c3!07!03 Ts17176a-23 Two 2 Strands Vertical CCM

PT.
JAKARTA CAKRATUNGGAL STEEL Mills

Jl. Raya Bekasi km.21-22
Pulogadung, Jakarta 13920
Indonesia
TECHNICAL SPECIFICATION n°17176a/23
TWO STRANDS
VERTICAL CONTINUOUS CASTING
MACHINE
Udine, July 3rd 2023

1
Technical Specification n°17176a/23 – July 3rd, 2023
INDEX
1.0 INTRODUCTION ............................................................................................... 4

2.0 MAIN DESIGN DATA ..................................................................................... 12
2.1 TECHNICAL FEATURES OF THE PLANT .............................................. 12
2.2 UTILITIES REQUIREMENTS.................................................................... 14
2.2.1 TOTAL WATER FLOW & QUALITY PRELIMINARY REQUIREMENTS . 14
2.2.2 COMPRESSED AIR PRELIMINARY REQUIREMENT............................ 14
2.2.3 OXYGEN PRELIMINARY REQUIREMENT(for cutting torches+
emergency use) ....................................................................................... 15
2.2.4 GAS PRELIMINARY REQUIREMENT (for cutting torches + tundish
heating).................................................................................................... 15
2.2.5 ELECTRIC PRELIMINARY POWER(excluding water pumps and water
system) .................................................................................................... 15
3.0 CASTER MAIN EQUIPMENT DESCRIPTION ................................................ 16
3.1 MAIN CASTING PLATFORM WITH STAIRWAYS, FOUNDATION
BOLTS, STAIRCASES, HANDRAILING, SLAG BOXES, LAUNDERS,
COVERS & VARIOUS STRUCTURAL & SUPPORTING PARTS FOR
SECTORS AND COOLING SYSTEM INSIDE THE VERTICAL PART
OF THE MACHINE ................................................................................... 16
3.2 LIFTABLE LADLE CARS SYSTEM EACH SUITABLE FOR LADLES
WITH 80t LIQUID STEEL WITH WEIGHING SYSTEM ............................ 16
3.3 LADLE SHROUD MANIPULATOR .......................................................... 17
3.4 TUNDISH PRE-HEATER .......................................................................... 18
3.5 TUNDISH WITH COVER .......................................................................... 18
3.6 SEMI CANTILEVER TUNDISH CAR, LIFTABLE TYPE WITH
WEIGHING SYSTEM ................................................................................ 19
3.7 TUNDISH TO MOULD SHROUD TUBES HEATING STATION ............... 22
3.8 NOZZLE SLIDING GATE SYSTEM COMPLETE ..................................... 22
3.9 MOULD ASSEMBLY COMPLETE WITH FOOT ROLLS AND COPPER
TUBE FOR BLOOMS, DESIGNED FOR STIRRER, EQUIPPED FOR
ROUND Ø180 mm .................................................................................... 22
3.10 MOULD STRIRRER .................................................................................. 24
3.11 LOW RADIOACTIVITY AUTOMATIC LEVEL CONTROL........................ 26
3.12 MOULD OIL LUBRICATION SYSTEM FOR ALL STRANDS .................. 27
3.13 MOULD POWDER LUBRICATION SYSTEM FOR ALL STRANDS
28
3.14 MAIN STRUCTURAL SUPPORT FOR OSCILLATORS .......................... 30
3.15 HYDRAULIC TYPE OSCILLATORS ........................................................ 30
2
3.16 PRIMARY WATER REGULATION SYSTEM ........................................... 31
3.17 UPPER COOLING CAGES AND BLOOM GUIDING SYSTEM................ 32
3.18 SET OF COOLING CAGES ...................................................................... 33
3.19 COMPLETE SET OF NOZZLES ............................................................... 33
3.20 SECONDARY WATER REGULATION SYSTEM ..................................... 33
3.21 BLOOM GUIDE AND SUPPORT ROLLERS GROUPS ........................... 34
3.22 HYDRAULIC UNIT FOR DRIVEN ROLLERS & BLOOM
DISCHARGING AREA .............................................................................. 35
3.23 COOLING CHAMBER ENCLOSURE WITH STEM DUCT ....................... 36
3.24 STEAM EXAUST FAN .............................................................................. 36
3.25 TORCH CUTTING SYSTEM ..................................................................... 36
3.26 BLOOM GUIDE SUPPORTING & TILTING SYSTEM AFTER CUTTING
TORCH ..................................................................................................... 37
3.27 DUMMY BAR STORAGE SYSTEM.......................................................... 37
3.28 DUMMY BAR WITH HEAD FOR Ø180mm .............................................. 38
3.29 BLOOM EXTRACTION SYSTEM ............................................................. 39
3.30 BLOOM TILTING SYSTEM AT GROUND LEVEL ................................... 39
3.31 BLOOM SIDE PUSHER SYSTEM ............................................................ 40
3.32 NOTCH TYPE COOLING BED FOR BLOOMS UP TO 6m LONG .......... 40
3.33 HYDRAULIC CYLINDERS FOR COOLING BED ..................................... 41
3.34 HYDRAULIC PACK FOR COLLECTING BED ......................................... 41
3.35 AUTOMATIC MARKING MACHINE ......................................................... 41
3.36 ELECTRICAL PANELS ............................................................................ 43
3.37 SUPERVISION STATION ......................................................................... 49
3.38 MACHINERY COOLING CIRCUIT ........................................................... 58
3.39 WATER INTERCONNECTING PIPING FOR MOULDS, SPRAYS AND
MACHINERY WITH FLANGE, HOSES AND ACESSORIES .................. 58
3.40 COMPRESSED AIR PLANT WITH REDUCERS, PIPES AND AIR
RESERVOIR (COMPRESSORS AND DRYERS EXCLUDED) ................ 58
3.41 HYDRAULIC PIPING WITH HOSES AND INSTALLATION
ACESSORIES ........................................................................................... 58
3.42 ELECTRICAL CABLES AND INSTALLATION ACESSORIES................ 58
3.43 SPECIAL CABLES ................................................................................... 58
3
1.0 INTRODUCTION
This specification covers the scope of supply for a heavy duty vertical continuous
casting machine equipped with two strands capable to cast rounds in sizes up to
330mm.
We propose a vertical caster as the best solution to cast the special steel grades
requested in the production mix with the best quality standards.
The absence of straightening in the vertical machine will assure perfect surface and
inner quality of the cast product without any compromise.
At the same time the vertical design allows an extremely compact machine layout with
reduction of space requirements and building expenses.
The available height of the building is not known and thus the ground level is just
indicative in the attached proposed machine layout: machine can be lowered down
increasing in consequence the excavation for the underground part or vice versa
according to Customer specific situation.
The
Layout of vertical slab caster realized and started-up in 2005.
4
The product of vertical slab caster: up to
thickness 400mm!
5
Main view of the containment part during slab caster installation.
6
Main roller area during machine assembling.
7
Vertical caster equipped for slabs
Study for oscillator installation on vertical caster.

