IVACO

L’Orignal, Canada

CONTINUOUS CASTING MACHINE

3(4) - STRAND BILLET CASTER 10-18 CCS

METALLURGICAL
MANUAL

C.4619/401
 METALLURGICAL MANUAL
_______________________________________________________________________

CHAPTER MODULE DESCRIPTION REGISTER

_______________________________________________________________________

1 METALLURGICAL CONCEPT 1
IN MACHINE DESIGN

2 CASTING OPERATIONS 2

3 OPERATION IN CASTING AUXILIARY AREAS 3

4 CASTING PARAMETERS 4

5 GUIDELINES FOR BILLET 5

QUALITY EVALUATION

6 STARTUP AND COMMISSIONING 6

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 CHAPTER 1

METALLURGICAL CONCEPTS
IN MACHINE DESIGN

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METALLURGICAL CONCEPTS IN MACHINE DESIGN

TABLE OF CONTENTS

1. MACHINE DESCRIPTION 4
1.1 STEEL PLANT DATA 4
1.2 STEEL GRADES AND PRODUCTION TABLE 4
1.2.1 STEEL GRADES 4
1.2.2 PRODUCTION MIX 4
CASTER MAIN DATA 6
1.3 DRAWINGS 8
2. TUNDISH AND TUNDISH REFRACTORY SPECIFICATION 9
2.1 DESCRIPTION 9
2.2 TUNDISH REFRACTORIES 9
2.3 PERMANENT LINING AND INSULATION 9
2.4 WORKING LINING 10
2.5 TURBOSTOP 11
2.6 SPECIAL PIECES 11
2.7 ISOSTATIC (SHAPED) COMPONENTS 11
2.8 TYPICAL OPERATION LIFE OF REFRACTORY MATERIALS 11
2.9 TUNDISH PREHEATING 12
2.10 TUNDISH POWDER 13
2.11 DRAWING AND DATASHEETS OF THE REFRACTORY MATERIALS 13
3. MOULD 14
3.1 DESCRIPTION 15
3.2 EFFECT OF MOULD COOLING 15
3.3 CONTROL OF MOULD COOLING WATER 15
3.4 WATER QUALITY 15
3.5 EMERGENCY COOLING WATER 16
4. AUTOMATIC MOULD LEVEL CONTROL 16
4.1 FUNCTION 16
4.2 THEORY OF OPERATION 17
4.3 CALIBRATION 18

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4.4 MOULD LEVEL SIGNAL ACCURACY AND STABILITY 19
4.5 MOULD LEVELS 19
4.6 DRAWINGS 20
5. MOULD OSCILLATION 21
5.1 FUNCTION 21
5.2 OPERATION 21
5.3 OSCILLATION PARAMETERS 21
5.4 SYMMETRY 22
5.5 FREQUENCY 23
5.6 AMPLITUDE (STROKE) 23
5.7 CONSIDERATIONS FOR SELECTING OF OSCILLATION PARAMETERS 23
5.8 OSCILLATION MARKS 25
5.9 DEVIATION OF OSCILLATION 26
5.10 LIST OF DRAWINGS 26
6. SECONDARY COOLING 27
6.1 INTRODUCTION 27
6.2 SECONDARY COOLING INTENSITY 27
6.3 SHELL THICKNESS 28
6.4 SECONDARY COOLING LAYOUT 29
6.5 CONTROL 29
6.6 SPRAY NOZZLES 32
6.6.1 RELATIONSHIP BETWEEN WATER FLOW VERSUS WATER PRESSURE AT
NOZZLE TIP – SINGLE FLUID NOZZLE (WATER) 32
6.6.2 RELATIONSHIP BETWEEN WATER FLOW VERSUS WATER PRESSURE AT
NOZZLE TIP – DOUBLE FLUID NOZZLES (AIR MIST) 32
6.7 DRAWINGS 33
7. FINAL ELECTROMAGNETIC STIRRER 33
8. STRAND GUIDE SYSTEM 34
8.1 INTRODUCTION 34
8.2 FOOT ROLLS 35
8.3 STRAND GUIDE ROLLS 36
8.4 WITHDRAWAL STRAIGHTENING 41
8.5 CROP END PINCH ROLL 43
8.6 LIST OF DRAWINGS 44

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1. MACHINE DESCRIPTION

1.1 STEEL PLANT DATA

Plant production minimum capacity:

3(4) strand caster producing initially 700 000 short tons per year increasing to
900 000 sht py with the addition of a forth strand

– Heat Size 75 sht (68 tonnes).

1.2 STEEL GRADES AND PRODUCTION TABLE

1.2.1 STEEL GRADES

The steel grades produced shall be as follows

1.2.2 PRODUCTION MIX

Liquid steel after refining in the ladle furnace will be cast into the following sizes:

160 x 160 mm 100% of total production

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C.4619/401 Chapter 1 Rev0
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CASTER MAIN DATA

Machine type CONVEX CONCAST 18 - 10 CCS

Machine radius 10/18m

Number of strands 3/4 with space for the 5th strand

Provision The CCM foresees the future installation of the 4th

strand
.

Strand distance 1’300 mm

Design limit
- section range 130 mm sq. to 180 mm sq.
- cutting length 7.6 to 14 m

Section to be casts 160 mm square

Metallurgical length ca. 30 m

(top of mould up to torch cutting position)

Ladle support Independently rotatable arms

Provision for lifting/lowering system and weighing
facilities.

Tundish Car Cantilever tundish cars with weighing facilities.

Provision for lifting/lowering system.

Tundish For hot or cold tundish practice, reinforced

steel shell made up of heavy steel plates, with
permanent- and wear refractory lining.
Designed for 3 strands with 1’300 mm of
strand distance.
19.7t (20.4) working (overflow) capacity at
900 (950)mm steel level

Tundish Preheater 3 burners using natural gas

Tundish Nozzle Preheater Venturi Type

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Tundish Stopper Control Electro mechanical stopper boxes mounted to
Tundish shell

Mould Oil Lubrication Independent oil lubrication of each mould face

Casting Powder Feeder Supplying mould powder stored in two overhead

hoppers and controlled via a pneumatic pinch
valve

Mould Oscillation compact type

- hydraulic drive
- Frequency and stroke remotely controlled
- Frequency 20 ÷ 350 strokes/min
- Stroke 1-10 (±20mm) mm
- any oscillation curve shape is possible
(sinusoidal, non sinusoidal and user defined)

Mould tube design: Tubular moulds

- Convex® Mould technology, 1000 mm long

Mould housing - Cartridge type for billet sections

Mould Electro Magnetic Stirrer Rotative stirring movement of the liquid core in
order to improve billet centre soundness. The
stirrer generates a rotating magnetic field
about the casting axis.

Mould Attached Foot Rolls 2 row (8 rolls) attached to cartridge.

Templates provided for alignment

Mould Level Control Radioactive Type

Source - Co60

Strand guide system 4 Segments for billet and dummy bar guidance,
Segment 1 containing 2 guide units

Secondary Cooling 4 zones. Zones 1 & 2 water only, zones 3 & 4 air
mist

Final Electro Magnetic Stirring The stirrer coils are mounted in the lower part
of the machine radius at an optimised position
(depending on section size and casting speed).

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Withdrawal Straightening and MSR Continuous straightening (CCS) with multiple
straightening points (two) The modules are
designed to handle the dummy bar and to
straighten the strand.
Future installation of additional modules of the
same construction (maximum 6 total per strand)
will allow performing Mechanical Soft Reduction,
without need to replace the two existing
modules.
In this future configuration, modules 2 to 6 will
perform Mechanical Soft Reduction on the billet.

Dummy bar system Chain Rigid dummy bar

Suitable for Conseal Head preparation

Strand cutting by oxy-cutting machine

Discharge area Cross transfer, walking beam cooling bed.

1.3 DRAWINGS

LONGITUDINAL SECTION 3029522

CCM PLAN VIEW 3029521

DISCHARGE AREA 3020723

LADLE/TUNDISH/MOULD 95090

ROLLER DIAGRAM 93313

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 Tundish Car 1 in Preheating Position Tundish Car in Casting Position Tundish Car 2 in Preheating Position
(FUTURE)

C.L. MACHINE

C.L. STRAND 1
C.L. STRAND 2
C.L. STRAND 3
C.L. STRAND 4

Face Of End Stop

Printed by: C808 on 11. Februar 2014 - Status: Released

 FIXED SIDE

-2950

Printed by: C808 on 11. Februar 2014 - Status: Released

Printed by: C808 on 11. Februar 2014 - Status: Released
100% 100%
60% WORKING LEVEL 60% WORKING LEVEL
0% 0%
 400
8027.506

250
1000 CL Casting Radius

1
2
FR
Future SEMS

s1
4

5
000
0
6 R1

Future MSR
7
8

R18000
9
s2

Disconnection
10

Tangent Axis
Fixed Side

z 11
12
13 Future MSR
x

Disconnection

Cutting Start
14
15
16
17 -2000
s3 18 Passline
19 20 21
1 2 3 4 5 6 7 8 9 10 11 12 13

s4 750 760 750 820 690

800 750 800 750 800 750 760

10662.83 13879.6
2. TUNDISH AND TUNDISH REFRACTORY SPECIFICATION

2.1 DESCRIPTION
The tundish is the last refractory-lined unit through which the steel passes before
entering the mould. Therefore it can have an important influence on the quality of
the cast product as well as on the casting yield.
The thermal conditions of the tundish are to a large degree influenced by the
conditions of the steel in the ladle (steel temperature, presence of stratification).
High-temperature preheating of the tundish is commonly used to minimise the
heat lost during the initial filling and the thermal losses through the refractory
lining.
The steel leaving the tundish flows into the mould through a nozzle. The type of
nozzle is the basis for the “Casting System”, and is chosen depending on the
quality requirements of the steel being cast, and the operational aspects of the
caster.
In general the tundish is either equipped to cast with some form of automatic flow
control, or with a metering nozzle that has no automatic flow control

2.2 TUNDISH REFRACTORIES

The tundish is usually lined with a permanent refractory lining (in most cases
monolithic, alternatively bricks can also be used) and a sacrificial working lining.
Insulation layer
This layer is normally provided in the form of ceramic-fibre boards with low
thermal conductivity. Its purpose is to reduce the temperature of the outer
tundish shell.
Typical material:
RHI PYROSTOP BOARD 1260 (see annex)

2.3 PERMANENT LINING AND INSULATION

Normally monolithic permanent linings are used because of the absence of space
between bricks and the higher duration in service.
Monolithic linings can be applied as either thixotropic mixes, thickened by
vibration, or free-flowing castables. It requires anchors welded to the tundish to
keep it in place.
A newly made permanent lining has to be carefully dried.

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 Before placing it into the dryer, the new permanent lining must be allowed to dry
in air for 24 hours.
A reference drying cycle is shown in the following diagram. Always apply to the
refractory supplier for the correct curve to use for the specific material!
Mainly two holding times (12-18 hours each, approx. 1 hour per 10 mm of
refractory thickness) are shown in the diagram at 175°C and 450°C. They are
needed to evaporate the moisture and water of crystallisation. Failure to do this
would crack the permanent lining. Finally the temperature can be raised to
700°C.
A tundish is completely dry if no more steam comes out of the evaporation holes
in the tundish shell.
Refractory supplier’s preparation specifications must be strictly adhered to, to
ensure safe operation and optimum performance.
Thermal insulation boards (typically 10 mm thick) are placed below the
permanent lining to keep the steel shell of the tundish cool.

