'U7' 'U*' *'U*'' &' 6' '#& 1'

cooling +ater "b 4UG ,'U,7' 'U1*' &'U,'' *&' *'' '#& 4&

+ater cb 4UG ,'U*6' 'U=' &'U*'' *'' 1&' '#& &'

-mgD1?iF<*<. 67


a9# total dissol5ed solid

1'''

&''

1&''

1'''

-mgD1. Total suspended solid

1'U*'

1'U*'

&'U='

1'U*'

-mgD1. a9# suspended solid si;e

1''

&'

*''

1''

-‰m. a9# oil content -mgD1.

1

1

1'

1

1. 3ater technical parameters of different users n the ta"le%   ma9imum +ater flo+ rate Pem  ma9imum emergency pressure em  emergency flo+ rate Ti ma9imum inlet temperature Pi  '#''m pressure Te ma9imum outlet temperature VP Pressure drop Type

aab ab "b

 mP,PDh b *6' 1'' &'

Ti ℃b

Te ℃b

Pi pab

VP pab

,& ,& ,&

&' &' D

'#= '#, '#=

'#&' '#, D

em mP,PDh b

D

Pem pab '#, D D

$ote% 1 Vuration% &min *#,#, 2ompressed air 2ompressed air user of continuous caster  Vri5en "y cylinder  Air for instruments  Air for cylinder and cooling) etc The compressed air circuit shall has an air dryer to reduce the humidity to the allo+a"le range#

2haracteristics%  Pressure% '#60'#7pa  uality% industrial compressed air

68


`ser

]eneral user Pressure head nstrume nt air

 -$mP,PDh . 1'

Pi -pa.

-mgDmP, P.

-mgD$mP,P.

-mgDmP ,P.D -mm.

'#7

*'

&'''

1&D'#'&

1='

'#7

1

&#'''

1&D'#'&

7

'#7

1

&D1pm -de+ point 8*'x.

*#,#6 F9ygen Pressure required% 1#*pa `ser F9ygen lance

Pea: 5alue -mP ,PDh.

ean 5alue -mP ,PDh. 1''

Pea: 5alue -mP ,PDh.

ean 5alue -mP ,PDh. 11' 14&

*#,#& /uel /uel type and user 2ontinuous caster o9ygen lance 2ontinuous caster

,#1 Ladle turret Turn the ladle full of molten steel from the recei5ing position to the pouring position) at the same time) mo5e the empty tundish "ac: to the recei5ing position to recei5e molten steel# Type% ?traight arm type) +ithout capping mechanism ?tructural components% ladle sle+ing "earing) dri5e unit) sle+ing arm) upper sle+ing "ody) lo+er "ase) slip ring parts) anchoring parts) slide gate no;;le operating parts and operating platform) protecti5e structures) etc# ain turret technical parameters% 2arrying capacity

*(,'t

?le+ing radius

,,''mm

?le+ing dri5ing mode

By

operation. 69

hydraulic

motor

-normal


$ormal sle+ing speed%

1rDmin

Emergency sle+ing speed%

1rDmin

*4'

Equipment +eight%

1='''Cg

Equipment uantity%

1 set

1. Vri5e unit ?le+ing "earing

1,1#&'#1='' X*' ;X146 X*' ;X146

?le+ing motor%

2V',6443

?peed%

&'rDmin

Pressure difference%

1'Pa

Vri5e unit quantity%

1 set

,#* Tundish /or recei5ing the molten steel in the ladle and pouring it to the mold# The co5er on the tundish is mainly for the heat preser5ation of molten steel# 1. ain tundish technical parameters Tundish structure% T8type) +ith retaining +all and retaining +eir) o5erall pouring tamped Tlining $o;;le quantity%

*Pcs

$o;;le inter5al%

1,''mm

$o;;le opening si;e%

W17'mm

olten steel depthD+eight +hile pouring% 6''mmD&t olten steel depthD+eight +hile o5erflo+ing% 7''mmD=t Equipment +eight%

1=''CgDset

Equipment quantity%

* sets

,#, Protecti5e casting de5ice -optional. /or reducing the inclusions in steel# This continuous caster has a design of casting protection from ladle to tundish# ain technical parameters% 7


?tructure% Le5er type Fperation mode%

anual

Equipment +eight%

*''CgDset

Equipment uantity% 1 set ,#6 Tundish car t is on the fi9ed trac: of the pouring platform) and for carrying tundish in and out of the pouring station# There are t+o tundish cars for alternati5e use# ?tructure% The thndish car adopts the trac: type) and consists of the "ody) +or:ing mechanism) adusting mechanism) etc# ts tra5el mechanism adopts the single side dual8dri5e mode "y electric dri5e# The tra5erse position of no;;le is fine tuned "y hand# ain tundish car technical parameters 2arrying capacity%

*'t

Trac: gauge si;e%

17''mm

Equipment uantity%

* sets

Equipment +eight%

*&''CgDset

1. Tra5el mechanism parameters Tra5el stro:e%

mm

Tra5el speed%

1#*U1'mDmin

3heel diameter%

W*&'mm

]ear motor odel% Po+er%

*#*C3

Futput speed%

1*#4rDmin

/requency%

,U&'[;

*. Tra5erse mechanism parameters 71


3or:ing stro:e%

 &'mm

,#& Telescopic tu"e for suspended control "o9 t is used for the suspended electric control "o9 of ladle casting platform) of +hich one end is fi9ed under the "eam of the ladle casting platform and the other end is connected +ith the electric control "o9 "y a chec: ring# This tu"e e9tends and +ithdra+s through a supporting roller for operators to mo5e and operate# ?tructure% ?uspended telescopic steel structural component ain technical parameters%

?tro:e%

1=''mm

Equipment +eight%

7'CgDset

Equipment quantity%

* sets

,#7 Protecti5e slee5e mechanism /or the installation "et+een the ladle and tundish ?tructure% 2onsist of "earing) compression mem"er) cross"eam and other components ain technical parameters% 2ontrol mode%

anual

uantity%

1 set

,#4 old t is for the initial setting of shells# After initial setting) "illets are continuously dra+n out from the lo+er outlet of the mold) then come into the secondary cooling ;one# t includes steel tu"es) internal +ater ac:et) e9ternal +ater ac:et) drainage pipe) +ater ring) foot roller) "ottom and top flanges) lu"ricating flange and other components# ain technical parameters% Type%