8
The machine proposed is eqwuipped with double ladle car that is the simplest solution
for ladle managing and completely cantilever tundish car for easy access and a clean
cast floor (no rails on the casting platform!).
Both cars are liftable to optimise height available at the same time allowing shrouding
tube utilization between both ladle and tundish and tundish and moulds.
Both cars are also equipped with load cells in order to monitor the liquid steel with the
furnace output and synchronize it efficiently with the caster.
The slide gate has been chosen as the safest and the most flexible solution for steel
flow control from tundish to moulds; the same device is completely automatically
controlled from the automation system and driven by dedicated hydraulic units on
board of each tundish car.
The mould is specifically designed for the stirrer application and using tubular copper
cristallizator with design studied on the casting condition and technological process to
be applied at this plant.
The machine will be supplied with Co60 low radioactivity automatic mould level control
that will allow an efficient automatic liquid steel mould level control even at the cast
start that is performed automatically eliminating the most critical human errors.
STS has developed an amplifier / filter system in order to use the smaller radioactive
source available with emissions almost compatible without protections and at the same
time obtain the best strong and reliable signal.
Under the mould there’s a spraying zone that is long enough to assure containment of
the metallurgical length to obtain a compact machine at the same time assuring the
soft cooling necessary for the hard and special steel grades selected.
The roller containment zone is extending approximately 6 m under the moulds and will
be needed for the bigger blooms. The containment segments can be easily inserted
from the top of the machine and are to be prepared off line for a short cast size
changing time.
The spray water will be collected at bottom of the hole and pumped up to more suitable
level for settling and treatment.
For size change it is necessary to change the mould size and the spraying
holders/containment segments to guarantee a perfect secondary cooling that is critical
for good quality billets especially at high casting rates.
Cutting automatic torches have been applied for minimum gas / oxygen steel waste
as the gas is only opened at the time of the cut that by controls directly installed on the
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torch unit, the cutting time and quality are the highest obtainable with a cutting steel
waste of only 4-5 mm and an outstanding quality of the cut almost burr free.
The dummy bar will be a solid design to be lifted from the bottom of the machine during
re-stranding and to be finally parked on the external side of both strands at bottom of
the pit, in a protected dedicated location.
The bloom discharging and lifting system has been proposed with the aim of reducing
the space requirement but can also be re-organised with different layout according to
specific preferences of the Customer.
The blooms will be tilted after cutting and loaded into the notch type bloom lifter, at
ground floor the blooms are tilted down in a intermediate bench from which a bloom
pusher is loading every single bloom to the notch type cooling bed.
This is just one of the solutions and we are open to any discussion to tune and select
the best option also according to specific preferences and situations related to blooms
further managing and storage.
The cooled straight blooms are grouped together at the end of the cooling bed for an
easy removal by overhead crane that should be equipped with suitable tongues or
magnets (not included in this supply).
The electrical controls and process supervision use the best components available in
the market like Allen Bradley, Siemens, ABB, Telemecanique, Rockwell, Weldmuller,
Frer, Merlin Gerin, Botter or equivalent.
The design of the mechanical parts and controls is made for a fast and inexpensive
erection: just laying and connecting few main power cables plus a couple of signal
cables to several local panels plus the pulpit room with several main cabinets.
Such system has been already made in several plants where we have even eliminated
completely the electrical control room as the local panels near the machinery not only
reduce installation cost but it is better for trouble shooting and periodical maintenance
under full safety.
The process supervision made by industrial personal computer and touch screen
monitors based on windows operating system, it is so user’s friendly to allow prompt
operation without reading manuals and it covers all casting parameters for a
comprehensive MMI system capable to manage the casting operation, collect all
operating parameters, print all details including any manual inputs and make available
operating profiles to reproduce the best operating results.
All operating data can be stored for a selected lap of time for any needed play back of
all details, than stored or printed required.
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WE WANT TO STRESS A VERY IMPORTANT POINT: this caster is made fully in
Europe with the best available market components and it is a heavy duty solid
construction, the supply includes the complete machinery with the most reliable
operational tools like alignment stands, templates and larger machinery to cope with
extra safety on design sizes.
Only simple structural parts will be made by Customer according to the detailed
drawing supplied by STS.
The Customer must also supply the necessary foundations with structural parts to be
embedded in the concrete and the necessary foundation bolts.
All machinery is designed for heavy duty and high reliability with minimum and easy
preventive maintenance.
The complete system controlled by STS unique supervision control allow the maximum
steel production with easy multiple sequence casting utilizing at the maximum the
melting capability of the plant.
The machine is requiring little spares as it is designed for long operation time with little
preventive maintenance and minimum lubrication points being most of the machinery
equipped with life lubricated bearings or oil bath lubrication.
The machine is supplied with a comprehensive erection & maintenance manual for an
easy and fast erection work to be done with minimum assistance.
After forty years of experience in designing and installing casters and steel plants in
many countries, this caster is the genuine product designed for today and tomorrow
with features and capabilities for the most exigent steel producer.
We are proud to have made possible such features with machinery of high reliability
but simple to operate and maintain and must thank all our customers / friends
worldwide that made this possible with their precious contributions.
The result, that is every day under an improvement process, is a machine comparable
or even much better than any other leading caster available nowadays, its supervision,
fully in house developed, covers manages and processes all working parameters.
11
2.0 MAIN DESIGN DATA
2.1 TECHNICAL FEATURES OF THE PLANT
Steel to be cast HIGH QUALITY CARBON STEEL for seamless Pipe,

grinding Balls, Automotive Shafting
Number of machines One (1)
Number of strands Two (2)
Ladle capacity 80t of liquid steel
Ladle type Bottom pouring with sliding gate system (ladles excluded
from this supply)
Sequencing facility Twin ladle car, suitable for two ladles, complete with load
cells in order to detect and manage the timing for
subsequent ladle
Machine design range rounds Ø180, Ø210, Ø280, Ø330mm
Machine design speed Operative maximum 1m/min. 2m/min for re-stranding
Tundish type Capacity of approx. 15t of liquid steel
Tundish car Fully cantilevered, manually adjustable nozzle-mould

centering device, complete with load cells
Equipment to cast Round Ø180mm
Mould type Straight, tubular, multi tapered, approx. 750mm long
Mould body Designed for radioactive mould level control, equipped with
adjustable foot rolls and suitable for external stirrer
application
Mould lubrication Automatic mould oil feeding and semi-automatic mould

powder feeder systems considered. Both systems
controlled by the caster supervision program to follow the
casting condition
Mould oscillator Hydraulically controlled by dedicated hydraulic unit, both

frequency and stroke completely adjustable and linked to
12
the steel grade and casting condition System designed for
high frequency and small stroke with minimum vibrations to
obtain the best billet surface quality.
Guiding system Hydraulically pressurized guide rolls automatically

adjustable for the different cast sizes proposed and rolls
driven by electric motors, gear reducers and cardanic shafts
to allow positioning the drives in a safe and protected
environment out of the cooling chamber. All motors
controlled by AC motor and inverter to precisely control
casting speed and bloom length.
Dummy bar system Solid type, straight with head suitable for the Ø180 round
size.
Cutting control of length Controlling any length in approximately 1 mm fractions
Cutting length Adjustable from minimum 3,5 to 6m
Cutting system Automatic cutting torches for carbon and alloyed steel
Bloom tilting & extraction notch type lifter hydraulically controlled
Bloom discharge Bloom tilting station and bloom pusher to load the product
to the notch type cooling bed
Bloom removal Overhead crane duly equipped with suitable billet lifting
devices (crane and lifting system excluded from this supply)
Environmental to be confirmed
Electrical supply 380 V (main) - 220 V (aux.), 50 Hz
Plant supervision Heavy-duty computer supervision level 1 and MMI

management system for an effective production operation
allowing one-week play back of set and actual operating
parameters, remote in line monitor.
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2.2 UTILITIES REQUIREMENTS
2.2.1 TOTAL WATER FLOW & QUALITY PRELIMINARY REQUIREMENTS
The indicated quantity is valid for one strand measured at the service utilization point,
respectively: moulds, sprays and machines cooling
- Moulds: 330 m3 / hour 7 bar max. 35°C

• max. impurities in suspension 100 PPM
• max. impurities diameter 0,2mm
• max. hardness 10 PPM
• max. total hardness 100 PPM
• pH value to be maintained 8
• temperature built up in operation 10°C
• average losses in operation 0,4%
- Sprays / Torch: 65 m3 / hour 10 to 12 bar max. 45°C

• pH value to be maintained 8 to 9
• scale built up in operation 0,2 to 0,5% of steel weight.
• average losses in operation 7%
- Machines: 65 m3 / hour 4 bar max. 35°C

• pH value to be maintained 8
• average losses in operation 0,4%
2.2.2 COMPRESSED AIR PRELIMINARY REQUIREMENT
Reservoir 3.500 liters (air tank excluded from supply)