Typical material
Permanent lining:
ANKOCAST SV90 0-6 C, bauxite-based low-cement vibrating mix
Thermal insulation:
PYROSTOP BOARD 1260, ceramic fibres, thermal conductivity ~0.1 W/mK
(see refractory documentation)

2.4 WORKING LINING

In most cases a basic gunning mix is used for the working lining, with a
composition that is chemically inert towards liquid steel. (normally, MgO, which
ensures longer casting time).
It is also possible to use dry settling mixes, which are poured in place around a
template. Heating the template makes the mix sinter and form a monolithic
layer.
The working lining facilitates cleaning after use and is to be newly applied after
every cast.
The thickness of the spray-gunned layer is about 30 mm and about 50 mm on the
slag-line.
After spraying the tundish should be dried in the drying station according to the
curve given by the refractory supplier. After drying the tundish can be let cool
down to room temperature without prejudice for the refractory lining. A reference
drying cycle is shown in the following diagram

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 Typical material:
RHI ANKERTUN CS10-M (see refractory documentation)

2.5 TURBOSTOP
A Turbostop is a specially designed refractory piece which is placed over the
Impact Area of the ladle stream. Its purpose is to equalise the flow of steel to
each of the strands, and also to direct the flow of steel upwards to enable capture
of non-metallic inclusions in the tundish surface layer. Ankoform M90S-IP 0-6 C
(see refractory documentation).

2.6 SPECIAL PIECES

An impact plate is placed underneath the tubostop. Their purpose is to resist the
strong mechanical aggression by the steel stream in the event that the
turbostopper becomes worn or damaged.
Typical data:
Lower impact plates:
Ankoform M97S 0-6 C, based on sintered magnesia (see refractory
documentation)

2.7 ISOSTATIC (SHAPED) COMPONENTS

(See Drawings and Datasheets in Annex 2.13)

2.8 TYPICAL OPERATION LIFE OF REFRACTORY MATERIALS

Insulation layer 1 or 2 tundish re-linings
Permanent layer, monolithic Approx. 500 ladles
Working layer, MgO gunning 12 to max. 48 hours (depending on layer
thickness and steel grade)
Ladle shroud Approx. 5 ladles - needs to be cleaned
with oxygen during ladle change
Lower impact plate 1 to 3 sequences, depending on
sequence casting ratio

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 Upper impact plate or turbulence inhibitor 1 sequence
Intermediate walls 1 sequence
Nozzle seating blocks 2 – 3 sequences
Stopper rods 1 sequence
SENs Normally 5 max. 10 hours with “normal”
steels (low Mn, low S)
Max. 4 hours with “aggressive” steels
(high Mn or free-cutting steels)
Lifetime depends strongly on the thickness of the refractory tube and the
conditions in the mould (composition of slag layer, intensity of stirring

2.9 TUNDISH PREHEATING

Suppliers’ specifications of preheating should be strictly adhered to.
The tundish pre-heater is equipped with a programmable controller to enable
various automatic preheating cycles to be stored. Prior to preheating a tundish
with the wear lining ready, the tundish should be carefully cleaned to remove
debris that could block the nozzles.
After preheating, the lining temperature should be about 1’200 °C. A higher
temperature may be dangerous for open nozzle casting since lining debris might
melt and clog the tundish nozzles if they are not sealed.
A tundish once preheated must be used, if cooled down to ambient temperature
the ordinary magnesite coating may collapse.
A typical preheating curve is shown in the following diagram. (See data sheets for
drying and heating curves)

1400

1200

1000
Tem perature (°C)

800

600

400

200

0
0 30 60 90 120
Time (minutes)

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2.10 TUNDISH POWDER

The liquid steel in tundish must be covered with powder in order to:
 Prevent reoxidation (especially important for Al-killed steels and for “clean
steels” generally). This is by far the most important function of the
powder.
 Reduce temperature loss and limiting the radiation from the steel surface
to the ladle slide gate mechanism and stopper gear (important when
there is no tundish cover)
Tundish powder should be applied soon as the steel level is approx. 250 - 350
mm. New powder must be added during casting when necessary, especially
after a sequence change. The appearance of sparks around the ladle shroud is
a clear indication that there is not enough powder around it.

2.11 DRAWING AND DATASHEETS OF THE REFRACTORY

MATERIALS

TUNDISH – TA 10044714
TUNDISH COVER 10044772
RHI REFRACTORY DOCUMENTATION PDF
VESUVIUS REFRACTORY DOCUMENTATION PDF

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 8 7 6 5 4 3 2 1

Number Plate to be weld on every Tundish

140 140 3059
4040
F 180 F
1725

0.5

E E
825

5000

Printed by: C850 on 24. September 2013 - Status: Released RE

4700 0.5
D D

C C

1) OUTER DIMENSION FOR PACKING

2) DIMENSION TO BE CHECKED AND RECORDED.

65 0.2 RECORD TO BE SIGNED AND SUBMITTED TO CONTRACTOR.
50 0.2

0.5
0.2

0.2

950
65

100
1 1 Tundish Shell 1725x3058.9x5000 - 7.011 TO 546539 10044235
Item Qty Description Dimension Basic Material Weight Ut. MM-No. DRW-No. Norm/Remark

Modell: 10000291454_IAM_000.iam Modellversion: -

B 0.2
200 B

THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
Section Weight Main Scale Format
Standard Workshop
1050 0.5 ISO 128
Instructions 9800.4 110.100 7.011 TO 1 : 20 A2
Replaced by

2347 Released 15.03.2013 CHVI

0.5
Tundish-TA Approved 15.03.2013 GAIR

Drawn 23.01.2013 GAIR

3644 0.5 Document No. Version
A A
10'044'714 -
Sheet: 1 of 1
Material No.

Index Description of Modification Date Name SMS group

546543
8 7 6 5 4 3 2 1
CPU Old File Name: File Name: 10044714_DRF_000.idw
 8 7 6 5 4 3 2 1

4040

F 3800 F

160
E E

20

20 20

Printed by: C850 on 24. September 2013 - Status: Released RE

1200
D D
505

C C
600 1297 1297

2
1

2 3 Cover - - 15.8 KG 435389 10015366

A 1 1 Tundish Cover Frame 160x1200x4040 - 242.8 KG 546927 10044760

Total Weight Item Qty Description Dimension Basic Material Weight Ut. MM-No. DRW-No. Norm/Remark

Modell: 10000291775_IAM_000.iam Modellversion: A

Description Weight (Kg)
B Tundish Covers ~290 B
Refractory ~1514 A

Total ~1804

THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
Section Weight Main Scale Format
Standard Workshop
ISO 128
Instructions 9800.4 110.120 290.3 KG 1 : 10 A2
Replaced by

Released 22.04.2013 CHVI

Tundish Cover-TA Approved 22.04.2013 SHIY

Drawn 19.04.2013 CHVI

Document No. Version
A A
10'044'772 A
Sheet: 1 of 1
A Drg Revised 19.04.2013 CHVI Material No.

Index Description of Modification Date Name SMS group

546906
8 7 6 5 4 3 2 1
EBA Old File Name: File Name: 10044772_DRF_000.idw
SMS Concast AG, Zurich, Switzerland
Project number C.4619.401 – Ivaco, Canada
__________________________________________________________________________________

"Ivaco Rolling Mills"

Billet/bloom 3-strand caster
Canada

Vesuvius Tundish Proposal:

Tundish Flow Control and Tundish Linings Products

_________________________________________________________________________________________

Revision 0 June 19, 2013 Page 1 of 58

SMS Concast AG, Zurich, Switzerland
Project number C.4619.401 – Ivaco, Canada
__________________________________________________________________________________

Table of Contents
1. General Information [page 3]

2. VISO Flow Control Caster Refractory [pages 4-22]

2.1. Flow Control Caster Refractory Designs

2.2. Material selection by application, Technical Data Sheets

2.3. References for Vesuvius Caster Refractories (NAFTA)

2.4. Manufacturing of Vesuvius Caster Refractories

2.5. Product development and Technical Service

3. Mold and Tundish Fluxes [pages 23-34]

3.1. Mold Flux (Metallurgica Scorialit) Recommendations, Technical Data Sheets

3.2. Tundish Flux (Vesuvius AFAX) Recommendations, Technical Data Sheets

3.3. Vesuvius – Dilute Phase, Air Assist Flux Feeder

3.4. References for Vesuvius Mold Fluxes (NAFTA)

3.5. Product development and Technical Service

4. Tundish Lining Refractory [pages 35-52]

4.1. Bill of Material, Technical Data Sheets

4.2. Refractory Drawings

4.3. Thermal Calculations

4.4. Refractory Materials and Equipment

4.5. References for Vesuvius Tundish Linings Refractories (NAFTA)

5. SERT – Mold Level Control System [pages 53-56]

5.1. Description of SERT Mold Level Control System

5.2. References for SERT (global)

6. Timeline and Requirements [page 57]

7. Intellectual Property [page 58]
8. Disclaimer [page 58]
9. Contact Information [page 58]

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SMS Concast AG, Zurich, Switzerland
Project number C.4619.401 – Ivaco, Canada
__________________________________________________________________________________

1.0 General Information

Vesuvius is a global leader in metal flow engineering, providing a full range of engineering services and solutions to
its customers worldwide, principally serving the steel and foundry industries.

VESUVIUS Steel Flow Control and Advanced Refractories business units exist to assist Steel makers to enhance
the quality of their products, increase their competitiveness and reduce their environmental footprint.

VESUVIUS achieves this by working closely with its customers, to develop customized refractory systems,
services and technologies that enable them to improve their performance.

From ladle to mold, VESUVIUS provides the most advanced tundish refractory systems. As the market leader in
tundish refractories, VESUVIUS provides technologically advanced products for casting applications and complete
installation services and support to ensure your unique operation is optimized.

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SMS Concast AG, Zurich, Switzerland
Project number C.4619.401 – Ivaco, Canada
__________________________________________________________________________________

2.1 VISO - Flow Control Caster Refractory Designs

Segment of SMS CONCAST Drawing 95090.1 “Submerged Casting Situation”

Drawing provides overall dimensions but not the required detail to develop specific designs. For this exercise and
from this drawing:

Ladle Shroud: Length 1250 mm

Stopper Rod: Length approx. 1335 mm (1375-200+160)

Submerged Entry Nozzle: Length approx. 1260 mm (860+200)

The following pages show “sample” or “example” designs that would be a starting point for design development
based on input on the application. Development of actual designs for the application will required a detailed
understanding of the application. Should SMS wish to proceed with Vesuvius then a dialog will commence with
Vesuvius requested specific details for that purpose.

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SMS Concast AG, Zurich, Switzerland
Project number C.4619.401 – Ivaco, Canada
__________________________________________________________________________________

2.1.1 VISO - Ladle Shroud (LS) with Argon

Sample Ladle Shroud of prefered design

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SMS Concast AG, Zurich, Switzerland
Project number C.4619.401 – Ivaco, Canada
__________________________________________________________________________________

2.1.2 VISO - Ladle Shroud Gasket

Sample Ladle Shroud Gasket of prefered design

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Revision 0 June 19, 2013 Page 6 of 58

SMS Concast AG, Zurich, Switzerland
Project number C.4619.401 – Ivaco, Canada
__________________________________________________________________________________

2.1.3 VISO - Stopper Rod

Sample Stopper Rod of prefered design

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SMS Concast AG, Zurich, Switzerland
Project number C.4619.401 – Ivaco, Canada
__________________________________________________________________________________

Various stopper nose geometries are available. To suit the application two features need to be considered. First the
mechanical arrangement needs to be suitable in terms of the interaction of the rod and the nozzle seat. Secondly
the flow characteristics of the regulating refractory must be appropriate.