Para"olic tu"ular mold

old type%

Para"olic cur5ed copper tu"e

2opper tu"e material%

2hromeplated

2uAg

tu"e

+ith

appro9imately '#1mm plating coat 72


E9ternal arc radius of tu"e% 7'''mm old

lengthDpouring

sectionDfillet

radius%

=&'mmD1&'(1&'mmD,07mm 2opper tu"e cooling%

2losed

primary

cooling

system 3ater seam si;e%

Appro9 &mm

/lo+ rate%

Appro9 =01'm D s

3ater supply pressure%

'#70'#=Pa

3ater temperature -inDout.%

6'xD6=x

/oot roller material%

?t&*8,

/oot roller "earing%

Bron;e sliding "earing

/oot roller quantity%

*Dset

$o;;le distri"ution and quantity%

Fne

ro+

a"o5e)

three

ro+s under\ 17Dsets uantity%

* sets

,#= old oscillator /or pre5enting initial solidified shell from "een "ro:en due to its stic:ing to mold +all# ?tructure% ?emi8leaf spring type This equipemt consists of upper and lo+er guide leaf springs) eccentric oscillation mechanism) oscillating ta"le frame) medium pipeline) etc# The oscillator has a con5erse oscillating characteristic) that is) in

order

to

maintain

a

certain

negati5e

strip

rate)

the

oscillating frequency can "e reduced to increase the oscillating stro:e) +hen speeding up the continuous casting speed# ain technical parameters% Vri5ing mode%

^^^/

Amplitude range%

*UGmm

/requency%

,'0*&' timesDmin

Fscillation mode%

?ine 73


Amplitude adustment%

?hutdo+n regulation

/requency regulation%

Automatic

adustment

according

to

casting speed Fscillator quantity%

* sets

,#G ]uide frame and spray de5ice of secondary cooling section /or directly spraying "illets for cooling) and support and guide "illets or dummy "ar# This de5ice consists of three supporting and guide sector sections +ith same radium +ith the "asic arc) a spray +ater cooling de5ice) a fi9ed "ase) etc# The secondary cooling is mainly for directly spraying the cooling +ater to the "illet surface to ha5e "illet rapidly get cool and solidified#

The

cooling

intensity

and

the

structure

and

configuration of no;;le are all directly related to the "illet quality and yield# ain technical parameters% ?tructure%

?implified structure

pass distnce%

1,''mm

$o;;le type%

?quare and hollo+

$o;;le model%

,D= PZ7'7&*6

Total equipment +eight%

1'''Cg

,#1' +ithdra+al straightener /or

"illet guiding

and

straightening#

The

dra+ing

speed is

adusta"le to meet the different speed requirements of different steel grades# This equipment consists of the rac:) scre+do+n and fi5e rollers up and do+n) dri5e system) +ater8cooling system) etc# Before casting) the +ithdra+al straightener transfers the dummy "ar to the specified position in the mold\ during pouring) it forci"ly dra+s the dummy "ar and the "illet solidifying +ith the "ar out from the mold\ after passing the supporting and guide de5ice of the secondary cooling) it separates the "illet and dummy 74


"ar and "egins continuous dra+ing and straightening# ain technical parameters of +ithdra+al straightener% Type%

ntegrated

rac:

fi5e8roller

+ithdra+al straightener Vri5ing modeDTscre+do+nT mode% Electric

dri5eDThydraulic

scre+do+n ?traightening radius%

7'''mm81*'''mm8Š

?traightening temperature%

G&'x U1'&'x

Vra+ing speed%

'#,U,#'mDmin

~,''mm ( *,'mm

otor po+er%

11C3

,6'

ode of speed control%

âria"le -&8&'[;.

?ystem +or:ing pressure%

1'pa

[ydraulic medium%

ineral oil

nlet hydraulic cylinder model%

LA8 ‹*''@‹='@7'

Futlet hydraulic cylinder model%

LA8 ‹*''@‹='@**&

Equipment +eight%

&''':gDset

Equipment quantity%

* sets

,#11

eliminate the deformation# ain technical parameters% E9ternal arc radius of dummy "ar%

<7m

Angle of contact%

G*

Vummy "ar Tshan: Tsection%

*''(16'mm

Vra+ing speed%

'#&Œ&mmin

Po+er%

1#&C3

Futput po+er%

rmin


2onstant speed

Platform si;e%

Appro9 1*m(,#6m(*m

3eight of dummy "ar and storage de5ice% Platform +eight%

1774:gDset

1'''':g

,#1* ?hear entry ta"le ,#1*#1 2entrali;ed li5e roll ta"le /or con5eying "illets and end "illets# ?tructure% 3ater8cooling roll ta"le that consists of the rollers) roll ta"le "earing "eams) guide guard) roll ta"le co5er plate) dri5e plat) dri5e unit) etc# ain technical parameters% Vri5ing mode%

2entrali;ed

-electric.

dri5e Llinear 5elocity of roller surface%

*#&mmin

F5erall dimension of roll ta"le -per pass.% &'''(&''(6&' mm
~*6'*,' mm

1'7' mm

&Dpass(* passesX1'

1#&C3

otor speed%

1&''rmin

Positi5e and negati5e

otor quantity%

1 setDpass(* passesX* sets

,#1*#* After8shear ta"le 76


The first group of roll ta"les after cutting) consisting of rollers) roll ta"le "earing "eams) guide guard) roll ta"le co5er plate) +ater cooling system) dri5e unit) etc# ain technical parameters% Ta"le distance%

1,''mm

~*6'*,'mm

1'7'mm

&Dpass

,#1,
2entrali;ed motor dri5e

Ta"le speed%

1&mmin

~*6'*,'mm

1'7'mm

Ta"le distance%

1,''mm

&Dpass

Po+er%

6#'C3

êlocity ratio%

&G

otor speed%

16&'rmin


2onstant speed

]ear motor quantity%

1 setDpass

,#16 /lame cutting machine `se the flame cutting machine to cut the "illet "y the length required "y users# ain technical parameters% 2utting stro:e%

1'''mm 77


2u 2utting seam%

4mm

a9# cutting section%

1&'(1='

,#1& The roll ta"le for the cold "ed /or con5eying the "illets of fi9ed dimension to the parallel flo+ ta"le rapidly and sta"ly# ?tructure% 3ater8cooling roll ta"le that consists of the rollers) roll ta"le "earing "eams) guide guard) roll ta"le co5er plate) dri5e unit) etc# ain technical parameters of runout ta"le% Vri5ing mode%

2entrali;ed dri5e

Bear Be arin ingg ca capa paci city ty of ro roll ll ta ta"l "lee%

&'C$ &' C$Dp Dpas ass( s(** pa pass sses esX1 X1'' ''C$ C$

Linear 5elocity of roller surface% 1& mmin
~*6'*,' mm

1,'' mm

&Dpass(* passesX1'

otor type%

A2 motor -A2,='^) &'[;.