Flow (average) 300 Nm3/hour
Pressure 6 bar
14
2.2.3 OXYGEN PRELIMINARY REQUIREMENT(FOR CUTTING TORCHES+
EMERGENCY USE)

Pressure 12 bar
2.2.4 GAS PRELIMINARY REQUIREMENT (FOR CUTTING TORCHES +

TUNDISH HEATING)

Pressure 2-3 bar
2.2.5 ELECTRIC PRELIMINARY POWER(EXCLUDING WATER PUMPS AND

WATER SYSTEM)
Installed ~680 kW
Demand ~550 kW
15
3.0 CASTER MAIN EQUIPMENT DESCRIPTION
3.1 MAIN CASTING PLATFORM WITH STAIRWAYS, FOUNDATION BOLTS,

STAIRCASES, HANDRAILING, SLAG BOXES, LAUNDERS, COVERS &
VARIOUS STRUCTURAL & SUPPORTING PARTS FOR SECTORS AND
COOLING SYSTEM INSIDE THE VERTICAL PART OF THE MACHINE
Function:
The structure provides suitable sturdy support for the ladle car, tundish cars, oscillator,
top portion of the bloom guiding system with other related machinery, piping and
systems.
Some parts of the structures will extend into the vertical part of the machine providing
support and precise reference positions for mobile sectors and secondary cooling
system mechanical parts.
The casting platform with his access stairs and handrails provides the vital working
space for the caster operators and accommodation for all auxiliary services at casting
and intermediate floor areas.
Construction:
The supporting structure is designed as a prefabricated steel welded construction for
easy site assembling. It will be prefabricated utilizing standard structural steel sections
assembled into beams, columns, prefabricated frames, stairways, hand railing and
protective guards in order to make up a complete operative unit.
The structure is designed for easy installation so it will be equipped with assembling
bolts for easy lining up before solid welding.
As it will constitute the support for the main process machinery and utilities, in order to
guarantee a solid support for the oscillation units plus ladle & tundish cars and other
services, the lower part is normally integrated with foundation construction over the
floor level.
The platform has been especially designed to take care of emergency situations both
for ladles and tundishes.
The supports in the vertical part of the cooling chamber will comprise machined
reference surfaces and saddles for easy and precise positioning of the containment
and cooling equipment in that area.
The supply is for detailed engineering for local construction at Customer care.
16
3.2 LIFTABLE LADLE CAR SUITABLE FOR TWO LADLES WITH 45t LIQUID
STEEL COMPLETE WITH WEIGHING SYSTEM
Function:
Supporting two ladles in order to bring in casting position the ladle full of steel and at
the same time remove from casting position the empty ladle reducing in this way to
minimum the time for ladle changeover for sequence casting.
The car is fitted with load cells to monitor the liquid steel in the ladles and is equipped
with suitable hydraulic lifting system to allow easy installation of ladle shrouds in the
case of submerged nozzle casting.
Construction:
The construction includes two cars mechanically joint together for a simultaneous
transversal movement but completely independent for the lifting movement that is
powered by one hydraulic unit installed in one of the cars.
The supporting frame and runways are made of heavy welded steel structure that is
parts of a superstructure over the casting floor that acts as a service platform and
protection for the operators.
The driving system includes suitable AC motors and attached reducers (one each car)
controlled by inverter for programmed gradual acceleration and deceleration.
Each car is equipped with hydraulic lifting system with a couple of cylinders for each
side of the ladle.
The electric supply is assured by a number of cables and hoses trough suitable cable
chain installed on the upper service platform.
Each car is also equipped with a ladle weighing system by load cells, the load cells
signal is detected and controlled by a number of cables trough dedicated feeding
system.
The supply includes cable slab plus cables up to a terminal box in a stationary position
on one side of the platform.
Travelling speed: up to 10m/min
3.3 LADLE SHROUD MANIPULATOR
Function
To remove and install the shrouds in the ladle bottom to protect steel stream.
Construction:
Arm and support suitable to manage, move and keep the ladle shrouding tube in
position during ladle change and casting operations.
The support will be provided with suitable connection for Argon supply in the vicinity of
nozzle-ladle shroud connection.
It is a steel construction that can be easily manually operated.
17
3.4 TUNDISH PRE-HEATER
Function:
The system is designed to preheat and keep the tundish hot on the tundish car parked
on the side at the casting floor platform while waiting for the start of the casting process.
Construction:
The unit consists in a system equipped with a set of burners with all controls and safety
features.
The supply starts at the main fuel shut off valve where the fluids are supplied duly
calibrated with suitable pressure reducer as the gas main supply has to be brought into
pre-heater position and connected at Customer care.
The system can operate with Natural Gas or LPG.
The combustion air is ensured by a dedicated fan driven by electric motor on board the
preheating unit.
The peculiar type of burners will assure uniform efficient heating also in the nozzles
attachment area.
3.5 TUNDISH WITH COVER
Function:
The tundish is designed to hold the liquid steel with minimum loss of temperature and
allows floating of impurities while dividing the liquid stream into the required number of
strands with minimum oxidation of the metal.
Another important feature is to reduce the ferro-static pressure existing in the ladle
reducing in this way to the minimum, the liquid steel turbulence inside the mould.
Construction:
Welded steel fabricated frame with suitable stiffening steel sections welded in the most
stress exposed areas.
The tundish side supports are duly machined in order to ensure a good bearing
capacity and safe / fast mounting on the tundish car.
The body incorporates an overflow launder and the reference logs for the tundish cover
plus lifting trunnions for easy and safe crane handling.
The tundish bottom is provided with suitable openings and fittings devices where the
sliding gate system is mounted.
The side and bottom walls are provided with venting holes for humidity release from
the refractory during tundish preheating operation.
The tundish is suitable to be lined inside either with standard refractory bricks, ramming
mixes or special "dry settign mixes".
18
In the case of ramming practice it is necessary to use a suitable template, the
engineering of which is not included in the supply as it is made according to refractory
materials being used.
The capacity considering standard thickness lining is approximately 8÷10t of liquid

steel.
The depth of liquid steel bath with full tundish at operating level is ~750mm with the
overflow designed at 800mm level.
The tundish bottom will be designed to receive the sliding gate mechanism not part of
this supply like the refractory lining.
Typical 3D tundish study.
3.6 CANTILEVER TUNDISH CAR, LIFTABLE TYPE WITH WEIGHING SYSTEM
Function:
The tundish car is designed to support the tundish full of steel during the casting
operation in the correct position of alignment with the moulds and at the correct
elevation from the moulds.
The tundish car will move effectively in transversal direction from the casting direction,
the tundish moving it from the casting position towards the side parking and back.
The tundish handling from side parking & heating into operative position and back is a
normal operating routine sequence plus it is vital in case of emergency situations.
19
The car is equipped with lifing and lowering system to fit the shroud and a load cell
system in order to determine the gross/net liquid steel weight and monitor the liquid
steel level during the whole cast and for efficient cast sequencing.
Construction:
The AC motor drive with suitable reducer is controlled by inverter and the power supply
is ensured by suitable cable slab installed on the top service platform.
The car structure in the tundish supporting area is equipped with lifting hydraulic
cylinders powered by an hydraulic unit installed on board, the car is also equipped with
load cells sending their signal to the main control unit trough a cable slab system.
The car speed controls are programmed with preset acceleration or inching modes in
order to avoid dangerous sudden speed variations in any production operation.
The tundish position (lining-up with moulds) in order to centre the liquid steel stream
can be manually adjusted by suitable hand wheels.
Technical data:
" two wheels on casting floor level
" two reaction wheels on upper service platform
" max travelling speed 12 m/min
The supply includes:

- tundish car main frame
- wheel groups
- cable slab with cables
- weighting system
- motor reducers
- hydraulic unit and lifting pistons
- tundish centring mechanisms
20
Fully cantilever tundish car in final assembling in workshop.
21
3.7 TUNDISH TO MOULD SHROUD TUBES HEATING STATION
Function:
The unit is an oven to keep hot the tundish to mould shrouding tubes.
Construction:
The oven is a refractory lined construction operated by natural gas to be installed in
suitable position on the casting platform.
The oven will have space for shrouds ready to cast plus spare places for any required
emergency tube changing on the fly (2+2 places).
3.8 SLIDING GATE MECHANISM FOR TUNDISH
Function:
The unit is designed to control effectively the steel flow coming out of the tundish
independently for each strand.
Construction:
It is a mechanism attached to the tundish bottom operated by suitable hydraulic
cilinders.
The system will be supplied complete of all accessories to equip two tundishes plus
the parts to prepare the tundishes in the preparation area.
The supply includes the following parts excluding refractory materials:
- 2+2+2 sliding gates mechanichs (2 in working position + 2 in preheating and 2 in
preparation)
- 4 hydraulic cylinders with hoses (2 each car)
- 2 valve stands (one each car)
- dedicated car for gate installation under the tundish
- tools and equipment for gates maintenance and testing
3.9 MOULD ASSEMBLY COMPLETE WITH FOOT ROLLS AND COPPER TUBE
FOR BLOOMS, DESIGNED FOR STIRRER INSTALLATION, EQUIPPED
FOR Ø180mm
Function:
The mould assembly is a welded steel fabrication, annealed and machined, suitable
for all sizes of blooms in the casting capability range of the machine.
It is supplied with the internals to receive a copper tube suitable for casting the desired
bloom size.
It is designed to optimize the cooling effect of the water for an effective and uniform
solidification of the liquid steel. In order to reduce the negative effects of the water
cavitations at high speed it is designed to operate safely under back water pressure.
22
Construction:
It is a complete body easily assembled with all parts to contain the copper tube and
with Stainless steel body suited for the application of the stirrer.
The copper tube or crystallizator is provided with two machined grooves for the
attachment to the steel body by suitable collars to be slipped in, from the sides.
The water jacket made of precision machined stainless steel is designed to provide
high heat transfer rate and uniform water flow pattern.
The nominal water speed inside the jacket is approx. 10m/sec.
The offer includes high performance water jackets with approximately 4,0 mm water
gap and high-pressure operation suitable for high casting speeds and high water
speeds, such jackets operate with 800mm long copper tube so the mould body will be
designed accordingly.
The mould assembly is provided with attachments to the oscillating table for lubricating
oil and also suitable attachments for cooling water inlet / outlet and water supply to the
spray ring installed at the mould bottom.
The mould bottom flange is suitable to receive two rows of independently adjustable
foot rolls to hold the bloom in the centre at the exit side of the mould and dedicated
spray ring in order to smooth cool the bloom while casting.
The mould body is designed to receive also the radioactive type automatic level control
system or on request could be made suitable for magnetic or other level controls
available on the market today.
All gaskets are of the O-Ring type using a standard profile of materials the ones in
contact with the hot areas are made of very high quality black silicon suitable for the
purpose.
The mould bodies are equipped with easily removable top protection and lubrication
plates, most internals are for bolt or screw free installation making the whole operation
fast, easy and mistake free.
The mould body is supplied with copper tube designed for the specific casting condition
selected for the required production, and with water spraying nozzles.
Suitable alignment reference surfaces will assure perfect positioning and alignment
with following containment sector (when isn usage fro the bigger blooms).
23
Ty pical mould assembly after final testing in workshop.
3.10 MOULD STRIRRER
Function:
To stirr according to the desired pattern the liquid steel inside the solidifying bloom in
the mould area.
Construction:
It is a coil that creates a magnetic field concentrated in the mould area inside the bloom
being cast.
The technical feature of the equipment covers mould stirring system for blooms caster
for sizes up to maximum Ø330mm.
The rotating magnetic field stirrer for blooms can be compared to the stator of an
asynchronous motor, it's fed by a 3-phase system at a settable frequency.
The generated magnetic field is a rotating one, and its variation produces eddy currents
within the steel that also interact with the magnetic field, generating a force called
Lorentz force.
This result is the development of a torque that causes the steel to rotate.
The generated torque is a function of the following factors:
" current intensity
" number of coil windings
" rotation frequency
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" System configuration
These parameters change in relation to the type and positioning of the stirrer.
The supply is for TOP mould stirring system specifically designed for the Customer
situation by the best available partner having worldwide experience and references for
stirrer application.
The supply includes stirrer coils with independent inverter panels and transformers for
all strands that are designed for all sections in the design range of the machine.
The scope of supply of external mould EMS includes one external mould
electromagnetic stirrer (stirrer M-EMS) for each strand.
Quantity Description
2 External Mould Electromagnetic Stirrer (stirrer M-EMS)
2 Frequency converters with Control System (integrated in STS PLC); 45°C Max
Ambient temperature
1 Water cooling system with the following main parts: 1 pump, 1 fine filter, 1 heat
exchanger, flow indication, valves, mounted on a base and tank
2 Disconnect Switch, non-fused with micro switch
2 Transformers
1 Technical documentation (equipment manual and plan)
16 man days of stirrer specialists on site for commissioning of the system.
External type mould stirrers in a recent installation.
25
Mould and stirrer assembly in a recent 3D study.
3.11 LOW RADIOACTIVITY AUTOMATIC LEVEL CONTROL
Function:
The system is designed to monitor the liquid steel level inside the mould bringing it to
the maximum upper elevation in order to reduce the effective distance from the tundish
outlet to the mould level reducing in this way the metal turbulence.
The system allows an automatic start up operation reducing the possibility of failures
due to operator's mistakes.
The sistem is in-huose designed by STS and is fast enough to manage automatically
any emergency situartion related to level anomaliess and fluctuations.
Construction:
In line with today's trend to reduce to the minimum, the installed radioactivity and
exposure in any application, we have adopted a source of Co60, with a hihg efficiency
26
counter and very low emission source having an activity of only 20MBq (approximately
0,54 mCi).
The transport of the radioactive source from factory directly to Customer is at STS
care, Customer must provide all necessary import and safety formalities.
STS will supply as basic engineering the following information:
a. installation instruction
b. operating instructions
c. radioactive sources technical characteristics
d. measuring methods
STS level control system main screen.
3.12 OIL LUBRICATION SYSTEM FOR MOULD
Function:
To provide the necessary lubrication to the copper mould inside face in case of open
casting in order to assure best bloom surface quality.
Construction:
The system consists of one steel fabricated tank, with sufficient oil capacity for one day
operation and it includes oil filling filter, level indication, and oil dehydration heater with
relevant controls.
On the side support built in the tank there are installed the oil piston pumps with suction
filters, (each pump serving one strand).
Each piston type pump has individual speed control in order to calibrate the oil flow as
required, by acting only on the driving motor RPM.
The supply includes also a remote potentiometer and oil flow indicator to be installed
on the casting operator's pulpit for direct prompt monitoring during cast.
27
Mould lubrication unit after final testing in the workshop.
3.13 MOULD POWDER LUBRICATION SYSTEM
Function:
It is used with submerged nozzle casting to provide the necessary lubrication powder
to the mould for a proper lubrication of the bloom in order to avoid surface defects.
Construction:
28
The system consists of silos for storage of lubricating powder to keep the material
ready for cast protecting it form air and water contamination.
The powder can be changed in case of different steel grade casting and a suitable
dosing system conveys the correct quantity to the moulds linking it to casting speed to
ensure uniform lubrication.
POWDER SILOS
Function:
To store the mould lubrication powder over mould area ready for use.
Construction:
The storage silos are constructed in steel plate with suitable strength and rigidity to be
easily managed, lifted, filled and changed on the casting platform.
The silos material is properly treated in order to avoid lubrication powder contamination
and duly covered against accidental foreign material mixing.
The service silos are designed to be easily installed on board of the tundish car where
it is also necessary to provide easy changeover also according to steel grades.
SET OF DOSING VALVES