The chart below serves to illustrate the impact of nose shape on steel flow. Specific calculations should be made
for the IVACO application.

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SMS Concast AG, Zurich, Switzerland
Project number C.4619.401 – Ivaco, Canada
__________________________________________________________________________________

2.1.4 VISO - Tundish to Mold Shroud or Submerged-Entry-Nozzle (SEN)

Sample Tundish Shroud of prefered design

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Revision 0 June 19, 2013 Page 9 of 58

 SMS Concast AG, Zurich, Switzerland
Project number C.4619.401 – Ivaco, Canada
__________________________________________________________________________________

2.1.5 VISO - Advanced designs through Flow Simulation – Actual project results

Project 1

Background: A bloom caster who’s product is used for locomotive rail was having quality issues and requested a
review of their stopper and SEN designs in pursuit of a refractory solution. Conventional Stopper and SEN’s were
being used.

Flow Simulation project: There conventional designs were modeled and compared to more sophisticated designs.
For the SEN a multi-port “Swirling” SEN was developed and the stopper developed had a “Ripple” nose geometry.

Results of modeling:

Greater flow stability seen for the stopper and more evenly distributed rotational flow predicted for the SEN.
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SMS Concast AG, Zurich, Switzerland
Project number C.4619.401 – Ivaco, Canada
__________________________________________________________________________________

Project status: During trial customer saw significant steel quality advantage. They also saw improved stopper rod
position stability and reduced wear of the regulation refractories (seat & nose). See trial data below

Customer is 100% converted to the 5-port swirl SEN and Ripple Rod and has been running that combination for
several years.

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SMS Concast AG, Zurich, Switzerland
Project number C.4619.401 – Ivaco, Canada
__________________________________________________________________________________

Project 2

Background: Traditional Submerged Shrouds used for billet casting are of a through-bore single exit design.
Vesuvius has developed, through Flow Simulation, advanced designs that significantly improve steel mold flow
behavior. For this project such a design was evaluated in comparison to the conventional design in use.

Flow Simulation project: Cast conditions are inputted and the flow simulation predicted key casting parameters
within the mold. The following graphics are from a recent project which was for a 160mm x 160mm billet
application.

Velocity [m/s]

Through port SEN Modeling of Temperature Modeling of Velocity

Velocity [m/s]
Temperature [K]

Five port SEN Modeling of Temperature Modeling of Velocity

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SMS Concast AG, Zurich, Switzerland
Project number C.4619.401 – Ivaco, Canada
__________________________________________________________________________________

Flow Simulation project results:

versus

Through port SEN Five port SEN

• Non-uniform steel shell solidification • Swirling SES produces hot meniscus with
• No flow rotation, EMS is required optimized mold powder melting and
• Flow in the upper mold region controlled by free lubrication
convection • Uniform steel shell solidification
• Flow rotation, EMS is NOT required
• Improvement of steel microstructure
(dendrites vs equiaxes)
• Reduction of carbon segregation
• Improved inclusion floatation

Rotational flow induced by the 5-port swirling SEN is similar to that achieved with Electro Magnetic Stirring, without
the capital and operating expense.

Project status (June 2013): The modeling results were presented and customer has committed to a trial of the new
5 port design. Pieces are being manufactured.

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SMS Concast AG, Zurich, Switzerland
Project number C.4619.401 – Ivaco, Canada
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2.2 VISO: Material selection by application (most common for these applications, MANY more available)

Material Material
Application Comments
group (Mix) code

TS630 To resist oxidation during lancing

TS238 Bore liner should acute internal erosion be a concern
Alumina-
Graphite TS1128 Bore liner that extends service life
Ladle
Shroud TS1145 Barrel material for moderate cooling between heats
TS365 Standard barrel material
Zirconia- TS351 Slag line sleeve if necessary
Graphite TS1224 Slag line sleeve, lower wear than TS351
TS101 Barrel material for lighter duty and if preheat temperature low
Alumina-
Graphite TS238 Standard barrel material
TS288 Nose mix for longer AK casts
Stopper
Rod Magnesia- TS1111 Nose mix for Calcium treated grades
Graphite TS1096 Heavy duty nose mix for aggressive grades
Zirconia- TS351 Slag line sleeve if necessary
Graphite TS1224 Slag line sleeve, lower wear than TS351
Magnesia- TS1111 Seat mix for Calcium treated grades
Graphite
Zirconia TS711 Seat mix for aggressive grades
TS101 Seat and barrel material for lighter duty applications
TS238 Standard seat and barrel material for AK casts
Alumina- TS288 Seat mix for longer AK casts.
Subentry
Graphite TS1043 Bore and port material for Alumina clogging grades
Shroud
TS1000 Cold (dry) start barrel material
TS1128 Barrel material if preheat temperature is low
TS351 Cold (dry) slag line sleeve
Zirconia- Slag line sleeve if preheat temperature is low AND reduced
TS1224
Graphite erosion rate (vs. TS351) Cold (dry) slag line sleeve
TS240 Standard slag line sleeve

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2.2.1 VISO - Technical Data Sheet for TS365 Ladle Shroud barrel material

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2.2.2 VISO - Technical Data Sheet for TS238 Stopper and SEN barrel material

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2.2.3 VISO - Technical Data Sheet for TS1111 Stopper nose and SEN seat material

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2.2.4 VISO - Technical Data Sheet for TS240 SEN slag line material

VISO 3.0: NAFTA references

VISO 3.1 Vesuvius Billet / Bloom Customers using Stoppers and SEN’s for Submerged casting

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2.3 VISO - Vesuvius VISO References (NAFTA)

Customer Country
GERDAU MANITOBA Canada
SIMEC INTERNATIONAL-TLAXCALA Mexico
TAMSA Mexico
TERNIUM MEXICO-PUEBLA Mexico
CARPENTER TECHNOLOGY USA
CHARTER STEEL CLEVELAND USA
EVRAZ PUEBLO USA
GERDAU MACSTEEL FORT SMITH USA
GERDAU MACSTEEL JACKSON USA
GERDAU MACSTEEL MONROE USA
IPSCO KOPPEL TUBULARS CORP. USA
NUCOR STEEL MEMPHIS USA
NUCOR STEEL MEMPHIS USA
REP-CANTON USA

VISO 2.3.1 Vesuvius Billet / Bloom Customers using Tundish Gates with SES’s for Submerged casting
Customer Country
ARCELORMITTAL CONTRECOEUR EAST Canada
HAMILTON SPECIALTY BAR Canada
TAMSA Mexico
ARCELORMITTAL E. CHICAGO # 1 - EAF USA
ARCELORMITTAL STEELTON USA
CMC STEEL ARIZONA USA
NAS USA
NUCOR DARLINGTON USA
NUCOR NORFOLK USA
TIMKERN HARRISON USA
USS FAIRFIELD WORKS USA
V & M STAR-YOUNGSTOWN USA

VISO 2.3.3 References for Stopper / SEN applications outside of NAFTA

Hundreds worldwide (South America, Europe, Asia, etc.) and available on request.

VISO 2.3.4 References - Service and Consistency

The vast majority of Vesuvius customers are long time users. Global average is 15 years customer loyalty.

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2.4 VISO - Global Manufacturing local to regional Steel Making centers

• The VISO Caster Refractories required to operate the IVACO bloom caster would be manufactured in
North America, at either our Charleston Illinois facility or our Monterrey Mexico facility.

• NAFTA manufacturing, backed by capacity at numerous other global locations, gives us flexibility and
supply assurance.

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2.5 VISO - Product development and Technical Services “Local presence with a Global Reach”

• Local Sales and Service personnel

• Local Technical Support

• Regional Technical Leadership and support (M&T)

• Global Technical Leadership and support

• Research and Development Resources

These resources are used in concert to ensure continuous product development; and to solve applications
problems that arise, on a timely basis.

2.5.1 VISO - Vesuvius R&D resources – Caster Refractories (other product groups not shown)

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2.5.2 VISO - Research & Development Facilities:

Three (3) sites – Pittsburgh, PA; Feignes France; and Suzhou, China.
All equipped with melting (steel), blending and forming (refractory) equipment with extensive analytical equipment
for both steel and refractory applications (SEM, XRD, XRF, etc.).

2.5.3 Flow Simulation Centers:

Six (6) sites – Cleveland, OH & Pittsburgh, PA; Borken Gmbh, Rio Brasil, Suzhou China, and Kolkata India.

5-port SES

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FLUXES 3.1: Mold Flux (Metallurgica Scorialit) Recommendations – by steel grade

Note that Vesuvius is able to offer Metallurgica mold flux recipes for start-up, manufactured in either Mulheim,
Germany or Conneaut, OH, USA.

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FLUXES 3.2: Tundish Flux (Vesuvius AFAX) Recommendations

Three options available for your review:

1.2.1 MGR Rice Hull Ash – manufactured by our sub-contractor, Agrilectric (Louisiana, USA)
• Good insulator, cost effective; silica based
1.2.2 AFAX Tundolite TU875G – manufactured in Conneaut, OH
• Basic tundish flux, balances need for insulation with quality enhancement
1.2.3 AFAX R795 - manufactured in Conneaut, OH
• Premium product , recommended for use on quality critical grades

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3.3: FLUXES - Vesuvius Flux Feeder – Dilute Phase, Air Assist Flux Feeder

Vesuvius can offer our dilute phase, air assist flux feeder for use - subject to agreement; picture attached for
reference. More detail can be provided at a later date, but Ivaco will provide all necessary utilities to operate the
flux feeder - 110 V electrical connection, ¾” air/nitrogen line with a minimum of 80 psi, and a suitable location for
the equipment - and Vesuvius will ensure that the unit(s) provided is within ESA compliance.

We note that use of flux feeders at billet casters has been limited to date, due to very low consumption rate of mold
fluxes - it is difficult, but not impossible, to accurately regulate flow of flux material at such low levels.

