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Hydraulic Mould Oscillation - Recent Installations in India - Presentation
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Transcript of Hydraulic Mould Oscillation - Recent Installations in India - Presentation
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
Corus Process Engineering
Hydraulic Mould Oscillation – Recent Installations in India
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
• Overview of mould oscillation• Comparison of Electro-mechanical and Hydraulic oscillation systems• Considerations before upgrading an existing caster• Recent hydraulic oscillation installations in India
Presentation Outline
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
Slab
Billet
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
Mould Operations
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
• Overview of mould oscillation• Comparison of Electro-mechanical and Hydraulic oscillation systems• Considerations before upgrading an existing caster• Recent hydraulic oscillation installations in India
Presentation Outline
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
• Within the mould a solid shell is formed• Mould Oscillation is essential
• Delivering lubricant between shell and mould walls• Minimising mould friction• Obtaining good surface quality• Promoting uniform shell thickness• Controlling lubricant consumption
Overview of mould Oscillation
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
• Overview of mould oscillation• Comparison of Electro-mechanical and Hydraulic oscillation systems• Considerations before upgrading an existing caster• Recent hydraulic oscillation installations in India
Presentation Outline
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
• Typical electro-mechanical oscillation system
• Electric motor• Gearbox• Eccentric• Overload spring box
Comparison of Electro-mechanical and Hydraulicoscillation systems
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
Mould hydraulic oscillation cylinder
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
• Typical hydraulic oscillation system
• Hydraulic cylinder• Control valve• Accumulators
Comparison of Electro-mechanical and Hydraulicoscillation systems
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
• Pros• Simple• Easily maintained• Low electrical power consumption• Basic Control
• Cons• Waveform fixed (Sinusoidal)• Compromise between steel grades and section sizes• Stroke cannot be changed whilst casting
Pros & Cons of Electro-mechanical Systems
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
• Pros• Each steel grade & section size can be optimised• Not restricted to sinusoidal waveforms• During development, practices can be easily altered• Mould powder consumption optimised
• Cons• Requires hydraulic power pack and clean fluid• Electrical power consumption high• If using mineral oil – fire hazard• Relatively complex control equipment• Hydraulic equipment maintained by specialists
Pros & Cons of Hydraulic Oscillation Systems
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
• Overview of mould oscillation• Comparison of Electro-mechanical and Hydraulic oscillation systems• Considerations before upgrading an existing caster• Recent hydraulic oscillation installations in India
Presentation Outline
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
• Market Considerations• What does the market want ?• What current product is being produced ?• How will the future change ?
• Existing Practices• How good are the current practices
• Consistency• Mould level control• Mould powder practices
• Have current oscillation practices been optimised
Considerations before upgrading an existing caster
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
• Engineering Considerations• What is the condition of the mould table ?• Can a hydraulic cylinder be installed safely ?• Is there space & protection for a power pack ?
• People Considerations• Do the existing people have the experience to operate and maintain a hydraulic oscillation system ?
Considerations before upgrading an existing caster
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
• Overview of mould oscillation• Comparison of Electro-mechanical and Hydraulic oscillation systems• Considerations before upgrading an existing caster• Recent hydraulic oscillation installations in India
Presentation Outline
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
• Casting Machine A• 3 strand Billet / Bloom machine• Section sizes 130 x 130 – 280 x 340
• Casting Machine B• Single strand Bloom machine• 300 x 300 – 350 x 350
• Steel grades of both machines• LC, MC, HC, LAS, SS & BG
Recent hydraulic oscillation installations in India
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
• Operational• Stroke +/- 25mm @ cylinder (+/- 12mm @ mould)• Waveform sinusoidal or +/- asymmetric• Frequency range 5 – 250 c.p.m.• Can alter stroke, frequency and waveform during casting
• Control System• Allan Bradley PLC control• Oscillation parameters automatically downloaded from main PLC• Control via SCADA or local HMI• Can operate individual strands
Description of hydraulic mould oscillation system
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
Hydraulic cylinders being tested prior to despatch
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
Control PLCCabinet andLocal HMI Panel
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
Operator’s SCADA Screen
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
• Hydraulic & Mechanical• Hydraulic fluid - Mineral oil • Single servo-cylinder per strand• Automatic burst hose protection system• Hydraulic accumulators on cylinder and in main pressure line• Typical power pack 2 x 90kW motors powering 2 x 220l/min hydraulic pumps
Description of hydraulic mould oscillation system
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
Hydraulic power pack
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
Main line accumulators
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
Mould hydraulic oscillation cylinder
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
Individual strand burst hose protection device
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
• Ability to optimise oscillation practices for each steel grade and section size• Much smoother start and finish to casting• Better surface quality on cast product
Benefits Achieved
5th International Iron & Steelmaking Conf, Vizag 6-7 Aug10 2010
Corus Process Engineering
Hydraulic Mould Oscillation – Recent Installations in India