Function:
Activate lubrication powder flow down to the moulds.
Regulate powder feeding rate according to casting conditions.
Construction:
The dosing valve control lubrication powder stopping or delivery to the moulds.
The controls consist of electro-pneumatically activated valve that delivers exactly the
required specific quantity of lubrication powder.
Each valve is independently regulated for each casting strand and it is located
immediately below the silos in order to be protected from harsh environment.
This location allows also an easy inspection and maintainance as it is fully exposed by
just removing the powder containing silos.
SET OF RIGID PIPING AND CONNECTING HOSES

Function:
They provide the compressed air system supply (connected to TOP by Customer) to
the powder distributing system.
The hoses also connect the lubricating powder dosing valves exit to the mould feeding
pipes assuring the proper mould powder flow from silos down to steel level into the
moulds.
Construction:
The rigid pipes and flexible hoses are connecting compressed air system to the dosing
valves.
Suitable hoses are connecting also each dosing valve exit to the respective mould;
where a final part of rigid pipe specifically designed for the purpose, distributes the
lubricating powder over the liquid steel meniscus.
29
The necessary powder for the test period and agreed steel quality range will be
proposed by STS, the Customer must provide all steel analysis as the powder quality
must be calibrated with steel quality.
The powder flow regulation is manually set to the required level and occasionally re
adjusted manually according to the actual needs visually detected.
3.14 MAIN STRUCTURAL SUPPORT FOR OSCILLATORS
Function:
The frame provides the necessary solid support duly machined n order to be the base
for change over of oscillation mechanisms when removing them for periodical
maintenance.
The frame is equipped with water cooled shields to properly protect the mechanical
parts.
Construction:
The support is made by heavy steel sections machined after proper stress relieving.
3.15 HYDRAULIC TYPE OSCILLATORS
Function:
The unit is suitable for moving the mould up and down along the radius as per machine
design, the stroke and the frequency can be adjusted according to the size to be cast
in order to obtain the optimum casting parameters.
The system will allow direct linkage to the casting speed in order to guarantee the
production of the whole bloom with the same operating parameters for a consistent
product quality.
Construction:
The oscillators are installed on a common heavy duty steel machined support that
guarantees a solid support and reference for future oscillator interchange.
The unit is made by a sturdy steel fabricated frame (fixed table) containing the
oscillation mechanism and holding the oscillation table itself.
The fixed table is made by a very strong frame that is installed at casting floor level.
The oscillation movement is activated by suitable hydraulic system interfaced with
electronics for full automated management.
30
OSCILLATOR
OSCILLATOR - TYPICAL
3.16 PRIMARY WATER REGULATION SYSTEM
Function:
The system provides and controls the necessary cooling fluid for the moulds in order
to influence and manage the steel solidification according to the best pattern.
Construction:
31
The supply includes all necessary equipment like: shut off valves, non return valves,
pressure indicators & transmitters, flow transmitters etc.
MOULD WATER CONTROL RACK
3.17 COOLING CAGES AND BLOOM GUIDING SYSTEM
Function:
Upper cooling cages and simple guide roller system will be used to cast rounds.
The system needs to be changed with special containment sectors for casting sizes
bigger than Ø250mm.
Construction:
The supply includes a simple machined frame with guide rollers suitable to be quickly
positioned on the reference supports on the vertical part of the machine and locked in
position for casting the smalle rround blooms.
The system is comprehensive of dedicated spray cooling cages specifically designed
for round bloom casting.
The cooling system will be connected via quick coupling systems.
The sector will be removed by the upper part of the machine after having removed the
mould assembly.
For size change will be possilbe to dismantle mould and mobile sector together to
speed up the machine setting operation.
The sector will be pre-set off line in suitable stands for the reduction of cast size change
times.
32
3.18 SET OF COOLING CAGES
Function:
Provide even distribution of the correct amount of cooling water to the billet surface
inside the cooling chamber.
The water cooling system is using air-mist to obtain the better flexibility of the system
for all steel grades and cast sizes as per production requirement.
Construction:
The spray cages are covering the complete apron curved area in case containment
sector will not be needed (for rounds and smaller sizes) or only the final part after
containment sector for the bigger blooms when containment sector will be used.
The cages are made of stainless steel tubular construction with male thread to receive
suitable brass spraying nozzles normally of the full cone pattern.
Each unit is connected with hose and rigid piping up to the water feeding system and
can be easily replaced.
Naturally the spraying nozzles holders have to be replaced for each bloom size change
especially in the upper area when cooling a cast section with a thinner solid skin.
The spraying nozzles and hoses are included in the supply (nozzles as separate item).
3.19 COMPLETE SET OF SPRAYING NOZZLES
Function:
Provide even distribution of the correct amount of cooling water to the billet surface
inside the cooling chamber.
The nozzles are full cone type to obtain the better flexibility of the machine for all steel
grades and cast sizes as per production requirement.
Construction:
The spray nozzles are designed for the particular casting condition selected for the
Customer production.
3.20 SECONDARY WATER REGULATION SYSTEM

Function:
To provide the necessary quantity and distribution of the cooling fluid for an effective
spraying and cooling pattern.
Construction:
The supply includes all necessary controls such as: shut off valves, strainers, non
return valves, local pressure indicators, flow indicators, etc.
33
The water with the scale produced in the process will be collected in a tank in order to
be pumped back by Customer into the water circuit or at disposal.
In this item field controls are included while the automation system is comprised in the
electrical and supervision plant.
The system as a whole is designed to work in completely automatic mode giving the
possibility of controlling:
- specific water flow,
- total water flow,
- water flow distribution,
The water with the scale produced in the process will be collected in a tank in order to
be pumped back by Customer into the water circuit or at disposal.
The system is supplied assembled on a rack while rigid water supply to the TOP and
installation accessories is for Customer supply.
SPRAY COOLING CONTROL RACK
3.21 BLOOM GUIDE AND SUPPORT ROLLERS GROUPS
Function:
The bloom guide and support groups are positioned along the vertical part to drive up
the dummy bar and to guide the dummy bar and the billet down during casting
controlling the speed.
The groups are postioned to give correct guide and to be always in force on the billet
two at a time to reduce pressure and avoid any damage on the cast product.
34
Construction:
The guide and support groups are installed on the machine along he vertical part at
corect distances to manage the billet and the dummy bar during all operation.
The driven rollers are pressed on the billet by dedicated cylinder controlled by suitable
system to assure the proper support without any damage to the cast product.
In between the part of the area air mist cooling system is installed to continue the heat
extraction avoiding any over heating and improper cooling of the product.
The hydraulic feeding of the cylinders is assured by a dedicated unit.
3.22 HYDRAULIC UNIT FOR DRIVEN ROLLERS & BLOOM DISCHARGING