6#'C3

otor speed%

16&'rmin

otor quantity%



,#17 [ydraulic steel shift machine /pr mo5ing the "illet on the roll ta"le to the cooling "ed# ?truc ?t ructu ture re%% 2o 2ons nsis isti ting ng of hy hydr drau auli lic c dri dri5e 5e mec mecha hani nism sm)) hy hydr drau auli licc cylinder and other components# ain technical parameters% Vri5ing mode%

[ydraulic

[ydraulic cylinder model%

T21*&(1=''

[ydraulic cylinder stro:e%

1=''mm

[ydraulic cylinder +or:ing pressure% [ydraulic cylinder +or:ing medium% ineral oil [ydraulic cylinder quantity%

* pcs 78


Equipment quantity%

1 set

Total equipment +eight%

1&'':g

,#14 2ooling "ed 3hen the heating furnace) or the steel rolling can not match the steel ma:ing) the superfluous "illets +ill "e mo5ed out of the roll ta"le and enter into the cooling "ed# ain technical parameters of cooling "ed% i9# "illet stac:ing quantity%

1'T

a9# "ed surface load%

*'C$

2harring "illet specification%

1&'(1&'(7'''mm

Effecti5e si;e of cooling "ed -L(3.%

b 7'''(,''' mm mmb

Equipment quantity%

1 set

Equipment +eight%

*''':g

,#1= Fff8line and au9iliary equipment 1. Tundish sling /or hoisting tundish and steel structural parts# ain technical parameters% Loading capacity%

*''C$

3eight%

16G':g

ty%

1 set

*. Tundish sling storage rac: /or storing the tundish sling and steel structural parts# ain technical parameters% Bearing capa pac city ofthe storage rac:%

&'C$

3eight%

,'':g

uantity%

1seat

,. old maintenance stand -optional. 2onsisting

of

the

rot ro tating

components# 79

de55ice) de

plat atfo forrm

and

other


The mold can turn to any angle though the rotating de5ice for maintenance# ain technical parameters% otor po+er%

'#6C3

1'',

Equipment +eight%

,&':gDset

Equipment quantity%

1 set

6. old storage rac: storing the mold and steel structural parts# ain technical parameters% Equipment +eight%

,4*:gDgroup

Equipment quantity%

* groups

&. Arc aligning templet /orr th /o the e ar arc c al alig igni ning ng in insp spec ecti tion on of th thee mo mold ld)) se seco cond ndary ary cooling section and +ithdra+al straightener# ain technical parameters% E9ternal arc radius%

7'''mm

Equipment +eight%

16:g

Equipment quantity%

1 set

model ,#1G [ydraulic system ain a inly ly fo forr th thee dr dri5 i5in ing g an and d co cont ntro rol l of th thee "o "ody dy of co cont ntin inuo uous us caster and off8line de5ices# n order to ensure safe and relia"le continuous running of the equipment) domestic "rand8name components are to "e adopted as the main components of the hydraulic system# The main pump is an a9ial plug pump to adapt to the needs of high pressure and large flo+ rate# Vuee Vu

to

thee th

tran tr ansm smis issi sion on

requ re quir irem emen ents ts

andd an

diff di ffer eren entt

cont co ntro roll

accuracy of the equipment) as +ell as the difference "et+een the actions and functions of the main and au9iliary de5ices) hydraulic 8


station is designed# [ydraulic station# To supply po+er to the +ithdra+al straightener) ladle turret) roll ta"le flap) pusher) etc# ?ystem pressure%

=Pa

Total motor po+er%

66C3

Tan: capacity%

*'''L

[ydraulic medium%

ineral oil

6#1 ?ystem design "asis n *1st century) +e are facing a distri"uted field "us oriented re5olutionary reformation and de5elopment trend of integration of electric

control

technology)

electronic

instrument

control

technology) electronic computer technology -E2. in the +orld+ide automatic control field# Based on our ad5anced design concepts of the +orld8class continuous caster automatic control system in 1GG's) +e selected the ad5anced and relia"le control equipment +ith full consideration to many factors) such as the ad5antage) openness and sta"ility of the equipment) the relia"ility of sources) as +ell as costDperformance# oreo5er) +e also com"ined our

e9perience

accumulated

during

the

installation

and

commissioning of control systems of shaped continuous casters and the deep study in introduced automation equipment# /or the automation system of the production line of the t+o8pass "illet continuous caster) +e ta:e high relia"ility) dura"ility and costDperformance as the principle) "y +hich +e select the quality transmitter for the measurement of the flo+ rate) pressure and pressure difference for the primary instruments) select the fluid le5el gauge for the measurement of liquid le5el) select the electromagnetic flo+ meter) +hich o+ns high precision and lo+ 81


maintenance) as the detecting element for the measurement of the secondary

cooling

+ater)

and

select

the

safe

and

relia"le

pneumatic 5al5e as the actuator to ensure sta"le and smooth adustment# 6#* Vetecting instrument 6#*#1 2ontrol requirements The

soft+are

of control

system includes the

system control

soft+are and management application soft+are# 1. 2ontrol system soft+are features% F"ect8oriented graphical interface\ ?creen display system esta"lished "y the system\ that is +e can get the same direct impression form o"ect8oriented user interface as

from

o"ects#

The

man8machine

interface

is

accessi"le)

intuiti5e and impressi5e# Alarm and alarm management Be a"le to carry out continuous monitoring of the process# ts alarm dra+s your attention to the potential ris:s# The alarm limits can "e fle9i"ly defined) and the information can "e displayed on the screen# *. anagement soft+are pac:age features Vynamic editing function%