Dilute Phase, Air Assist Automatic Flux feeder:

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3.4 FLUXES - Vesuvius Mold Flux References (NAFTA)

Vesuvius - NAFTA Billet / Bloom Reference List

Cast Speed Powder Grade

Plant City Machine Mold Size (mm) (m/min) Steel Grade SCORIALIT

ArcelorMittal Indiana Harbor East Chicago/ IN P. Wurth 178 x 178 1.3 - 1.8 Free Cutting steel SPH-C 126/A

CMC Arizona Mesa/ AZ Danieli 130 x 130 4.0 - 6.0 C-Steel 0.20 - 0.40% C SPH-C 189/GM5

Gerdau Macsteel Monroe/ MI Danieli 152 x 152 2.1 - 3.3 C-Steel <0.08%C, 0.23 -0.45% C SPH-C 411-81E
C-Steel 0.08 -0.23%% SPH-C 176/ALS9
C-Steel >0.45%C SPH-C 189/E1

North American Stainless Ghent/ KY Danieli 160 x 160 0.7 - 1.6 AISI 303, 304, 316, 321, SPH-C 163/D2
AISI 430 SPH-C 449/2.5
AISI 400 SPH-C 412/1

V&M Youngstown/ OH Rokop 223  1.6 - 2.0 C-Steel 0.12-0.48% SPH-C 126/M5
286  1.2 - 1.4 C-Steel SPH-C 126/R1

Ipsco Koppel Koppel/ PA Mecan-Arbed 140  2.0 - 2.9 C-Steel SPH 126/K1

Ternium Puebla Puebla Concast 120 x 120 1.0 - 2.0 C-Steel 0.35 - 0.80% C SPH-C 189/E1
160 x 160 C-Steel < 0.35% C SPH-C 411-81/E
215  1.6 - 2.0 Tube SPH-C 126/F3

Ternium Tamso Veracruz SMS Demag 205, 270, 310, 370  0.6 - 2.0 C-Steel < 0.20 % C SPH-C 126 II
C-Steel 0.20 - 0.40% C SPH-C 126F4

Timken Canton/ OH SMS Demag 180 x 375 0.3 - 0.5 C-Steel 0.15 - 0.65% C GR628X

REP Canton Canton/ OH Danieli 254 x 330 0.5 - 0.8 C-Steel 0.66 - 1.00% GR675X
Danieli Flex 170 x 170 1.0 - 1.7 C-Steel 0.20 - 0.40% C GRC17R

Charter Cleveland Cuyahoga Hts/ OH Danieli 178 x 178 1.3 - 1.8 C-steel 0.15 - 0.85% C GRC17R

SDI Pittsborough/ IN Demag 254 x 381 0.8 - 1.0 C-Steel 0.18 - 0.60%C GR628X

Carpenter Technology Reading/ PA Demag 127 x 127 1.3 - 1.8 AISI 304, 316 GR636

Arkansas Steel Newport/ AR Mitsubishi 140 x 266 0.8 - 1.8 C-Steel 0.20 - 0.70% C GR676X

Simec International Apizaco Danieli 160 x 160 1.0 - 1.7 C-Steel 0.25 - 0.60% C GRC17R
120 x 120 C-Steel With Lead GR27

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3.5.1 FLUXES - Manufacturing, R&D Facilities:

Two(2) sites – Mulheim, Germany and Conneaut, OH, USA.

Fully ISO certified.

3.5.2 FLUXES - Research and Development Facilities:

Two(2) sites – Mulheim, Germany and Cleveland, OH, USA

3.5.3 FLUXES - Technical Support (NAFTA):

Full complement of eight (8) engineers and scientists dedicated to flux technology in NAFTA.

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4.1 TUNDISH LININGS REFRACTORY - Bill of Materials:

Section view

Working Lining
Permanent Lining

Insulating Board

4.1.1 Tundish Working Lining

Working Lining; MgO-based Dry Vibratable 1.5” thick side and end walls, 2” thick floor.

4.1.2 Tundish Permanent Lining

Permanent Lining; low cement, low moisture, high alumina castable , 7.4” thick.

4.1.3 Tundish Insulation Lining

Ceramic fiber board ½” thick.

4.1.4 Bill of Materials (BOM ) for Tundish

Name Type Quantity Unit

Anchors VBN 155 Pcs

Insulating board Kaowool A 184 sq. ft
Permanent Lining Foscast MT 7.5 tons
Working Lining Basivibe SP76* 1.2 tons
Turbostop® CS-7426 Foscast 70Z 273 lbs
Tundish Cover Criterion 60 tons
* Shown for reference only, actual material TBD following more detailed discussion

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4.2 TUNDISH LININGS REFRACTORY - Tundish Refractory Drawings:

4.2.1 Turbostop® Impact Pad

Turbostop is a pre-cast & pre-fired custom designed shape to optimize tundish flow. The Vesuvius flow
simulation group uses physical water modeling and CFD mathematical modeling to optimize tundish flow for
various attributes such as reduced splash, surface directed flow for clean steel,and minimum radical grade
transition for steel yield improvements.

A custom Turbostop will be designed for this tundish. The CS-7426 Turbostop was included in this
presentation as an example. For a typical flow pattern of a Turbostop see the CFD example below.

CFD Examples from tundish drawing provided

Velocity Contours

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Velocity Flow Trajectories

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Turbostop® Impact Pad

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4.3 TUNDISH LININGS REFRACTORY - Thermal calculations

Tundish refractory thermal calculation at steel making temperature using dryvibe working lining option.

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4.4 TUNDISH LININGS REFRACTORY - Tundish Refractory and Equipment

4.4.1 Anchor Design and Pattern

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Welded anchors

Anchors are welded prior to installing insulation board and casting permanent lining.

4.4.2 Permanent Lining castable installation

Vesuvius supplies a variety of tundish permanent lining products designed for cost effective performance.

Steel Form

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Dry-out Curve

1200
18 Hours
1100 FOSCAST MT
1000 Extend soak/ hold time Temp F
in 4 hour incroments if
900 dripping w ater or
12 Hours 16 hrs at this point steam is present.
800 all embedded
60' per hr thermocouples
8 hours at
700 should read +220'F
88' per hr
or extend time 4
Temp

600 hours at a time.

500
12 Hours
400
Shut off dryer and
4 Hours
allow to cool
300
83' per hour
200

100

0
Start Ramp Soak/ Hold Ramp Soak/ Hold Ramp End
Step

Cycle Start Ramp up Soak/ Hold Ramp up Soak/ Hold Ramp down End
Time 0 4 hrs 12 hrs 12 hrs 18 hs 8 hrs 0
Temp F 70 F 400 F 400 F 1100 F 1100 F 400 F 70 F
83' per hour 60' per hour 88' per hour

4.4.3 Working Lining Options

Vesuvius supplies a variety of tundish working lining products designed for cost effective performance.

DryVibe Working Lining Option:

Basivibe™ Dry Vibration Mix

• Magnesia based dry mix designed to be installed with a heated form

• Higher density lining for longer casting sequences.

• Basivibe

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Basivibe™Material Feed Hooper

Hopper with scale and PLC for material Consumption tracking per tundish. Optional scale can be provided to
track the amount of material used for each tundish. This information can be tracked for each tundish by tundish
number

Basivibe™ Form

Vesuvius designs and builds the forms and curing units. Curing unit is unique and has the capability to be removed
from the steel form and attached to a fiber lined cover for drying out castable safety linings

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Basivibe™ cured tundish

The product is installed dry in between a metal form and the tundish backup lining refractory.

The form is heated to 650 deg. F (350 deg. C) to set the Dryvibe.

Once set, the form is pulled and the tundish is ready to be sent to the caster.

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4.5.1 TUNDISH LININGS REFRACTORY - Vesuvius Turbostop® References (NAFTA – billet / bloom)

Customer Country Caster Type Details

Alta Steel Canada Billet 3-Strand
Evraz Ipsco Canada Bloom 1-Strand
Gerdau Cambridge Canada Billet 3-Strand
Gerdau Whitby Canada Billet 5-Strand
Hamilton Bar Canada Billet 4-Strand
ArcelorMittal Contrecoeur East Canada Billet 5-Strand
ArcelorMittal Contrecoeur West Canada Billet 4-Strand
QIT Canada Billet 4-Strand
USS Hamilton Canada Bloom 2-Strand
ArcelorMittal rebar Mexico Billet 6-Strand
Deacero Saltillo Mexico Billet 6-Strand
Deacero Celaya Mexico Billet 6-Strand
Simec International GDL Mexico Billet 5-Strand
Simec International MXL Mexico Billet 5-Strand
Simec International ADM Mexico Billet 4-Strand
Simec International ASL Mexico Billet 3-Strand
TAMSA Mexico Bloom 6-Strand
Ternium Norte Mexico Billet 5-Strand
Ternium Puebla Mexico Billet/Bloom 6-Strand
Charter Steel USA Billet 4-Strand
CMC Birmingham USA Billet 4-Strand
CMC SeguinTexas USA Billet 4-Strand
Gerdau Jackson USA Billet 2-Strand
Gerdau Midlothian USA Billet various
ArcelorMittal IHE Bar USA Billet 4-Strand
ArcelorMittal Steelton USA Bloom 3-Strand
Nucor Memphis USA Bloom 4-Strand
Nucor Yamato #2 USA Bloom 4-Strand
REP Canton-Flex Caster USA Billet 5-Strand
SDI Bar USA Billet 3-Strand
Sterling Steel USA Billet 6-Strand
TAMCO USA Billet 4-Strand
Mid-American USA Billet 2-Strand

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4.5.2 TUNDISH LININGS REFRACTORY - Vesuvius Basivibe™References (NAFTA)

Customer Product Details

AK Steel – Butler, PA Basivibe HP76, Aluvibe HP85 Stainless/Electrical

CMC Birmingham Basivibe CP76 Billet Caster

Electralloy – Oil City, PA Basivibe HP85 Powdered Metal

Ervin AMA Steel – Adrian, MI Basivibe HP85 Powdered Metal

EVRAZ – Rocky Mountain Steel Basivibe HP52 Billet Caster

Pueblo, CO
Gallatin Steel – Ghent, KY Basivibe HP76 Thin Slab

Gerdau – Charlotte, NC (have supplied) Basivibe CP85 Billet Caster

Gerdau – Jackson, TN (have supplied) Basivibe CP90 Billet Caster

MITTAL – Georgetown Basivibe CP90 Billet Caster

Nucor - Birmingham, AL Basivibe HP76, HP55 Billet Caster

Nucor – Hickman – Blytheville, AR Basivibe HP85 Thin Slab

Nucor – Tuscaloosa – Tuscaloosa, AL Basivibe HP55/HP76 Thin Slab

Nucor – Plymouth – Plymouth, UT Basivibe CP85 Billet Caster

Severstal – MS Basivibe HP84 Slab Caster

SSAB – Iowa Basivibe HP85 Slab Caster

Ternium CSP Plant - Monterrey, Mexico Basivibe HP85 Thin Slab

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5.1 SERT – Description of Mold Level Control System

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5.2 SERT – Reference List (Global)

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6. IVACO Bloom Caster project time line (proposed) and required commitments

Note that timeline varies by product line; below is timeline for VISO, which has the longest lead time.

6.1 Time line chart

2013 2014
JUNE JULY AUG SEPT OCT NOV DEC JAN FEB
1 8 15 22 29 6 13 20 27 3 10 17 24 31 7 14 21 28 5 12 19 26 2 9 16 23 30 7 14 21 28 4 11 18 25 1 8 15 22
CASTER START UP
Proposal *
Design
Manufacture
Cold commissioning
Hot commissioning
CONTINUOUS IMPROVEMENT
Proposal / Design
Trial

2014
MAR APR MAY JUNE JULY AUG SEPT OCT NOV DEC
1 8 15 22 19 5 12 19 26 3 10 17 24 31 7 16 21 28 5 12 19 26 2 9 16 23 30 6 13 20 27 4 11 18 25 1 8 15 22 29 6 13 20 27
CASTER START UP
Proposal *
Design
Manufacture
Cold commissioning
Hot commissioning
CONTINUOUS IMPROVEMENT
Proposal / Design
Trial

6.2 Commitments required ensuring on time delivery of start-up refractories:

1. Start-up - Assume commissioning Feb 1, 2014.

2. Design and pricing – by Mid-July 2013 for us to gain the application knowledge required and to develop
the specific designs.

3. Product manufacture – by mid-September 2013 for us to manufacture start-up pieces

4. Advanced designs – by early July 2013 if to be available for commissioning, April 2014 to be part of
developmental work (continuous improvement project).

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7. Intellectual property:

The contents of this document are the exclusive properties of Vesuvius and are subjected to copyright. Any
use, copy, dissemination of this document or its use contrary to its intended purpose is not permitted without
the prior written consent of Vesuvius.