AREA
Function:
The units provide for each strand the necessary hydraulic power and controls for driven
rollers, bloom tilting systems, and discharge area.
Construction:
Complete hydraulic unit with dedicated valve stands for the control of each movement
in the guide and support and machine discharge area.
The hydraulic unit is supplied with all on board accessories for the correct functioning.
Valve stand and hydraulic unit in workshop after final testing.
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3.23 COOLING CHAMBER ENCLOSURE WITH STEM DUCT
Function:
The enclosure creates a cooling chamber safely containing the bloom spraying water
system conveying outside the steam produced by forced suction and exhaust to the
atmosphere.
In order to avoid inter-strand damages during a possible breakout, a steel frame with
individual suction system separates each strand.
Construction:
It is made of steel frames welded or hinged to the steel structure to create enclosures
and openings according to the production and maintenance exigencies.
3.24 STEAM EXAUST FAN
Function:
The steam suction fan assures efficient removal of steam created during bloom
cooling.
Construction:
The system is a set of two fans complete with the exhaust ducting capable to operate
with high temperature, provided with suitable water condensation traps & suitable
drains to the cooling chamber.
3.25 TORCH CUTTING SYSTEM
Function:
The system is designed to cut the hot cast section at the correct length while travelling
at the casting speed.
The whole system is completely automatically controlled utilizing the sensors on the
machine to cut the bloom at correct lenght in any casting condition.
The system ensures a billet cut according to pre selected lengths adjustable during
casting operation in multiples of 1 mm with temperature sahrinkage adjustment in order
to obtain the effective cold length.
Construction:
A cylinder that will receive the impulse from the lenght measuring encoder installed in
the guide and supporting group activates the clamps on the unit.
As the clamps are powered, the machine is grabbed to the cast section so the torch
assembly will travel with the bloom.
After an initial lap of time used for bloom edge heating, it start its cutting stroke across
the bloom following the profile setting designed for each billet size.
36
At the end of the cut the clamp cylinder will open, releasing the cutting torch that will
return to its initial position by counterweight and lever.
Should the cut be interrupted with the cast section stoppage or any other reason,
including the last cut with the cast section out of the supporting system it is possible to
manually operate the cut until it is completed.
The torch is designed for natural gas and oxygen operation and it is equipped with slag
granulation device by suitable water jets
The supply includes the control panel installed on board of the torch with shut off
valves, reducers, safety valves, solenoid valves and other process controls fully
connected for easy site assembling.
This solution allows a more effective fluid and cut control and easy pre calibration of
the unit.
The torch carriage is also equipped with stainless steel plates and other suitable
shields properly protect all heat exposed parts.
3.26 BLOOM GUIDE SUPPORTING & TILTING SYSTEM AFTER THE CUTTING
TORCH
Function:
The function is to support and smoothly transport to the bottom of the machine the
produced cast sections after cut.
The sysitem will automatically tilt the cut bloom and deposit it on the inclined lifting
system for evacuation form the hole.
The same procedure will be adopted also with dummy bar that will than be removed
on the side for both strands.
Construction:
The support and guide system is designed with suitable simple structure to assure the
smoothest operation with minimum maintenance.
The system is mechanically driven with drive system dislocated in suitable accessible
location at the torch cutting system level for easy inspection.
The system is totally automation controlled for simple and safe operation in the
underground situation.
The receiving frame of the tilter will be equipped with dedicated spacers to be quicly
adapted to the different cast sizes.
The same system will allow also easy dummy bar insertion evcuation and re-stranding.
3.27 DUMMY BAR STORAGE SYSTEM
Function:
The system is designed for an easy and fast handling of the dummy bar during re-
stranding and during / after dummy head disconnection.
37
It provides also a very easy access to the dummy head in order to make it possible,
safe and comfortable the dummy head changeover even during casting operation.
Construction:
The dummy bar storage mechanism consists of a welded and machined steel frame,
holding and guiding the dummy bar to the bloom tilting system for insertion and back.
The dummy bar storing sytem is placed on the external side of both the strands and is
moved by suitable mechanical system placed at the torch cutter level.
The system is fully automatically operated.
3.28 DUMMY BAR WITH HEAD FOR Ø180mm
Function:
The dummy bar provides support and attachment for the bloom casting start up.
Construction:
The dummy bar is made by steel sections with the same overall size of the bloom being
cast, in case of different sizes it could be provided with a suitable transition piece for a
bigger dummy head.
Dummy bar head for round shape in a bow machine.
3.29 BLOOM EXTRACTION SYSTEM
38
Function:
It is a sturdy simple structure laid on inclined plane and driven by hydraulic system to
remove the blooms from tilting system after cut and to bring them to the cooling bed
area at ground level.
Construction:
It is a heavy duty solid support with notches theat picks up the blooms from the tilting
system and bring them at upper elevation by suitable hydraulic driven movements.
The hydraulic system is placed on suitable accessible location on the side of the
mechanical system for easy access and inspection.
Billlet lifting device similar to the system proposed working for one strand caster.
3.30 BLOOM TILTING SYSTEM AT GROUND LEVEL
39
Function:
The function is to support and tilt the bloom at ground level to be after moved to the
coling bed.
Construction:
The support and guide system is designed with suitable simple structure to assure the
smoothest operation with minimum maintenance.
The system is mechanically driven with drive system dislocated in suitable accessible
location for easy inspection.
The sistem is totally automation controlled for simple and safe operation in the
undergraund situation.
3.31 BLOOM SIDE PUSHER SYSTEM
Function:
The system is designed to remove individually for each strand the cast product from
the bloom tilter and deliver it to one side where the cooling bed will provide an uniform
cooling pattern to finally deliver the product at a temperature low enough for safe
grouping ready for stacking.
Construction:
The pusher consists of a frame activated by hydraulic cylinders
3.32 NOTCH TYPE COOLING BED FOR BLOOMS UP TO 6m
Function:
The system is designed to provide an uniform cooling pattern than deliver the product
at a temperature low enough for safe grouping ready for stacking.
Construction:
The cooling bed consists of a fixed frame and a mobile frame activated by hydraulic
cylinders; it is designed to deliver the product with 6 m length at a temperature of 450°C
with an inlet temperature of approximately 900°C and has a horizontal assembling
table for easy product pick up by an overhead crane.
40
Typical notch type coling bed in operation.
3.33 HYDRAULIC CYLINDERS FOR COOLING BED
3.34 HYDRAULIC PACK FOR COLLECTING BED
3.35 AUTOMATIC MARKING MACHINE
Function:
Punching identifying number/codes on all the blooms coming from casting machine.
One machine will be needed to mark all the blooms.
Machine will be installed on side of the cooling bed in correspondence of one of the
first notches.
Each machine will mark the tail of all blooms 6m long.
Construction:
- 16 punches choice (number plus letters or numbers and some as spare)
- 10 mm characters height (best choice for marking even small billet sizes)
- 10 digits in 12 seconds marking speed
- Number of digits designed according to Customer need and cycle time requirements
- Air assisted mechanical punching movement
- Fast interchangeable punching heads
- Precise machine guiding and alignment system
- Life lubricated machine guidance system
- Reliable billet sensing system for machine cycle start
- Machine completely shielded for long life
41
- Machine shields design for easy access to machine even during casting
- Air cooling and cleaning at each cycle to preserve mechanical and electrical
equipment
- Single connection point for utilities (electric power and compressed air only)
- Easy local connection for working parameter setting and cycle programming
Machine utility requirements:

- Installed power: less than 4 kW
- Compressed air pressure: min 4 bar
STS marking machines during final testing in workshop.
42
3.36 ELECTRICAL CONTROL PANELS
Function:
To provide the complete process control of the entire machinery.
The electrical system will be composed of:
-Main electrical panels
-Main automation PLC panels
-Local Panels
-MMI system
-Automation Software
-Pulpits
In order to reduce erection time, expenses and guarantee an easier operation of the
whole plant, the supply will include waterproof local panels with local controls for test
and calibration.
Such solution will unable us to test and calibrate all machinery before shipping and the
Customer to connect all panels and machinery in a very short time.
In this way we can make a fast and cheap erection with only few cables communicating
with the central computer system and feeding the main power trough a main power
line interconnecting all local panels.
The PLC software controls completely the functions of all the machinery and has been
developed to communicate directly with our Supervision system.
STS Supervision software is very powerful and easy to use.
It is been designed to give the full computer power to those operators who are not
computer specialists.
The combination of the two software performs an optimal modern solution for the
complete plant.
Environmental Conditions
Max. Air temperature (for decentralized local panels): + 55°C
Max. Air temperature (for panels inside electrical rooms): + 45°C
Min. Air temperature: - 10°C
Elevation: <1000 m
Max. Relative humidity: 90 %
Power Data
Three-phase for the power line. 380 V - 50 Hz
Single-phase auxiliaries, coils relays, etc. 220 V
43
(The required power on 220 V is obtained directly from 380 / 220 V transformers
included in the supplied panels.)
Maximum Allowable Fluctuations In The Main Power Supply:

Voltage + 10%
Frequency + 1 Hz
Electric Boards, Panels and Desks:

The electrical equipment will be contained in factory assembled and wired cabinets,
made of thick steel plate, all doors equipped with gaskets and safety interlocks
according to I.E.C. regulations.
Local panels with local controls for test and calibration will be waterproof, such panels
may be equipped with Overload trip and operate lamps.
Control Pulpit:
For better operations there are various pulpits located in specific suitable positions in
the plant.
The pulpits are easy to operate and compact made in order to be integrated in their
specific location.
The system is composed of:
- One casting pulpit

- One main pulpit
- Local pulpits
Casting Pulpit:
This pulpit is located near the mould and is operated by the casting operator.
The main functions on this pulpit are:
- Main motor Start and Stop pushbuttons with related signaling lamps
- Oscillator Motor Start and Stop pushbuttons with related signaling lamps
- Manual casting speed regulator
- Manual/automatic level control selector with lamp
- Casting speed indicator
- Mould level indicator
- Lubrication oil control.
44
Main Pulpit:
This pulpit is located in the main control room.
Can be a traditional pulpit made of one cabinet with stainless steel top desk complete
with pushbuttons and lamps.
Alternatively the pulpit can consist of a Personal computer with touch-screen monitor
and our special software. For further information refer to the VIRTUAL PULPIT section.
The main functions of the pulpit, in both cases of traditional pulpit or virtual, are:
- Machine ready to cast /preparation selector
- Straightener rolls manual and automatic controls
- Dummy bar manual and automatic controls
- Cutting system control
- Roller table control
- Evacuation system control
Local Pulpit:
We consolidate the local pulpit functions with the local panel functions.
According to specific plant exigencies we can supply local pulpits that include also the
protection and control equipment.
Naturally the panels are key locked for safety against accidental non authorized
operations.
They are very handy for maintenance on individual machines in total safety and their
standard will require minimum stock of spares.
The main functions covered by local panels or pulpits are:

- Oil Lubrication motor control.
- Ladle car movement
- Tundish cars movement
- Water system flow control manual operations
- Torch cutting system manual operations.
- Roller tables manual control
- Discharge area manual control
45
LOCAL PULPITS AND BOXES – TYPICAL LAYOUT
The number and characteristics of local pulpits or local panels may change according
to specific exigencies, request or technological improvements.
PLC SOFTWARE FOR THE AUTOMATION OF A CONTINUOUS CASTING

MACHINE
The PLC software for management of a continuous casting plant it will be customized
on each plant in a way to optimize the functionality of the machine and to meet all the
Customer requirements.
The Software, which will be supplied, controls completely the machine either for
general services and services concerning single lines.
It has been studied to communicate directly with our systems of Supervision and Virtual
Pulpit.
46
Few typical features of a plant software may be analyzed, dividing it in two parts:
GENERAL MANAGEMENT and CASTING LINES MANAGEMENT.
PLC NETWORKS – TYPICAL DRAWING
GENERAL MANAGEMENT
It is a software for the control of the automation of a continuous casting machine

general services consisting of:
- Consents to cast management concerning general services
- Inverter management for tundish cars with alarm signals and

acceleration/deceleration ramps, automatic slowing down in casting position (for
mould lining up) control
47
- Inverter management for ladle car with alarms signal and acceleration/deceleration
ramps control
- Billet automatic discharging management: transfer carriage start control,

synchronization between transfer carriage, cooling bed and billet lifting system,
cooling bed control for casting end
- Management of the inlet signals of primary and secondary water systems.

- PLC failures signaling
- Data management and forwarding to the Supervision Software (MMI)
- Management and acquisition of signals coming from PLC of the casting lines
CASTING LINES MANAGEMENT:
It is a software for the automatic management of casting lines for a continuous

casting plant between others comprehensive of:
- Consents to cast management for each line
- Mould automatic level control through variation of casting speed.

Start automatic control, low/high level alarms.
There is the possibility to insert an automatic control of after-start.
- Primary cooling water system control with the possibility to maintain water flow or
ratio between inlet/outlet temperatures constant.
Possibility of manual control of valves through opening/closing pushbuttons.
Inadequate flow alarm, Delta T alarms, inadequate pressure alarms control
- Secondary cooling water system with possibility of maintaining water flow or ratio
between water liters/steel kg constant.
Possibility of manual control of the valves through opening/closing pushbuttons.
Inadequate flow and pressure alarms management.
Spray automatic opening together with casting start.
- Automatic control of shears or torches for billet cutting.

Possibility to work in manual mode
- Cut to length management.

Automatic control of the cutting length with use of an encoder to measure the billet
length.
Possibility of variation the shrinking parameter following billet cooling.
Automatic shutdown at the casting end.
48
- Management of the rigid dummy bar parking.
Automatic control of parking with automatic insertion during casting preparation and
automatic recover, comprehensive of release control during casting.
Possibility to work in manual mode.
- Oscillation control related to the casting speed with the possibility to vary the
negative strip parameter and oscillation stroke.
- Mould lubrication control
- Roller way control
- Management of the signals from and to general PLC
Signals preparation and forwarding of Supervision System
3.37 SUPERVISION STATION
STS supervision system is called HMI that stands for Human Machine Interface.
His function is to simplify data collection from the field sensors, allowing an efficient
working parameter setup, by the operator
Practically it operates as an interpreter that allows the operator to talk to the PLC being
the brain of the plant automation.
The supervision system is extremely important in a modern plant, for this reason it
must be powerful, very flexible but at the same time operator’s friendly.
Keeping in mind the need of simplicity, our technician have designed and developed a
system that was expressly created for the steel plants and in particular for the
continuous casting machines.
AUTOMATION
SUPERVISOR PLC
MACHINE
Typical configuration of a Supervision System

49
• One PC with industrial components
• One Monitor 15" TFT (sometimes integrated in the PC)
• One Touch-Screen pointing device
• One color printer
• One Supervision Software
STS supervision Software was completely developed in our automation office, for this
reason it is modular and easily configurable to meet any customer exigencies.
Whatever needed, we can match the most peculiar request without compromises.
The software will be in English Language
50
SUPERVISION STATION
GRAPHICAL ORGANIZATION
The system is organized in graphical pages fully interactive.
Every page is dedicated to a specific function or portion of the plant.
The pages include graphical objects accurately simulating the plant layout so it is
customer tailored to be as realistic as possible.
The supervision system includes typically one panoramic page that allow the operator
to have under control the complete plant
Panoramic page for a three- strand caster
It is possible to easily move from one page to the other just by finger pressing the
correct buttons at the lower part of the screen.
51
As mentioned above, STS system was expressly developed for the casting machines,
therefore all machines have a graphical interface allowing the maximum information
on their status just by a quick look at the screen; no need to read complicated numbers,
or change pages looking for the correct one.
In this way the operator can continuously keep under control the whole plant monitoring
with just a look the smooth operation or spotting promptly any abnormal situation or
problem both in automatic or manual operation mode.
WRITING AND READING WORKING PARAMETERS
If a specific data or detail are needed or it is necessary to modify the working

parameters of the plant, it is possible to reach quickly any specific page, just by
touching with your finger the desired machine on the touch screen monitor.
This operation will open on the screen a small window that contains only the data of
the specific machine.
It is also the possible, to fully reprogram all the production lines by one touch.
52
Any time it is possible to save the plant parameters (for example the parameters that
are most suitable for the production of one particular steel).
Having memorized the data, all can be re-called by just with one finger click and the
machine will reprogram itself without possibility of human errors.
.
Page for data setting management for a two-strand caster
ALARMS AND TRENDS
The software is studied to enable the operator to control both: the plant during
production and / or post-production for data analysis.
This can be done using three different routings.
Two of them are built in the supervision software and the third is a stand-alone
software.
The integrated instruments are the trends and the alarms.
The trends page enables the operator to view the data on-line (the last 10 minutes) or
to read from the historical archive. In this case it is possible to analyze, hour by hour
all the working parameters of the caster.
53
For a comparative analysis it will be possible to visualize in the same time up to four
parameter that will be displayed in different colors for prompt and efficient comparison.
Automatic Mould Level with SS software (PLS note no speed fluctuation)
on line TRENDS example
It is possible to personalize the functions to be visualized on the graphic page but