can ;oom out and in# By o"ser5ing the real8time and historical trend cur5es) +e can get full information of the control process) and use the historical trend treatment to collect) store and display real8time process data# The data o"tained can "e filed) so that it can "e made into reports for comparison# Alarm function% Be a"le to continuously monitor the process) and alarm as soon as failure occurs# Vata"ase function% The stronger data"ase management function can not only esta"lish a production data"ase and store the ra+ production data for statistics and analysis) "ut also esta"lish a fault data"ase to record system errors and failures# 6#*#* nspection and control items and control mode 1. old nlet "ranch tu"e pressure and temperature detection of cooling +ater) and lo+8pressure alarm nlet temperature and pressure detection of cooling +ater inlet manifold and lo+8pressure alarm nlet and outlet temperature difference detection of cooling +ater) and high8temperature alarm# *. ?econdary cooling ;one nlet pressure and flo+ rate detection of the manifold) and lo+8pressure alarm# /lo+ rate and pressure detection of each pass of "ranch tu"es# ,. 3ithdra+al straightener Vra+ing speed inspection Billet length inspection

Party As design scope #1 Vesign of plant related to the continuous caster# #* Vesign of off8line pipeline related to the continuous 83


caster# #, Vesign of common and au9iliary facilities -including +ater) electricity) +ind) gas. related to the continuous caster# #6 Vesign of the gas supply system and gas pipeline of gas "us# #& Vesign of the po+er line of o9ygen and compressed air# #7 Vesign of the tu"ing of gases -o9ygen) gas) compressed air. for continuous casting# #4 Vesign of the

po+er

ca"le

feeding

for

continuous

casting) and plant design lighting design\ #=

Vesign of the

air

conditioning)

5entilation)

fire

control and communication systems for continuous casting# #G Lighting design for the main electric room) each control room and hydraulic station of the continuous caster# #1' All hydraulic) lu"ricating oil and grease shall "e pro5ided "y Party A# #11 Party A shall pro5ide the con5enience of +or:) room and "oard for Party Bs felid staff# #1* Party A shall pro5ide cranes and crane operators to assist the construction# #1, All refractory materials and "ric: masonry materials shall "e pro5ided "y Party A# &#* Party Bs design scope &#*#1 Layout dra+ing of the equipment of continuous caster Ž &#*#* Basic data and dra+ings of the on8line equipment related to the continuous caster -including the foundation "olt si;e and load of equipment.# &#*#, Vesign of on8line non8standard equipment# &#*#6 Vesign of the tu"ing of a 5ariety pipelines of on8line equipment# &#*#&

Automatic

control

system 84

design

of the

continuous


caster# &#*#7 [ard+are configuration of computer system Ž &#*#4 Programming of application soft+are# &#*#= Vesign of the ca"le laying of on8line equipment# &#*#G Technical requirements and parameters related to the energy medium system) +ater) electricity and gas of the continuous caster) +hich shall "e pro5ided for Party A# &#*#1' Vesign of the continuous caster and rele5ant ci5il construction requirements# &#*#11 Vesign of the +ater supply system requirements of the continuous caster# &#, $odes of pipeline plans of "oth parties% &#,#1 The node of the compressed air pipeline% for the compressed air) Party A is responsi"le to design the pipeline form the gas source to the dedicated gas tan: -including gas tan:. of the continuous caster) and Party B is responsi"le to design the pipeline from the gas tan: to equipment# &#,#* The node of the energy medium pipeline% for the gas pipeline) Party A is responsi"le to design the pipeline from the gas source to the master 5al5e -including the master 5al5e. of the continuous caster) and Party B is responsi"le to design the pipeline from the 5al5e to the point of use# &#,#,

The

design

of

lu"ricating

pipeline

and

hydraulic

pipeline are assumed "y Party B# &#,#6

The

node

of

the

po+er

supply

line%

Party

A

is

responsi"le to design the line from the po+er source to the po+er recei5ing ca"inet in the main electric room of the continuous caster) and Party B is responsi"le to design the line from the po+er recei5ing ca"inet -including the po+er recei5ing ca"inet. to the use point of equipment## [anding o5er of dra+ings and data 85


#1 Vra+ings and data that Party A shall pro5ide for Party B# #1#1 2i5il construction dra+ings of plant in connection +ith the continuous caster\ 2rane outline and hoo: mo5ement location dra+ing) as +ell as hoo: head outline dra+ing) ladle dra+ing) ladle slide gate no;;le assem"ly dra+ing# #1#* Fther date related to the design of the continuous caster# #* Vate +hich Party B shall pro5ide for Party A# #*#1

Pro5ide

detailed

"asic

equipment

data

of

the

continuous caster# #*#* Pro5ide the ci5il construction data of internal ca"le trenches) pipe tunnels and em"edded parts of the continuous caster# #*#, Pro5ide the ci5il construction design data of the main electric room) each control room) and hydraulic station# #*#6 Technical requirements of the three8+ater system and energy medium consumption of the continuous caster\ Location coordinate dra+ing of the master three8+ater feed and return 5al5e) master gas tan: 5al5e) gas tan:) etc# #*#& Fther data related to Party As design# #*#7 T+o complete sets of installation and maintenance dra+ings of equipment) electric and instruments of this proect# #*#4

Technical

documents

and

data

attached

+ith

the

deli5ery) including% Equipment deli5ery list -pac:ing list.\ Futsourced

parts

and

standard parts

list -including the

suppliers) product certificates) etc# and other data of outsourced parts.\ Technical date of outsourced parts\ ?ingle machine trail run) acceptance and inspection reports\ 86


Program list or floppy dis:s\ PL2 operation manual and programming manual\ -4. Technical data of instruments and actuating apparatus# List of equipment deli5ery -pac:ing list.\

7#1 ?upply scope of complete set of equipment 7#1#1 All designed on8line non8standard equipment) off8line non8standard equipment) the hydraulic station and piping) and pneumatic control ca"inet# 7#1#*