8. Disclaimer

No warranty is expressed or implied regarding the accuracy of this information, the suitability of the product for
a particular purpose, or the results to be obtained by the use of the product. Users expressly assume all risks
and liabilities arising from the use of or reliance upon this information.

9. Contact

This documentation was compiled by the local Vesuvius Canada office

Vesuvius Canada Inc.

333 Prince Charles Dr., P.O. Box 220
Welland, ON, Canada L3B 5P4
Ken Harold – Regional Sales Manager, Canada (Flow Control)
[email protected]
289-439-6440 (mobile)

Above specified refractory materials can be inquired and purchased through

Same as above

For further information please contact

Walter Graf
Account Manager Flow Control
Vesuvius GmbH
Gelsenkirchener Str. 10
46325 Borken
F.R. of Germany
Tel: +49 6172 9459986
Mob: +49 171 3356161
Fax: +49 2861 83 99840
[email protected]
www.vesuvius.com

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 Refractory Documentation
IVACO Canada
for SMS Concast

REFRACTORY DOCUMENTATION
FOR
IVACO Canada
FOR
SMS CONCAST AG

3-STRAND BILLET CCM

Document Title: Refractory Documentation – IVACO Canada for SMS Concast page 1 of 36

Date: 05-07-2013 Author: SLO Zöhrer Rev. No.: 00

 Refractory Documentation
IVACO Canada
for SMS Concast

CONTENTS

1 OPERATION DATA FOR CASTER ......................................................................... 3

1.1 Main Data ........................................................................................................... 3
2 DRAWINGS AND BILL OF MATERIALS ................................................................. 4
2.1 Tundish Drawing ................................................................................................ 4
2.2 Tundish Cover Drawing ..................................................................................... 5
2.3 Tundish Bill of Materials ..................................................................................... 6
2.4 Tundish Furniture Drawings............................................................................... 7
2.4.1 Baffle Plate .................................................................................................. 7
2.4.2 Tunflow ........................................................................................................ 8
3 TECHNICAL DATA SHEETS - TUNDISH ............................................................... 9
3.1 Working Lining ................................................................................................... 9
3.2 Permanent Lining and Insulation ..................................................................... 11
3.3 Ramming Mix ................................................................................................... 13
3.4 Baffle Plate ....................................................................................................... 14
3.5 Tunflow............................................................................................................. 15
4 TECHNICAL DATA SHEET - TUNDISH COVER .................................................. 16
5 REFRACTORIES FOR OPEN STREAM CASTING .............................................. 17
5.1.1 Drawing and Technical Data Sheet ........................................................... 17
6 ISOSTATIC PRODUCTS – SUBMERGED CASTING .......................................... 21
6.1 Ladle shroud (LS) ............................................................................................ 22
6.1.1 Drawing and Technical Data Sheet ........................................................... 22
6.2 Monoblock Stopper (RB) ................................................................................. 24
6.2.1 Technical Data Sheet ................................................................................ 25
6.3 Submerged Nozzle (SN) .................................................................................. 28
6.3.1 Drawing and Technical Data Sheet ........................................................... 28
6.4 Wellblock .......................................................................................................... 33
6.4.1 Drawing and Technical Data Sheet ........................................................... 33
7 ATTACHMENTS .................................................................................................... 35

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 Refractory Documentation
IVACO Canada
for SMS Concast

1 OPERATION DATA FOR CASTER

1.1 Main Data

CCM type: 3-Strand Tundish, capacity 19.7 tons

900mm working level

Casting Steel grades Casting Casting

Section mode speed

(Open/ Sub) m/min

Low C Si Killed (Rebar) Open 3.4
Low C Welding Wire (<0.17%) 3.0
Medium C Steels 0.17-0.35%C AlK
2.9
160x160 Cold Heading. Cold Drawing
Sub
Medium C Steels 0.35-0.55%C 2.8
High C Steels 0.55-0.75%C 2.7
Very High C Steel >0.75%C 2.6

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 Refractory Documentation
IVACO Canada
for SMS Concast

2 DRAWINGS AND BILL OF MATERIALS

2.1 Tundish Drawing

Drawing No.: R200847A/1

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 Refractory Documentation
IVACO Canada
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2.2 Tundish Cover Drawing

Drawing No.: R200848A/2

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2.3 Tundish Bill of Materials

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2.4 Tundish Furniture Drawings

2.4.1 Baffle Plate

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2.4.2 Tunflow

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3 TECHNICAL DATA SHEETS - TUNDISH

3.1 Working Lining

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as an Alternative:

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 Refractory Documentation
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3.2 Permanent Lining and Insulation

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3.3 Ramming Mix

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3.4 Baffle Plate

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3.5 Tunflow

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4 TECHNICAL DATA SHEET - TUNDISH COVER

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5 REFRACTORIES FOR OPEN STREAM CASTING

5.1.1 Drawing and Technical Data Sheet

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 Refractory Documentation
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 Refractory Documentation
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6 ISOSTATIC PRODUCTS – SUBMERGED CASTING

The main function of RHI ISO products in continuous casting is the safe and
controlled transfer of liquid steel from the ladle to the mould via the tundish.

The ISO products must:

- protect the liquid steel stream from re-oxidation and N2 pick-up
- provide optimum flow patterns
- be resistant to thermal shock
- resist corrosion due to aggressive steel grades, slag, tundish cover powder
and mould flux
- resist mechanical stress due to contact with refractories or abrasion due to
high steel turbulences

Following ISO products will be used:

- Ladle shroud (LS)

- Monoblock stopper (RB)
- Submerged nozzle (SN)
- Wellblock

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 Refractory Documentation
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6.1 Ladle shroud (LS)

6.1.1 Drawing and Technical Data Sheet

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6.2 Monoblock Stopper (RB)

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6.2.1 Technical Data Sheet

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6.3 Submerged Nozzle (SN)

6.3.1 Drawing and Technical Data Sheet

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6.4 Wellblock
6.4.1 Drawing and Technical Data Sheet

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 Refractory Documentation
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7 ATTACHMENTS
Please also refer to the following attachments:

Tundish Drawing No.: R200847A/1

Tundish Cover Drawing No.: R200848A/2

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 Refractory Documentation
IVACO Canada
for SMS Concast

Detailed information at www.rhi-ag.com

RHI AG
1100 Vienna,
Wienerbergstraße 9,
Austria

Phone +43 (0) 502 13-0,

Fax +43 (0) 502 13-6588
E-mail: [email protected]

This document and its attachments are confidential and may be privileged. Any unauthorised
dissemination or copying hereof is prohibited without our written permission. The copyright for this
document and its possibly accompanying enclosures remain our property. This document and its
attachments serves for information purposes only and shall not have any legally binding effect.
It is also strictly prohibited to transmit or let these papers to third persons, especially competitors.

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Date: 05-07-2013 Author: SLO Zöhrer Rev. No.: 00

3. MOULD
The cartridge-type mould is a pre-assembled, quickly removable unit.
The self-centering design, together with the self-sealing connections for the
cooling water supply, assures optimal alignment and safe operation.
The mould assembly can be quickly changed (in 5 to 10 minutes) in case of a
section change or maintenance work, resulting in the shortest possible downtime
and maximum machine availability for high productivity.

The water jacket is an accurate machined element that guarantees uniform heat
removal and shell growth.
The mounting system for the mould tube at its upper end uses key clips that
freely allow expansion along the longitudinal axis under heat load
The design of the cartridge-type mould accommodates a common M-EMS for the
range of sections cast.
The EMS does not have to be removed or remounted during a section change.
Thus, the risk of damaging the equipment is reduced and the risk of dirt entering
the water system is eliminated.

C.4619/401 Chapter 1 Rev0

IVAC0 Page 14 of 44 February 2014
3.1 DESCRIPTION
The mould cooling water flows through the gap between the mould copper tube
and the water jacket in order to extract heat from the copper.
The water flow rate and backpressure are controlled to ensure that stable flow
conditions with no vaporisation occur.

3.2 EFFECT OF MOULD COOLING

Cooling water conditions have only a minor effect on overall heat transfer - but
can drive the copper (mould material) temperatures up or down, depending on
the flow conditions.
The water temperatures are measured in the main supply pipe and in each return
pipe so that for each strand the differential temperature (ΔT) and the removed
heat in k/W can be calculated and displayed.

3.3 CONTROL OF MOULD COOLING WATER

Water velocities must be maintained at minimum 10 m/sec to avoid vaporisation
and high thermal stresses in the mould wall due to high wall temperatures. The
flow rate necessary to achieve the desired velocity is calculated from the section
size, copper wall thickness and water gap width.
The water flow through the mould is controlled by means of manual valves in the
supply and return pipes.
The backpressure must be maintained above 1.5 bar to maintain stable flow
conditions. The backpressure is set using a manual valve.
It is important to note the standard mould cooling water pressure for each section
size in order that abnormal conditions, e.g. leaks, can be quickly recognised.

3.4 WATER QUALITY

One important aspect of mould cooling water which does have a major, although
indirect bearing on primary cooling, is the water quality, particularly with
seamless-tube copper moulds. The requirements for the primary cooling water
are specified in the Annex to this module.

C.4619/401 Chapter 1 Rev0

IVAC0 Page 15 of 44 February 2014
 The reduction in heat conductivity of the mould caused even by thin layers of
carbonates, metallic oxides or organic deposits on the water side of the copper is
sufficient to raise the mould wall temperature quite considerably.
It is possible that re-crystallisation and deformation of the copper can take place
with a permanent loss of the original dimensions. The resultant deformed mould
becomes useless for further casting, normally causing a regular series of
breakouts early in the cast. Therefore, a careful water treatment with regular
check-ups has to be emphasised.

3.5 EMERGENCY COOLING WATER

A mould cooling water failure is a top emergency case.

Casting without water circulating in the mould containing liquid steel will cause
boiling of the water and the resulting high steam pressure is capable of deforming
the mould tube, finally cracking it and causing an explosion, damaging equipment
and endangering operating personnel.
The mould must be cooled at all times whenever it contains steel. To ensure that
this is guaranteed even in the event of a power failure, an emergency water
system is provided. A supply of water for approx. 10 minutes is made available
from a high located tank within a few seconds (the emergency water volume
must > 50% of the target volume).
First the alarm lamp on the MOP shows that there is a shortage of water and if
the volume should sink any further the emergency water valve opens
automatically.

4. AUTOMATIC MOULD LEVEL CONTROL

4.1 FUNCTION
The function of the mould level measuring system is to measure the actual steel
level within the upper part of the mould and to transmit this information to the
control PLC. The signals are used by the PLC to control the steel level in two
ways, depending on the casting mode.
During Open Stream Casting the withdrawal drive speed (casting speed) is
adjusted to maintain the preset level.
During submerged casting the stopper position is adjusted to maintain the preset
level, whilst the casting speed remains constant.

C.4619/401 Chapter 1 Rev0

IVAC0 Page 16 of 44 February 2014
 The source can be closed manually and should be closed whenever the system
is not in operation.

4.2 THEORY OF OPERATION

The mould level comprises the following:
• a radio-active source.
• a variable absorption material (the liquid steel in the mould)
• a radiation detector.
• a signal processing unit and operator interface.