normally are the following:
Casting speed, Mould water flow, Delta T for mould water, Secondary water flow, Ratio
between Secondary water flow and Quantity of steel produced, Oscillation parameters,
Liquid steel level in the mould.
The alarms page is divided in two sections.
The upper section allows the instant display of the active alarms.
The abnormal situation is described in detail with a report showing the exact time of
the event.
54
The lower section is the historical function so all alarms are memorized with a report
showing the exact starting time and its end.
Page dedicated to the alarms
Every day all the alarms are stored into a file and may be printed for future retrieval
and analysis.
Like for the alarms, the system can display records to a file and point a set of
information called event.
Each new setting or change made by the operators changing working parameters ,
acting on push buttons or selectors, starting of stopping MMI supervision station or
others, will generate an event.
SYSTEM MONITORING
55
The supervision software is design to efficiently save on an external file, every prefixed
time normally one or five minutes, all working parameters.
In this way the filing can be easily traced, being stored with the number of each heat.
The stored files (saved in text format) can be taken from the supervision station and
separately analyzed using our dedicated software o by means of any electronic sheet.
This system allows not only to monitor and analyze the actual operational data but also
the preset data by the operator (it is much more than analyzing the integrated graphic
that show only the working data).
The manager can in this way monitor and correct also possible setting errors by the
operators.
One example of personalization allows recording of the following 28 parameters:

Hour, Ladle weight, Tundish weight, Tundish temperature, Casting speed, Oscillation
number, Steel level, Type of primary water regulation, Primary water flow, Primary
water flow setting, Primary water delta T, Primary water inlet pressure, Primary water
outlet pressure, Type of secondary water regulation at top cage, Secondary water flow
at top cage, Secondary water flow setting at top cage, Ratio Liters of water / kg of cast
steel for top cage, Setting for ratio Liters of water / kg of cast steel for top cage, Type
of secondary water regulation lower portion, Secondary water flow for lower portion,
Setting for secondary water flow for lower portion, Ratio Liters of water / kg of cast steel
for lower portion, Setting for ratio Liters of water / kg of cast steel for lower portion,
Pressure of secondary water, Billet length setting, Billet temperature.
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Inverters monitoring page
PLC network monitoring page

57
3.38 MACHINERY COOLING CIRCUIT
Function:
To provide correct water cooling for all the machine parts subjected to heaitng from the
process.
Construction:
The system will be supplied as loosed parts to be installed on the plant as per detail
information given:
The supply comprises manual regulating valves, main headers, instruments and water
collectors to be positioned and connected on the plant at Customer care.
3.39 WATER INTERCONNECTING PIPING FOR MOULDS, SPRAYS AND

MACHINERY WITH FLANGE, HOSES AND ACESSORIES
The supply comprises all basic information for interconnecting piping for water to be
executed at Customer care.
3.40 COMPRESSED AIR PLANT WITH REDUCERS, PIPES AND AIR

RESERVOIR (COMPRESSORS AND DRYERS EXCLUDED)
The supply comprises all basic information for interconnecting piping for air reticulation
to be executed at Customer care.
3.41 HYDRAULIC PIPING WITH HOSES AND INSTALLATION ACESSORIES

The supply comprises all basic information for interconnecting piping for hydraulic
circuits to be executed at Customer care
3.42 ELECTRICAL CABLES AND INSTALLATION ACESSORIES

The supply comprises all basic information for interconnecting cables to be supplied
and installed at Customer care.
Plaese see description ofthe electrical system.
3.43 SPECIAL CABLES

The supply comprises the network shielded cable for the complete caster.
58

c3!07!03 Ts17176a-23 Two 2 Strands Vertical CCM

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PT.

JAKARTA CAKRATUNGGAL STEEL Mills

TECHNICAL SPECIFICATION n°17176a/23

Udine, July 3rd 2023

1.0 INTRODUCTION ............................................................................................... 4

Layout of vertical slab caster realized and started-up in 2005.

Study for oscillator installation on vertical caster.

Steel to be cast HIGH QUALITY CARBON STEEL for seamless Pipe,

Number of machines One (1)

Number of strands Two (2)

Ladle capacity 80t of liquid steel

Machine design range rounds Ø180, Ø210, Ø280, Ø330mm

Machine design speed Operative maximum 1m/min. 2m/min for re-stranding

Tundish type Capacity of approx. 15t of liquid steel

Tundish car Fully cantilevered, manually adjustable nozzle-mould

Equipment to cast Round Ø180mm

Mould type Straight, tubular, multi tapered, approx. 750mm long

Mould lubrication Automatic mould oil feeding and semi-automatic mould

Mould oscillator Hydraulically controlled by dedicated hydraulic unit, both

Guiding system Hydraulically pressurized guide rolls automatically

Cutting control of length Controlling any length in approximately 1 mm fractions

Cutting length Adjustable from minimum 3,5 to 6m

Bloom tilting & extraction notch type lifter hydraulically controlled

Electrical supply 380 V (main) - 220 V (aux.), 50 Hz

Plant supervision Heavy-duty computer supervision level 1 and MMI

2.2.1 TOTAL WATER FLOW & QUALITY PRELIMINARY REQUIREMENTS

- Moulds: 330 m3 / hour 7 bar max. 35°C

- Sprays / Torch: 65 m3 / hour 10 to 12 bar max. 45°C

- Machines: 65 m3 / hour 4 bar max. 35°C

2.2.2 COMPRESSED AIR PRELIMINARY REQUIREMENT

Reservoir 3.500 liters (air tank excluded from supply)

Flow (average) 250 Nm3/hour

2.2.4 GAS PRELIMINARY REQUIREMENT (FOR CUTTING TORCHES +

Flow (average) 500 Nm3/hour

2.2.5 ELECTRIC PRELIMINARY POWER(EXCLUDING WATER PUMPS AND

3.1 MAIN CASTING PLATFORM WITH STAIRWAYS, FOUNDATION BOLTS,

3.3 LADLE SHROUD MANIPULATOR

3.5 TUNDISH WITH COVER

The capacity considering standard thickness lining is approximately 8÷10t of liquid

Typical 3D tundish study.

3.6 CANTILEVER TUNDISH CAR, LIFTABLE TYPE WITH WEIGHING SYSTEM

The supply includes:

3.8 SLIDING GATE MECHANISM FOR TUNDISH

3.10 MOULD STRIRRER

External type mould stirrers in a recent installation.

3.11 LOW RADIOACTIVITY AUTOMATIC LEVEL CONTROL

STS level control system main screen.

3.12 OIL LUBRICATION SYSTEM FOR MOULD

3.13 MOULD POWDER LUBRICATION SYSTEM

SET OF DOSING VALVES

SET OF RIGID PIPING AND CONNECTING HOSES

3.14 MAIN STRUCTURAL SUPPORT FOR OSCILLATORS

3.15 HYDRAULIC TYPE OSCILLATORS

3.16 PRIMARY WATER REGULATION SYSTEM

MOULD WATER CONTROL RACK

3.17 COOLING CAGES AND BLOOM GUIDING SYSTEM

3.19 COMPLETE SET OF SPRAYING NOZZLES

3.20 SECONDARY WATER REGULATION SYSTEM

SPRAY COOLING CONTROL RACK

3.21 BLOOM GUIDE AND SUPPORT ROLLERS GROUPS

3.22 HYDRAULIC UNIT FOR DRIVEN ROLLERS & BLOOM DISCHARGING

Valve stand and hydraulic unit in workshop after final testing.

3.24 STEAM EXAUST FAN