Vesigned complete

sets of electric

and

instrument

automation equipment#

4#1 Electromagnetic stirring) automatic liquid le5el control and

aerosol

cooling

system

are

not

ta:en into

account

for

continuous casting at present) "ut in the o5erall design) space is reser5ed for their further installation) so that) user can impro5e the equipment for the production of high8quality special steel# A part of performance of iaolian [ea5y ndustry in complete small continuous caster equipment n complete small continuous caster equipment) the products of iaolian [ea5y ndustry has "een seriali;ed and ha5e unique [aiun features# $o+) there are <=) <7) <6 and other standard series) as +ell as

tens of <B of "rea:do+n cost and impro5e the effecti5eness "y se5eral times for users# *#& series is the typical model of iaolian [ea5y ndustry to o"tain lo+ cost +ith high technology# At present) the technical personnel of iaolian [ea5y ndustry are de5eloping 4'4' continuous casters +ith great concentration and aim to ultimately o"tain 7'7') so that) small and medium8si;ed mill users do not need to modify casters) "ut use it for direct rolling# The small sla" continuous casters of [aiun are in impro5ement) and the engineers are +or:ing hard to meet the requirements of maority of users as soon as possi"le# The follo+ing is a part of performance of [iaun in complete small continuous caster equipment in recent years# •@i9ing ron z ?teel 2o#) Ltd#
<7

t+o8pass

continuous

caster •3u9i iangsheng ron z ?teel 2o#) Ltd#

<7

t+o8pass

<7

t+o8pass

continuous caster •]uang9i ingang ron z ?teel 2o#) Ltd# continuous caster •$ingde
<7

three8pass

continuous caster • iangsu 2hangiang
<7 t+o8pass continuous

caster • ]uangdong @iaoheng [uidong ?teel8casting /oundry <= t+o8pass continuous caster • iangsu iangyin @inshengang ron z ?teel 2o#) Ltd# <7 t+o8pass continuous caster 88


• Ca;a:stan ?teel ill

<7 t+o8pass continuous caster

• iangsu Liyang @inguang ?teel ill


caster • iang9i ?hangrao ?teel ill


caster • Zheiang ingtai ron z ?teel 2o#) Ltd#

<7

t+o8pass

continuous caster • 2hongqing Pengcheng ron z ?teel 2o#) Ltd# <7 t+o8pass continuous caster • ]uangdong /engshun Agricultural achinery 2ontinuous 2asting /actory <7 t+o8pass continuous caster • ]uangdong Yongshun ?teel8casting /oundry <7 t+o8pass continuous caster • ?ichuan /ufeng ron z ?teel 2o#) Ltd# <7

t+o8pass

continuous

caste • ?handong Liaocheng ?teel ill

<7

t+o8pass

continuous

caste • iang9i ?hangrao etal Products 2o#) Ltd# <7

t+o8pass

continuous caste • ]uangdong [uafa etal Products 2o#) Ltd# <7

t+o8pass

continuous caste • ndonesia Velong ?teel ill

<7

t+o8pass

continuous

caste • Zheiang ingtai ron z ?teel 2o#) Ltd#

<7

t+o8pass

continuous caste • ]uang9i in;hou [engrong ron z ?teel 2o#) Ltd# <7 t+o8pass continuous caste • ]uangdong Zhongrun ?teel ndustry 2o#) Ltd# <7 four8pass continuous caster • ndonesia

/irst

?ource

?teel

continuous caster 89

2o#)

Ltd#

<7

three8pass


• îetnam [o 2hi inh Tongin ?teel ill


caste • Thailand Taifengrong ?teel ill <7 four8pass continuous caster • ?u;hou Vanuo 2asting 2o#) Ltd#

<7

three8pass

continuous

caster • ?handong Va;ong achinery 2asting 2o#) Ltd# <7 three8pass continuous caster • 2hongqing Yonghang etal Products 2o#) Ltd# <= four8pass continuous caster !

1#1 C]P? series integrated thyristor medium frequency po+er supply is to rectify &' [; or 7' [; alternating current into direct current fully controlled "y an ordinary thyristor) after the ripple

is

filtered)

in5erted

to

"e

1&'[Z01''''[Z

"y

fast

thyristor# t can "e used for thermal processing such as melting) forging) +elding) "ending) e9truding) rolling) etc as +ell as +or:piece quenching) annealing and other heat treatment processes# 1#* eaning of C]P? series model is as follo+s% !"PS

125

5

Controlled

Rated output frequency (!"

Controlled Rated output #o$er (!"

Frequency converter Water cooling

1#, The machine control system is full8integrated circuit# n the system)

in5erter

trigger

circuit

adopts

automatic

frequency8

s+eeping start8up technology) to ensure the success of full8po+er start8up of medium frequency po+er supply\ rectifier control circuit

adopts

large8scale

phase8shifting 9

rectifying

trigger


circuit) +ith strong anti8interference performance) "etter line shape) simple commissioning and sta"le operation\ good performance of current8limiting and 5oltage8limiting can a5oid the pro"lems on frequent o5er5oltage and o5ercurrent caused "y load 5ariation\ comprehensi5e protection functions can ensure that the equipment can carry out automatic safety shutdo+n in case of 5arious faults# The medium frequency po+er supply +ith full8integrated frequency8 s+eeping control is a :ind of ne+8generation medium frequency po+er supply +ith lo+ energy consumption) high efficiency) easy operation and maintenance#

*#1 This de5oce shall "e installed in the room) and meet the follo+ing conditions% *#1#1 The altitude should not "e more than 1''' m\ *#1#* The am"ient temperature does not e9ceed H6' x) not less than 81' x\ *#1#, The relati5e humidity of air is not more than =&k\ *#1#6 n a place +ithout conducti5e dust or 5arious corrosi5e gases\ *#1#& n a place +ithout e9plosi5e gas and no strong 5i"ration\ *#1#7 nstalled in a +ell85entilated places# *#* 2ooling +ater requirement% edium frequency po+er supply de5ice) sensor and medium frequency electric8heating capacitor are applied circulation +ater cooling) so the conditions of cooling +ater pro5ided +ill affect the relia"ility of equipment directly# t is recommended to carry out analysis on current cooling +ater and its result should meet the follo+ing requirements# t must "e sol5ed "y the method of corresponding purification in the e5ent of any difference# 91


echanical

characteristics%

transparent)

clear)

deposit

free

-screen si;e of '#,= inch.) total solid content not o5er *&'mlDL# 2hemical characteristics% at hardness of =V[) P[ 5alue is 4#=\ 2hloride

1'' mgDL\

$itrite -$F< *<.

'#'6 mgDL\

ron sulfur

'#,mgDL\

n

'#'& mgDL\

?