The source is mounted in a protective steel housing lined with lead. The source,
which is a so-called 'Pencil Source', is a long and thin rod of Co60. It radiates
gamma particles at a relatively stable rate through the narrow slit window of the
protective housing and the resultant beam of radiation is directed through the
mould to the detector.
Mounted on the opposite side of the mould to the source is the detector or
scintillation counter. This device, which is water-cooled using mould cooling
water, produces a stable reference signal proportional to the number of gamma
particles received. This signal is transmitted to the level detection processor via
shielded cables.
Measuring range
Mould

Detector

Crystal
Source

Shielding LB 352

The amount of energy that is absorbed by the liquid steel (and therefore is not
detected by the detector) is dependent on the level of liquid steel in the mould.
With Co60, the mould water causes additional attenuation.

C.4619/401 Chapter 1 Rev0

IVAC0 Page 17 of 44 February 2014
 The strength and geometry of the source have been selected such that they suit
the range of section sizes to be cast and the length of the measuring window
required. The length of the pencil source relative to the detector and the mould
section size determines the measuring range of the section.

4.3 CALIBRATION
The level measuring system must be re-calibrated with every section size. As the
geometry of the detection devices, the properties of the source, the attenuation
factor of the steel, and the detector characteristics are known we can calculate
the level of the liquid steel in the mould as a function of the number of gamma
particles received in a given time. This is converted into a measurement from a
datum point (established during calibration) by the level measuring processor and
transmitted to the mould level controller.
A calibration block for each section size is required. The block is a rectangular
solid piece of steel with section dimensions slightly smaller than the mould, and
length greater then the length of the measuring range (e.g. 300mm). The block is
lowered into the mould to block all the radiation to simulate a full mould.
After installation of a new mould and with all the sources open and all mould and
EMS water running, the procedure for calibration of the system is as follows:
• Switch the mode selection switch to 'PREPARE' position, push the ‘MIN.
LEVEL’ push-button on the mould operator pendant (MOP) to make an ‘empty’
calibration. The mould level indication is 0%.
• Lower a calibration steel block (of a size to fit just into the mould and with a
length of 300 mm) must be inserted into the mould, so that the top of the block is
80 mm below the top of the mould copper tube.

C.4619/401 Chapter 1 Rev0

IVAC0 Page 18 of 44 February 2014
 • When this is done and the mode selection switch is in the 'PREPARE' position
then the ‘MAX. LEVEL’ push-button on the MOP must be pressed to do a ‘full’
calibration.
• The mould level indication at the MOP should then be 100 %.
NOTE: The level measuring equipment enables only a calibration when the
actual measured signal is not too far away from the calibration point. This means
zero calibration with a filled mould is not possible. See also the level measuring
equipment handbooks.

4.4 MOULD LEVEL SIGNAL ACCURACY AND STABILITY

Ideally the level signal obtained is a completely stable and accurate measure of
the steel level, however, practically the steel level stability can be affected by
several factors as follows:
• Level measuring accuracy typically approx. +/- 3% of the level measuring
range.
• Statistical fluctuation of the source radiation
• Influence of casting powder
• Influence of slag fishing during open casting
• Influence of mould oscillation
• Influence of alumina or other deposits on refractories

4.5 MOULD LEVELS

The mould level is expressed as a percentage of the measuring range; there are
four important levels:
• Mould Level set point (Normal working level).
• Starting Level (Withdrawal drive is started during Automatic Start).
• High Level (Overflow alarm).
• Low Level (Breakout alarm).

C.4619/401 Chapter 1 Rev0

IVAC0 Page 19 of 44 February 2014
4.6 DRAWINGS

MOULD ASSEMBLY 10039161

COPPER TUBE 2230021
FOOT ROLLS 10039170
WATER JACKET ASSEMBLY 10039136
MOULD SUPPORT ASSEMBLY 10039065
MOULD LUBRICATION P&ID 88208
MOULD LEVEL MEASUREMENT 10040707
MOULD WATER P&ID 95606

C.4619/401 Chapter 1 Rev0

IVAC0 Page 20 of 44 February 2014
 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

30 6
L
B-B D-D E-E ( 1 : 1 ) L

15 21

A-A
650 5
620
14 8 13
11 6
540
K K
445
22 5
330 9
15
6 10
W 23 10
15
14
40

1
C-C 4
J J
3
36

5
24 F-F G-G ( 1 : 1 )
15
190
199
5 16
208 29
3 10
I I
20

12
28
400
397

2
2
H H
1
H-H J-J
26
6

18
of Mould
of Casting Radius
17
20
G 5 5 G
7.9
16
R9917.9 27
1 7
1093

25

F
25 F

8 13

Cu-Tube 2230020.2 9

19

F 20
E E
D 1) MOULD TO BE PRESSURE-TESTED AT 9 BAR FOR 30 MINUTES.
593

2) DURING PRESSURE-TESTING THE COPPER TUBE

F HAS TO BE CHECKED OF ANY INSIDE DEFORMATION,
ESPECIALLY ON THE LEVEL OF THE PACKING RINGS!
30 2 Lifting Eye Bolt M16 1.1141 / C15 0.304 KG 306291 DIN580
29 4 Washer M16 Steel 0.011 KG 353491 ISO7089

18 B
28
27
4
12
Hex. Cap Screw
Socket Head Cap Screw
M16X50
M16X35
8.8 zinc plated
10.9
0.117
0.098
KG
KG
344871
349605
ISO4017
ISO4762
D 26 2 Socket Head Cap Screw M16X30 8.8 zinc plated 0.09 KG 317578 ISO4762

Printed by: C850 on 25. September 2013 - Status: Released RE

25 12 Socket Head Cap Screw M12X25 A2-70 0.041 KG 361259 ISO4762
19
D
G 24
23
2
8
Socket Head Cap Screw
Socket Head Cap Screw
M8X20
M8X16
8.8 zinc plated
8.8 zinc plated
0.015
0.013
KG
KG
305982
305981
ISO4762
ISO4762
D
22 1 Socket Head Cap Screw M6X12 A2-70 0.006 KG 361478 ISO4762
21 1 O-Ring HITEC 16X2,65 NBR 70.5 0.003 KG 327158 DIN3771
17 20 1 O-Ring 380x 7 NBR 70 0.063 KG 420989 10012376 DIN 3771

G B CASTING
19
18
1
1
O-Ring
O-Ring
400x 10
440x 10
NBR 70.5
NBR 70.5
0.105
0.148
KG
KG
420963
420960
10012356
10012353
DIN 3771
DIN 3771
17 1 O-Ring 440x 10 NBR 70.5 0.147 KG 420960 10012353 DIN 3771
DIRECTION 16 1 O-Ring 440x 10 NBR 70.5 0.146 KG 420960 10012353 DIN 3771

16
A A 15
14
1
1
O-Ring
O-Ring
459.3x 5.7
222x 10.2
NBR 70.5
VMQ 55
0.048
0,098
KG
KG
420955
538809
10012351
10039169
DIN 3771
DIN 3771
13 1 O-Ring 222x 10.2 VMQ 55 0,124 KG 538809 10039169 DIN 3771
W(1: 1) 12 1 Centre Pin 20h9x25 1.0503 / C45 0.047 KG 383277 10005993

C 30 11 1 Key 12x20x30 1.0577 / S355J2+N (St52-3 N) 0.049 KG 385984 10005992

C E E 10
9
1
1
Lubrication Plate
Splash Guard
330x22
8x247x247
1.0577 / S355J2+N
1.4301 / X5CrNi18-10
8,73
1,27
KG
KG
538530
538533
10039293
10039168
C

J 8 1 Sealing Plate 12x247x247 1.0577 / S355J2+N 1,76 KG 538532 10039167

7

7 1 Bottom Plate 458x47 1.0577 / S355J2+N 31,5 KG 538531 10039166

H 6 1 Top Cover - - 62,9 KG 538529 10039225
27

5 1 Main Plate - 65,3 KG 538528 10039164

4 1 Tube Clip 8x208x208 1.0577 / S355J2+N 0,55 KG 538527 10039163

190 9 7 10 3 1 Flange 480x32.5 1.0577 / S355J2+N 26,7 KG 538526 10039162

2 1 Cooling Jacket Assembly - 67,9 KG 538521 10039136
- -
208 H J 14
1 1 Mould Casing
Item Qty Description Dimension Basic Material
117,2 KG
Weight Ut. MM-No.
538525 10039666
DRW-No. Norm/Remark

Modell: 10000261370_IAM_000.iam Modellversion: -

458

B B
4
THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
Section Weight Main Scale Format
Standard Workshop
ISO 128
Instructions 9800.4 115.500 390,8 KG 1:2 A0
Replaced by

Convex Mould Assembly Released

Approved
10.01.2013

12.12.2012
C603

T089

SQ.160,R10000 Drawn 04.10.2012 U039

Document No. Version

10'039'161 -
A C Sheet: 1 of 1
Material No.
A

Index Description of Modification Date Name SMS group

538524
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
EKI Old File Name: File Name: 10039161_DRF_000.idw
Geometrical Tolerances

Radius tolerance
VIEW 'X'
X

CD
Squareness

Twist

Printed by: C850 on 25. September 2013 - Status: Released

CL - MOULD

Eccentricity

Crowing

VIEW 'Y'

CD
Parallelism

Y
Wall thickness

CD
= CASTING DIRECTION
 12 11 10 9 8 7 6 5 4 3 2 1

H
C-C ( 1 : 1 ) H

A-A
356 10 356 150
6

11
9

2.5 ECC.

80
G G

4.34
12

5.34
4
(386)

F F

C 5 7 3 7 5
28
D
B
65

B
D-D ( 1 : 1 )
E 2 E

D
4.84
C
(380)

D D

Printed by: C850 on 25. September 2013 - Status: Released RE

260
B-B

C 12 8 Grease Nipple R 1/4" Galvanized Steel 0.033 KG 366914 DIN 71412A C

11 1 Precision Dowel Pin m6 10X30 Steel 0.018 KG 360133 ISO8734
10 4 Hex. Cap Screw M16X45 8.8 zinc plated 0.109 KG 344870 ISO4017
9 8 Hex Flange Bolt Screw M12X30 8.8 zinc plated 0.057 KG 341981 DIN6921
8 8 Socket Head Cap Screw M10X20 8.8 zinc plated 0.025 KG 305994 ISO4762
7 16 Deep Groove Ball Bearing 25/52x15 Standard 85 0.133 KG 427975 10013640
164.2 6 8 Fixation Plate 12x54x58 1.4301 / X5CrNi18-10 0.133 KG 496260 10028731
5 16 Seal Ring 60x14 Brass 0.195 KG 496262 10028734
CASTING 4 8 Eccentric Shaft 31x207 1.7225 / 42CrMo4+QT 0,74 KG 538470 10039324
260

DIRECTION 3 8 Roller 80x150 1.0503 / C45 4,28 KG 538469 10039323

163.2

2 1 Stiffener 18x324x324 1.0577 / S355J2+N 4,08 KG 538477 10039353

A A 1 1 Roller Support
Item Qty Description Dimension
-
Basic Material
40 KG
Weight Ut. MM-No.
538448 10039302
DRW-No. Norm/Remark

Modell: 10000261383_IAM_000.iam Modellversion: -

B B

THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
Section Weight Main Scale Format
Standard Workshop
ISO 128
Instructions 9800.4 115.101 91,8 KG 1:2 A1
Replaced by

Released 12.12.2012 C603

Foot Rollers Approved 08.12.2012 T088

SQ160, R10000 Drawn 04.10.2012 V628

Document No. Version

22 156 10'039'170 -
A A
Sheet: 1 of 1
Material No.