*&' mgDL\

+ater

on

a

hot

day)

it

is

important

to

a5oid

condensation on the surfaces of +ater8cooling components# 3ater inlet pressure% +ater pressure of controlled silicon and capacitor„1#&:gDcmP *P\ +ater pressure of sensor „*#&06:gD cmP *P# *#, Three8phase po+er grid 5oltage should "e appro9imate to sine +a5e) and harmonic distortion should "e less than  &k# *#6 The im"alance of three8phase po+er grid 5oltage should "e less than  &k) and its fluctuation range should not e9ceed  &k# *#& n order to ensure normal and sta"le operation of the de5ice) it is required that the furnace "uilding technology for melting furnace as a load should "e used dry furnace "uilding method that the lining materials can not "e +atered# *#7 3hen the de5ice is not in use temporarily) the 5entilation and drying measures should "e strengthened) so as to a5oid damaging the internal part of the de5ice due to damp# n the case that it may "e fro;en in the room) efforts should "e made to remo5e all cooling +ater in the de5ices clearly#

The technical parameters designed for C]P? series medium frequency po+er supply product produced "y our company are as sho+n in the 92


follo+ing ta"le% edium frequenc y melting furnace

ton x tonDh tonDh Pa x

1' U1* 17'' 7#& 1'' '#* 6'

+ater Temperature rise The inductor 5oltage The inside diameter The total height of the inductor Po+er consumption for steel of per

x ^ mm mm VegreeDton

*' ,*'' 16'' *''' 77'

ton-continuous casting. Turndo+n mode

[ydraulic turndo+n

odel 3inding structure

Z?87,'' VDdDy< n<11 ?econdaly

side

DY

duple9

+inding wdra+ing out of the center of the star +inding CÂ

Total capacity

C]P?

7,''

Primary 5oltage ?econdary 5oltage

C^ A

*' 1'''

Po+er range nlet +ire 5oltage a9imum inlet +ire 5oltage
C3 ^ A pulse tonDh Pa x

,&'' U&,'' 1''' 1=*' 1* &' '#1 ,&

+ater Temperature rise ntermediate frequency 5oltage /8/
x ^ [;

1& 17'' &''H&'


+or:ing#

6#1 ?eries structure and appearance of po+er supply ca"inet The series structure of the medium frequency de5ice comprises of four parts) as sho+n in /ig# 1% rectifier ca"inet) in5erter ca"inet) capacitor ca"inet and melting furnace) of +hich the rectifier ca"inet and in5erter ca"inet are the core of the +hole system) collecti5ely :no+n as po+er supply ca"inet that plays the role of con5erting po+er frequency 5oltage to medium frequency 5oltage# A2 nput

&nvert er ca%in et

Rectif ier ca%in et

Capa citor ca%in et

'eltin g furna ce

/ig# 1 edium frequency po+er supply system structure The appearance schematic diagram of po+er supply ca"inet is sho+n in /ig# *) in +hich) 78pulse lo+ po+er medium frequency po+er supply uses only t+o su"8ca"inets at the left side of sho+n ca"inet) 1*8pulse medium8high po+er supply uses the complete single ca"inet) as sho+n in the figure) and *68pulse high po+er supply

uses

indicator

parallel lamps)

dual8ca"inet#

operating

2orresponding

"uttons

and

instruments)

po+er8regulation

potentiometer are fitted on the left door of ca"inet to control and indicate the +or:ing conditions of the medium frequency po+er supply) called as operation door#

94


F5erall dimension% L -,7''mm. (3 -1*''mm.([ -**'''mm. /ig# * Appearance schematic diagram of po+er supply ca"inet V2 5oltage 1 V2 current 1 edium frequency current 1 edium frequency 5oltage V2 5oltage * V2 current * edium frequency current * /requency 2ontrol po+er supply ain s+itch lamp 1 ain s+itch lamp * 95


Protection lamp 2ontrol F$ 2ontrol F// Energy storage ain po+er supply F$ ain po+er supply F// Po+er measuring :no"
2ontrol F// -red.

ain po+er supply F// -red. 96



Po+er8regulation potentiometer% in cloc:+ise rotation) the po+er increases\ in countercloc:+ise rotation) the po+er reduces# The a"o5e instruments and indicator lamps are used to o"ser5e the +or:ing conditions of po+er supply# The operating "uttons and po+er8regulation potentiometer are used to control the +or:ing conditions of po+er supply# $ote% e9cept for the operation door) another t+o doors are fitted +ith one A2 5oltmeter respecti5ely) to sho+ the 5oltage amplitude of incoming line# 6#, 2ontrol ca"inet instructions Fpen the left door of po+er supply ca"inet) and then you can see a trigger control ca"inet on the top in the po+er supply ca"inet) of +hich the follo+ing schematic diagram is as sho+n in /ig# *#

Frequency +eter

Control #anel oc)ing *ole

A trigger control panel is placed in the ca"inet) and three small 5oltmeters installed on the control ca"inet panel are used to indicate the po+er supply situation of the trigger control panel# 97


n +hich) H*6 ^* and H*6 ^1 are output 5oltage of control po+er supply rectifier "ridge +ithout 5oltage sta"ili;ation) of +hich H*6 ^1 is rectifier trigger circuit po+er) and H*6 ^* is in5erter trigger circuit po+er and pro5ided for the control panel to form H1* ^ positi5e supply of 5oltage regulator# The display 5alue of H*6 ^1 and H*6 ^* changes slightly +ith the 5ariation of po+er grid 5oltage) usually in the range of 1=^ 0 *=^\ the 5alue sho+n in frequency meter is proportional to the highest frequency of the in5erter frequency s+eep#

?tart the +ater pump at first) and chec: that each +ater circuit meets the follo+ing requirements% #1

3ater inlet

pressure of medium frequency ca"inet

and

capacitor ca"inet% '#1pa0'#*pa\ +ater inlet temperature% ,'x\ #* 3ater inlet pressure of melting furnace% '#*pa0'#,pa\ '#1pa0'#*pa\ +ater inlet temperature% ,&x\ #, There is no +ater lea:ing at each +ater connection# &#* Before the medium frequency po+er supply is turned on) measure if each main component is normal at the resistance stage of multimeter% &#*#1 Each fuse resistance is ' -it can not "e measured until the main transformer is po+ered off) and the stage is in the position of (1‘.\ &#*#* Each controlled silicon resistance ’ *C‘ -the stage is in the position of (1C‘.\ &#*#,

"et+een

primary

and

secondary

sides

of

transformer I1''C‘ -the stage is in the position of (1'C‘.\ &#*#6
98


 The de5ice is strictly prohi"ited starting +ith empty furnace) and the furnace must "e charged in order to start properly#  t is prohi"ited that the furnace can not "e emptied +hen there is output po+er) that is to say) +hen discharging molten steel) the potentiometer must "e adusted anti8cloc:+ise "ac: to ;ero# 7#1 Turn anticloc:+ise the po+er8regulation potentiometer on the door of medium frequency po+er supply ca"inet to the end) then press 2ontrol po+er F$ "utton) so that the control system is po+ered on# F"ser5e that the indication of H*6^ 5oltmeter on control ca"inet panel is "et+een 1=^ and *=^) and that in5erter pulse lamp should "e fully lighted# 7#* Press 

frequency8s+eeping is ena"led# V2 5oltmeter of main circuit rectification

output

also

+ill

oscillate

up

and

do+n)

indicating that the self8starting of rectifier also +or:s# After start8up se5eral times) the medium frequency 5oltage +ill indicate) and it can hear the sound squea:ing from medium frequency) and rele5ant instruments stop oscillating and point to the appropriate position) indicating success of starting# 7#7 2ontinue to turn Po+er8regulation potentiometer slo+ly) until the medium frequency 5oltage is up to the operating position# Vuring this process) o"ser5e the t+o V2 ammeters and t+o medium frequency ammeters) of +hich the indicated 5alues should "e "asically same# f the difference "et+een indicated 5alues is too large) please as: electrician to chec:# 7#4 ?hutdo+n sequence% 7#4#1 Turn "ac: the po+er8regulation potentiometer anticloc:+ise\ 7#4#* Press the ain po+er supply F// "utton) the main s+itch is disconnected\ 7#4#, Press the 2ontrol po+er supply F// "utton) the control po+er supply is po+ered off# nstructions% /or this de5ice) after main circuit is po+ered on) each +or:ing status lamp of controlled silicon -located on the resistance8 capacitance a"sorption "oard. should "e lighted) other+ise) it shall as: the electrician to chec:# Vuring operating of the de5ice) it shall carry out record and o"ser5ation on all electrical instruments) if any a"normity is detected) it shall shut do+n immediately and chec:) after the fault is eliminated) it can "e continued to use# 3hen the protection lamp on the door of medium frequency po+er supply ca"inet is light) it shall record +hich red lamp is lighted 1


on the control panel) and o"ser5e if the status indicator lamp of controlled silicon

is e9tinguished#

f any)

please as:

the

electrician to chec:# After protection is presented) it shall "e a+are of +hether there is any ignition) +ater lea:age and other a"normal phenomenon) if no a"normity) and the status indicator lamp of controlled silicon and pulse lamp are normally lighted) then press the “
/or follo+ing introduced component names and their distri"ution positions on the control panel) please refer to hereinafter attached control circuit "oard function distri"ution dra+ing# set the protection 5alue of o5er8current *) increased in cloc:+ise rotation) in re5erse reduced# angle ” is reduced in cloc:+ise rotation and pulse mo5es for+ard\ angle ” is increased in anticloc:+ise rotation and pulse mo5es "ac:+ard# current limiting 5alue 11


is increased in cloc:+ise rotation and reduced in anticloc:+ise rotation# set the protection 5alue of o5er8current 1) increased in cloc:+ise rotation) in re5erse reduced# ” is reduced in cloc:+ise rotation and pulse mo5es for+ard\ ” is increased in anticloc:+ise rotation and pulse mo5es "ac:+ard# set the protection 5alue of medium frequency 5oltage) increased in cloc:+ise rotation) in re5erse reduced# 5oltage limiting 5alue is increased in cloc:+ise rotation and reduced in anticloc:+ise rotation# increased in cloc:+ise rotation and reduced in anticloc:+ise rotation# set the angle  of in5erting +or:)

increased

in

cloc:+ise

rotation

and

reduced

in

anticloc:+ise rotation#

of rectifier *\ of rectifier *\ +hen pressing the emergency stop "utton) the equipment stops emergently in the condition of protection# +hen +ater pressure is too lo+ or +ater temperature is too high) the equipment +ill shut do+n automatically) and this lamp +ill "e lightened#

12


+hen incoming line 5oltage is too lo+ or lac: of phase) reser5e phase) the equipment +ill automatically shut do+n and this lamp +ill "e lighted# of rectifier 1\ of rectifier 1\ +hen the medium frequency 5oltage is set up -a"o5e 1''^.) this lamp +ill "e lighted# +hen in5erter frequency is lo+er than an appropriate 5alue -"elo+ 1''[Z.) this lamp +ill "e lighted# ean+hile) V2 phase8shifting 5oltage is dra+n "ac: to ;ero point) and output frequency of frequency s+eeping

oscillator

is

dra+n

"ac:

to

the

highest

frequency# +hen the phase8loc:ed angle of in5erter is more than the set 5alue) this lamp +ill "e lighted# ean+hile) the current limiting 5alue +ill "e reduced to an appropriate 5alue) so that the phase8loc:ed trac:ing circuit may "e returned to the sta"le condition#

13


+hen s+itching on) the protection setting 5alue is reduced a half\ +hen po+er on) the current sharing function is a5aila"le\ +hen s+itching on) the protection setting 5alue is reduced a half\ +hen s+itching on) the protection setting 5alue is reduced a half\ +hen

s+itching

on)

the

function starting at large angle is a5aila"le\ the self8 starting function is a5aila"le\

1

Vuring

normal

+or:ing)

it

should

regularly

chec:

the

conditions of +ater circuit) such as too lo+ +ater pressure) small flo+ rate or too high +ater temperature) or +ater lea:age# f any a"normity is detected) it shall chec: and 14


eliminate it immediately# *# A drainage 5al5e is normally mounted on the end of +ater inlet pipe# Vrain off the +ater regularly so as to remo5e the solid sundries and sludge accumulated in the pipes# ,# /or hard +ater or +ith more solid particles -i#e# more tur"id.) the surface inside of +ater circuit and component radiator is lia"le to scale) so it must flush the +ater circuit and replace the radiator regularly# 1# Vuring normal +or:ing) regularly chec: the conditions of rele5ant indicator lamps -such as resistance8capacitance a"sorption