Index Description of Modification Date Name SMS group

538516
12 11 10 9 8 7 6 5 4 3 2 1
EKI Old File Name: File Name: 10039170_DRF_000.idw
 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

L L

930
8 4 5 4 5
5 18
K
7 19 2 K

29

14
382

399
J 10 J
519

522
OF CASTING RADIUS
11

83

120

1025
(3)
I I

462

503
1

H H

41
93.5
508
900

G G

A-A ( 1 : 2 )

12 16 17
C-C ( 1 : 2 ) D-D ( 1 : 2 ) E-E ( 1 : 2 )
680 760
F F
4 315
19 4 5
45 35
12
16

30
48
20 25
15 15
OUTLET
A
27 13

23
36

23
E E
(8

B
)

30

45
45
OF MOULD

F
270

15

B 8 A E
E 14
93.5

FIXED SIDE

55
20

950

CASTING
850
810

870

DIRECTION
3
540

8
18

Printed by: C850 on 25. September 2013 - Status: Released RE

10

D D
45
45
18

ATTENTION :
2 C CARRY
19 2 Hex.THE MOULD SUPPORT
Cap Screw M16X55 MOUNTED
8.8 zinc plated WITH TOP0.125
FLANGE
KG 344872 ONLY. ISO4017
435

18 6 Socket Head Cap Screw M10X45 8.8 zinc plated 0.041 KG 305999 ISO4762
17 1 Street Elbow B16 NPS 1/4 - 3M ASTM A182 0.066 KG 527433 ASMEB16.11
(34 16 2 Union M-F B16 NPS 1/4 - 3M ASTM A182 0.16 KG 527180 ASMEB16.11

INLET
)
B-B ( 1 : 2 ) F-F ( 1 : 2 ) 14 (1:5) 15
14
1
1
Hexagonal Nipple B16
Pipe Seamless ASME NPS 1/4
NPS 1/4 - 3M
13.7x2.24x470
ASTM A105-WP
ASTM A312
0.03
0,292
KG
KG
527020
531484
ASMEB16.11

20 25 D 4 13 1 Globe Valve NPS 1/4" 1/4" NPT F x 1/4" Bronze 0,274 KG 536077 10040013
NPT F
120
2 18 7 3 1/4" NPT 12 9 O-Ring 20x 4 NBR 70.5 0.007 KG 386708 10006417 DIN 3771
6 18 11 3 Elbow Catch 15X195DVP.LG 0.262 KG 380162 10005721
D 10 4 Screw 47.3x200 1.0577 / S355J2+N 1.95 KG 385191 10006416
40

C C
9 2 Block 30x70x145 1.0038 / S235JR+N 2.37 KG 426861 10013496

19 45 90 C 8
7
2
1
Centering Bar
Centre Pin
25x550
20h9x25
1.0577 / S355J2+N
1.0503 / C45
2.05
0.047
KG
KG
385297
383277
10006415
10005993
35 6 1 Pin 28x35 1.0503 / C45 0.098 KG 385135 10006376
5 2 Guide Bolt 25x82 1.0577 / S355J2+N 0,236 KG 540083 10041709
42

330
4 2 Guide Bolt 25x100 1.0577 / S355J2+N 0.237 KG 385327 10006442
3 1 Sealing Protection - 6.19 KG 431908 10014697
2 1 Top Flange - 129 KG 539083 10039325
630 710 50 A 1 1 Mould Support - - 621 KG 539151 10039321
Item Qty Description Dimension Basic Material Weight Ut. MM-No. DRW-No. Norm/Remark
1415 9

Modell: 10000260368_IAM_000.iam Modellversion: A

1530
B 1 160 B

THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
30 90 30 UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
Section Weight Main Scale Format
Standard Workshop
ISO 128
Instructions 9800.4 115.200 776,3 KG 1:5 A0
Replaced by

Mould Support Assembly Released

Approved
05.07.2013

21.06.2013
C603

U039

Drawn 20.06.2013 U039

Document No. Version

10'039'065 A
A Sheet: 1 of 1 A
A Mould Support mod. 20.06.2013 U039 Material No.

Index Description of Modification Date Name SMS group

539782
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
EKI Old File Name: File Name: 10039065_DRF_000.idw
 12 11 10 9 8 7 6 5 4 3 2 1

H A-A ( 1 : 2.5 ) H

OF MOULD
CU-Tube 268526

G G

CASTING
DIRECTION

360.5
F F

A A
108.4 92.6
OF MOULD RADIUS
B-B ( 1 : 1 ) C-C ( 1 : 1 )
7.9

E E

X(1:1)
0.5
R9817.4

920.5

R9917.9

R10018.4
D D

Printed by: C850 on 25. September 2013 - Status: Released RE

3
C C 6
(560)

4
5

C C

6 4 Precision Dowel Pin 8H8X24 Stainless Steel 0.009 KG 338977 ISO2338

B B 2
5
4
14
4
Hex. Socket Head Cap Screw
Hex. Cap Screw
M8X16
M8X35
A2-70
A2-70
0.01
0.02
KG
KG
362198
345140
DIN6912
ISO4017
3 4 Bush 20x24 1.4301 / X5CrNi18-10 0.033 KG 385458 10006564
2 1 Flange Plate 419.5x24 1.4301 / X5CrNi18-10 14,9 KG 538453 10039138
1 1 Cooling Jacket - - 52,6 KG 538501 10039137
Item Qty Description Dimension Basic Material Weight Ut. MM-No. DRW-No. Norm/Remark

Modell: 10000261119_IAM_000.iam Modellversion: -

B B

X THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
Section Weight Main Scale Format
Standard Workshop
ISO 128
Instructions 9800.4 67,9 KG 1:2 A1
Replaced by

200 Cooling Jacket Assembly Released

Approved
10.01.2013

12.12.2012
C603

T089

201 SQ.160,R10000 Drawn 04.10.2012 U039

214 Document No. Version

215 310 10'039'136 -

A A
Sheet: 1 of 1
419.5 Material No.

Index Description of Modification Date Name SMS group

538521
12 11 10 9 8 7 6 5 4 3 2 1
EKI Old File Name: File Name: 10039136_DRF_000.idw
Printed by: C850 on 13. November 2013 - Status: Released
 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

L L

A-A
< 0.01 Sv/h
A

K K
2
Top of Mould

(137)
B 100% 100%

-61
Working Level
J J
70%

277
B

201

400
2
0% 0%

I 1 I

1
Centerline Radius

517

H H

CASTING
DIRECTION

G G

B-B A

Thickness of:
F F
SECTION SQ.160
3 (Fe)
4 (Fe) 3 (Fe) 4 (Fe) Steel liquid 168mm
83 (H 2O) Steel (Fe) 14,0mm
73 (H 2O) 3.5 (H2O)
3.5 (H2O)
Copper (Cu) 28,0mm
Water (H2O) 163,0mm

E E

14 (Cu) 14 (Cu) The Shielded Source Co60 and

the Scintillation Detector are
oscillating with the mould.
Fe Fe

Printed by: C850 on 25. September 2013 - Status: Released RE

D D
(55)

Cu
CASTING
H2O DIRECTION
Fe

50
C C

168

2 1 Scintillation Detector 0,058 KG 537390 10040581

1 1 Radioactive Source Co 60 29,2 KG 537482 10040805
521 Item Qty Description Dimension Basic Material Weight Ut. MM-No. DRW-No. Norm/Remark

Modell: 10000270131_IAM_000.iam Modellversion: -

B B

THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
Section Weight Main Scale Format
Standard Workshop
ISO 128
Instructions 9800.4 115810 29,3 KG 1 : 2,5 A0
Replaced by

Mould Level Measuring System Released

Approved
17.04.2013

17.04.2013
C603

C603

Berthold Equipment Drawn 06.11.2012 V627

Document No. Version

10'040'707 -
A Sheet: 1 of 1 A
Material No.

Index Description of Modification Date Name SMS group

537391
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
EKI Old File Name: File Name: 10040707_DRF_000.idw
Printed by: C850 on 04. Oktober 2013 - Status: Released
5. MOULD OSCILLATION

5.1 FUNCTION
The mould is mounted on a mould oscillation system.
The oscillating “up and down” movement of the mould prevents the strand shell
from sticking in the mould, which could cause surface defects and breakouts,
promoting a uniform strand shell growths and good surface quality.

5.2 OPERATION
The motion is geometrically matched to the curvature of the casting machine
radius and may be adjusted in stroke and in frequency.
The mould oscillation table has a machined surface and has the water and oil
connections that are sealed with “O” rings when the mould/mould support casing
is placed onto the mould oscillation table.
A hydraulic servo cylinder, mounted on the mould operator side of the oscillator,
generated the oscillation sinusoidal movements.
A servo valve and a digital position controller (direct mounted in/on the hydraulic
cylinder) control the hydraulic cylinder. The cylinder movement is tolerance free
transmitted to the short levers system.
The actual pressure in the hydraulic cylinder is measured by means of a pressure
indicator; the oscillation force and friction in the mould can be recorded.
The mould oscillates according to a sinusoidal function, defined by:
• Frequency : from 20 to 400 stroke per minutes (0.33 to 5 Hz)
• Amplitude (stroke) : from 0 to +/- 10 mm at mould side
• Asymmetry : +/- 11°
These values are the minimum/maximum capacity of the controller, which exceed
the mould limits.

5.3 OSCILLATION PARAMETERS

With the system in Automatic Mode (see the Functional Description Manuals for
more details) the mould will oscillate according to “oscillation parameters” values
stored into the casting recipe, from which asymmetry, frequency and stroke are
continuously calculated.

C.4619/401 Chapter 1 Rev0

IVAC0 Page 21 of 44 February 2014
5.4 SYMMETRY
The asymmetry of the sinus curve is adjustable between –60° and + 60°,
although in practice it is never taken beyond +/- 11°.

The asymmetry value indicates the deviation to the 90° and 270° points at which
the standard sinus reaches it’s maximum respectively the minimum value.

Amplitude
[mm]

Asymmetry factor range

-30° 0° +30°
+10
Stroke = 2 * Amplitude

270° 360°
0
0° 90° 180°

-10

For example, with an asymmetry of -30° the sinus curve will start at 0%, goes to
the maximum value (100%) at 60°, goes down and crosses the 0% at 180°, and
reaches the minimum value at 300° before the it rises and goes back to 0% at
360°.

C.4619/401 Chapter 1 Rev0

IVAC0 Page 22 of 44 February 2014
5.5 FREQUENCY
The required oscillation frequency (cycle per minutes – cpm) is continuously
calculated with the formula:

 f  n f  VC2  m f  VC  c f  for _ f  20cpm


 f  C fO  20cpm  for _ f  20cpm

The values nf, mf, cf and CfO are stored in the caster recipe system and these
values are casting product depended.

5.6 AMPLITUDE (STROKE)

The required oscillation amplitude is continuously calculated with the formula:
h  nh  VC2  mh  VC  ch  for _ h  ChO

h  ChO  for _ h  ChO

The values nh, mh, ch and ChO are stored in the caster recipe system and these
values are casting product depended.