"oard)

pulse

transformer.

in

the

electrical

ca"inet and see if they are normal# *#

Vuring

normal

+or:ing

process)

regularly

test

the

temperature of each component and electrical connections "y infrared temperature measuring gun# ,#
2hec:

and

electrical

see

if

ca"inet

the are

electrical loose)

connections

heating

or

in

the

discharging

frequently# &# `nder

the

condition

of

shutdo+n)

regularly

chec:

the

resistance at each electrical point and component of the equipment "y use of multimeter# `nder the condition of startup) regularly chec: the +or:ing +a5eform of each :ey point "y use of oscilloscope) to ensure that the electrical indicator satisfies the requirements# 1#

Arrange

full8time

personnel

to

"e

responsi"le

for

maintenance of the furnace# 2hec: the furnace half an hour in ad5ance "efore starting it e5ery day# 15


*# `se air pump to "lo+ off the conducti5e dust on the surface of sensor\ use magnet to a"sor" the iron chips "et+een coils of sensor# ,# 2hec: the fi9ed scre+s of "a:elite column of sensor and see if they are loose) and chec: +hether the magnetic yo:e post rod is loose# 6# 2hec: the +ater circuit) if the +ater flo+ of some circuit is too small) or if +ater connector lea:s# &# Vuring production process) if the sensor has discharge ignition) resulting in car"oni;ing and dar:ening on the edge of mica plate) on the side of "a:elite column and on the surface of coated sludge) it must use a :nife to sha5e the "lac:ening layer clearly# The "are copper e9posed on the surface of copper pipe due to discharge shall "e "rushed a layer of insulating paint after +orn flat "y sand paper# 7# 3hen deslagging or tapping e5ery time) pro5iding that the furnace panel is not set le5el) it shall turn off the fan on the furnace platform) so as to pre5ent the iron chips "eing "lo+n into the sensor# 4# ?teel tapping must "e carried out after shutdo+n# After tapping) it shall charge completely "efore starting# ?tarting +ith empty machine is prohi"ited#

G#1
 The de5ice is strictly prohi"ited starting +ith empty furnace) and the furnace must "e charged in order to start properly# 17


 Emptying furnace +ithout shutdo+n is prohi"ited) that is to say) +hen discharging molten steel) the potentiometer must "e adusted anti8cloc:+ise "ac: to ;ero# 1'#1 Turn anticloc:+ise the po+er8regulation potentiometer on the door of medium frequency po+er supply ca"inet to the end) then press 2ontrol po+er F$ "utton) so that the control system is po+ered on# F"ser5e that the indication of H*6^ 5oltmeter on control ca"inet panel is "et+een 1=^ and *=^) and that pulse transformer lamp should "e fully lighted# 1'#* Press and hold the Pre8storage energy "utton) then the red

lamp

on

CP

inspection

"oard

is

e9tinguished#

After

releasing the "utton) the storage motor actuates) +ith energy storage in place# f the motor fails to actuate after releasing the Pre8storage energy "utton) please as: the electrician to chec:# 1'#, Press the ain po+er supply F$ "utton) then the main s+itch is turned on# $o+ V2 5oltmeter shall "e re5ersal of "iasing# 1'#6 Press the 
oscillating

and

point

to

the

appropriate

position)

indicating success of starting# 1'#7 2ontinue to turn Po+er8regulation potentiometer slo+ly) until the medium frequency 5oltage is reached to the operating position# /requently o"ser5e the t+o V2 ammeters) of +hich the indicated 5alues should "e "asically same# f the difference "et+een indicated 5alues is too large) please as: electrician 18


to chec:# 1'#4 ?hutdo+n sequence% 1'#4#1

Turn

"ac:

the

po+er8regulation

potentiometer

anti8

cloc:+ise\ 1'#4#* Press the ain po+er supply F// "utton) the main s+itch is disconnected\ 1'#4#, Press the 2ontrol po+er supply F// "utton) the control po+er supply is po+ered off# nstructions% /or this de5ice) after main circuit is po+ered on) each +or:ing status lamp of controlled silicon -located on the resistance8 capacitance a"sorption "oard. should "e lighted) other+ise) please as: the electrician to chec:# Vuring +or:ing process) +hen the protection lamp on the door is light) it shall record +hich red lamp is lighted on the control panel) and o"ser5e if the status indicator lamp of controlled silicon is e9tinguished# f any) please as: the electrician to chec:# After protection is presented) it shall "e a+are of +hether there is any ignition) +ater lea:age and other a"normal phenomenon) if no a"normity) and the status indicator lamp of controlled silicon and pulse lamp are normally lighted) then press the “
"e

repeated

se5eral

times

to

protect)

please

as:

the

electrician to chec: the pro"lem# Vuring +or:ing process) if such phenomenon as +ater lea:age or small flo+ of +ater outlet pipe or no +ater is detected) it shall immediately shut do+n and cut off the po+er to chec: and repair) after the pro"lems are eliminated) it can "e continued to use#

19


2ircui

t schematic dra+ing of 1&T edium frequency electrical furnace V2 5oltmeter 1 V2 5oltmeter * ntegrated protection circuit ôltage control circuit

?ynchr

onous 5oltage A +ayb pipe. /ig#& -A. location oscillogram of synchronous 5oltage of”X1&' and corresponding pulse

?ynchronous 5oltage A +ayb pipe. /ig#& -B. location oscillogram of synchronous 5oltage of”X' and corresponding pulse

111


/ig# 7 n5erting thyristor gate pulse +a5eform

Rectifying p*a,e-,*ifting angle

Rectifier %ridge voltage $avefor+

output

Rectifying tu%e end pre,,ure $avefor+

112


0 t n e r r u c r e v /

5 ( e r u r , e , t a e r W p

e r a p 3 . (

1 .u%-lo$er li+it

A%nor+al +ediu+ frequency

'ediu+ frequency

oltage li+iting

ain control panel schematic dra+ing

/ig#4 -A. lo+er +a5eform of V2 5oltage# Large fluctuation on the top 113

Technical Specification of steel rolling mill

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