5.7 CONSIDERATIONS FOR SELECTING OF OSCILLATION

PARAMETERS
For casting with oil lubricated moulds the negative strip is the guide figure for
oscillation parameter selection.
The negative strip (NS%) is the amount by which the mean mould speed (vm) is
higher than the casting speed (vc) during the down movement.
V c  Vm
NS %   100
Vc
2 f n
where: Vm 
1000

h = stroke (mm)
f = frequency (cpm)

C.4619/401 Chapter 1 Rev0

IVAC0 Page 23 of 44 February 2014
 From experience it is known that the negative strip can vary in a wide range from
-5 % to -80 % without any detrimental effect on surface quality.
A shorter stroke brings improvements in the mould lubricating mechanism. It also
lowers the chances that small mould/roller apron misalignment damage the
strand and the acceleration and deceleration forces of the mould oscillation
system are lowered, thus giving mechanical advantages.

The negative strip time (NST) is the decisive figure for closed pouring with
casting tubes and mould powder:
60 1000  Vc
NST   arccos
f h   f

where:
f = frequency (cpm)
h = stroke (mm)
Vc = casting speed (m/min)

The aim value for the negative strip time is between 0.10 - 0.15 sec. for open
pouring and 0.08 - 0.13 sec. for submerged casting.
Beside the above considerations from the billet surface quality point of view, the
frequency / stroke selection should be such that the resulting mould acceleration
forces are below 4.0 m/s2.
Due to the free programmable oscillation curves, allowed by the hydraulic
oscillation mechanism, negative strip time can be adapted to the specific needs.
The PLC controls if the frequency and stroke values are compatible with the
mechanical limits of the machine, described by the “operational window” shows in
the graph below.

C.4619/401 Chapter 1 Rev0

IVAC0 Page 24 of 44 February 2014
 OPERATIONAL WINDOW

5.8 OSCILLATION MARKS

During the time the downward mould velocity exceeds the strand velocity i.e.
during the period of negative strip, the newly formed strand skin just below the
meniscus is subject to compressive forces, which increase to a maximum value
when the mould reaches the highest velocity.
The stresses in the skin of the billet usually exceed the yield strength of the shell
and plastically upset. The shape of the resultant oscillation marks depends upon
the stroke length and the heat transfer below the steel meniscus.
Two observations can be made:
• Large oscillation strokes result in wider oscillation marks.
• Oil lubrication results in shallow oscillation marks because of higher heat
transfer producing a relatively cold, strong shell compared to closed pouring
practice with casting powder.
The spacing between oscillation marks is given by one over the proportionality
between casting speed and oscillation frequency, 1/mf (for nf and cf = 0).
Example: if mf is 100 the spacing between oscillation marks will be 10 mm
(1[m]/100 = 0.01 m or 10 mm).

C.4619/401 Chapter 1 Rev0

IVAC0 Page 25 of 44 February 2014
5.9 DEVIATION OF OSCILLATION
The oscillation movement of the curved and parallel mould tube sides should be
checked after every major repair period with a dial gauge. The max. tolerable
horizontal deviation measured on a new mould tube must not exceed 0.2 mm at
the casting stroke length. Naturally these tests are done dynamically with the
base of the dial gauge fixed to a solid independent structure (e.g. tundish car).
Periodic checking of the mould table position in relation to the fixed machine
points (e.g. withdrawal unit tangent roll) is advisable particularly if heavy steel
spillage around the mould table area has occurred.

5.10 LIST OF DRAWINGS

MOULD OSCILLATION MECHANISM– TA 10039208

HYDRAULIC DRIVE 10043374

C.4619/401 Chapter 1 Rev0

IVAC0 Page 26 of 44 February 2014
 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

L
A B2248 C L
(1270)
1125
43 175 900 1090
3 562.5 562.5
24 3
(155 )

15.021
K K
180

60
Of Neutral Axis

40 61
120

120
705

J J

30mm)
835= Neutral Position (Cyl.Stroke
646.168
K
1440
(1285)

I
43.811 I
53

901.066

Articulation

(803 )
Fixed Side
580

CASTING
DIRECTION
H H

330
74 1 AN Bulkhead Union 19.1x22x57.2 Galvanized Steel 0.071 KG 541935
73 3 Male Connector with nut-ring 3/8 x 3/8 NPTF Galvanized Steel 0.108 KG 537067 S-600-1-6
72 2 Union 1/4 Galvanized Steel 0.037 KG 540962 S-400-6
71 6 Union Elbow 1/4 - 90 Galvanized Steel 0,052 KG 540959 S-400-9
70 3 Male Tube Adapter 3/8x3/8 Galvanized Steel 0.039 KG 542403 S-6-TA-1-6
69 6 Male Tube Adapter 1/4x1/4 Galvanized Steel 0.024 KG 542401 S-4-TA-1-4
45

68 5 90 Elbow Union with nut-ring 3/8 Galvanized Steel 0.142 KG 530035 S-600-9
67 2 Male Tube Adapter 3/8x3/8 NPT Galvanized Steel 0,039 KG 540928 S-6-TA-1-6
4 2
66 12 Male Connector 1/4x1/4 NPT Galvanized Steel 0.037 KG 540956 S-400-1-4
8 B 9
(28)

65 5 Adapter 9/16-18 JIC to 3/8 Galvanized Steel 0.042 KG 540930 S-6-AN-1-6

Ref. Face
A Foot M30 NPT

G 785 115 C 64
63
4
1
Hex. Cap Screw
Hydraulic Tube Seamless ASME
M8X65
6.35x1.24x13m
8.8 zinc plated
ASTM A519, ASTM A179
0.031 KG 306952
1,85 KG 544792
ISO4014
ASME A519_H_C
G

50 990
31 M30
1/4
Theoretical 62 1 Hydraulic Tube Seamless ASME 9.525x1.65x1.3m ASTM A519, ASTM A179 0,332 KG 544793 ASME A519_H_C
to adjust height 1040 1340 970 3/8
on site ass'y 61 4 Lifting Eye Bolt M30 1.1141 / C15 1.7 KG 369167 DIN580
(1270) 60 1 Hex. Cap Screw M12X40 8.8 zinc plated 0.052 KG 344833 ISO4017
2430 59 4 Washer M12 Steel 0.006 KG 353489 ISO7089
28 58 4 Washer M16 Steel 0.011 KG 353491 ISO7089
32 Shim Plate Machined 57 8 Washer M30 Steel 0.054 KG 353501 ISO7089
After Leveling Oscillation 48 56 1 O-Ring HITEC 40X3,55 NBR 70.5 0.011 KG 327273 DIN3771
Support Beams 55 1 Hex. Nut 0.8d M12 8.0 zinc plated 0.016 KG 306634 ISO4032
29 54 4 Hex. Cap Screw M10X45 8.8 zinc plated 0.038 KG 306955 ISO4014
23 53 20 Hex. Cap Screw M16X40 8.8 zinc plated 0.101 KG 344869 ISO4017
52 4 Hex. Cap Screw M30X160 8.8 zinc plated 1.15 KG 345001 ISO4017
F F
590
25 51
50
4
16
Hex. Cap Screw
Hex. Nut 0.8d
M30X180
M30
8.8 zinc plated
8.0 zinc plated
1.26
0.253
KG
KG
306801
306642
ISO4017
ISO4032
49 56 Socket Head Cap Screw M10X80 8.8 zinc plated 0.062 KG 306005 ISO4762
48 12 Socket Head Cap Screw M12x20 8.8 zinc plated 0.03 KG 420829 DIN7984
For Mould Support Fixation 24 47 2 Socket Head Cap Screw M12X50 8.8 zinc plated 0.063 KG 306031 ISO4762
and Transport 46 22 Hex. Cap Screw M6X12 8.8 zinc plated 0.005 KG 306910 ISO4017
45 1 O-Ring HITEC 75X5,3 NBR 70.5 0.044 KG 327349 DIN3771
44 2 O-Ring 142.2x6.99 NBR 70.5 0,141 KG 443327 10018682 DIN-ISO 3601
43 4 Socket Head Cap Screw M16x200 8.8 zinc plated 0.359 KG 422765 10012688 ISO4762
43 42 6 Spacer - Pipe Clip 12x20x28 1.0038 / S235JR+N 0,051 KG 540043 10041673
7 41 22 Pipe Clip 6,35x6,6 1.0038 / S235JR+N 0,007 KG 539082 10041473 DIN 1592
40 1 Flexible Hose 3/8" 0,335 KG 543448 10043223
110

260
39 2 Flexible Hose 3/8" 0,278 KG 540078 10041676
38 2 Plate 15x76x80 1.0038 / S235JR+N 0.71 KG 507665 10033160
E E
6 37 2 Grease Distributor 4 Outlets 4 Outlets Galvanized Steel 0.000 KG 507500 10033014
26 36 2 Axle Guard 140/40x10 1.0038 / S235JR+N 0.82 KG 479951 10024166 DIN 15058
35 2 Spacer 80x17.5 1.0577 / S355J2+N 0,125 KG 538601 10041157
28 29 34 4 Cylindrical Roller Bearing 100/150x67 - 4.15 KG 420725 10012330 NNF 5020

500 54 59 33
32
4
2
Cylindrical Roller Bearing
Shim Plate
80/125x60
28x210x380
Standard 80
1.0577 / S355J2+N
2.76
16,2
KG
KG
420724
440841
10012326
10017197
NNF 5016

29 32 31 2 Shim Plate 28x210x260 1.0577 / S355J2+N 10.7 KG 422643 10012681

30 1 Seat 60x86 1.0577 / S355J2+N 1.55 KG 421007 10012392

4 29
28
3
2
Center Pin
Bolt
20x25
40x200
1.2510 / 100MnCrW4
1.0503 / C45
0.045
1,66
KG
KG
421064
421063
10012442
10012441
G G 2
51 50 57 27
26
2
4
Bolt
Bolt
80x167
100x145
1.0503 / C45
1.0503 / C45
5,37
5.87
KG
KG
538600
421016
10041155
10012406

Printed by: C850 on 25. September 2013 - Status: Released RE

Articulation

25 2 Bolt 100x145 1.0503 / C45 8.25 KG 421019 10012410

Fixed Side

24 2 Bolt 110x175 1.0503 / C45 9.61 KG 421012 10012393

D D
5 23 6 Axle Guard 8x30x90 1.0038 / S235JR (St37-2) 0.138 KG 421020 10012411
22 4 Ring 119x17 1.0038 / S235JR (St37-2) 0.487 KG 421061 10012439
CASTING
100

F 31 21 4 Ring 119x18 1.0038 / S235JR (St37-2) 0,5 KG 421062 10012440

F
870

DIRECTION 20 2 Ring 151.2x14.5 1.0038 / S235JR (St37-2) 0.62 KG 421045 10012428

=

=
Strand
1270

52 50 57
915

810

540

750

1010
1220

19 2 Ring 151.2x15.5 1.0038 / S235JR (St37-2) 0,68 KG 421044 10012427

=

=
50

18 1 Ring 151.2x18.5 1.0038 / S235JR (St37-2) 0.79 KG 421031 10012416

17 1 Ring 151.2x19.5 1.0038 / S235JR (St37-2) 0.86 KG 421043 10012426
55
60 16 2 Ring 151.2x19.5 1.0038 / S235JR (St37-2) 1.3 KG 421039 10012422

E E 15
14
4
4
Flange
Flange
180x16
180x16
1.0038 / S235JR (St37-2)
1.0038 / S235JR (St37-2)
1.85
1.74
KG
KG
421060
421059
10012437
10012429
13 1 Flange 210x14 1.0038 / S235JR (St37-2) 1.72 KG 421023 10012412
56 12 3 Flange 210x14 1.0038 / S235JR (St37-2) 1.76 KG 421040 10012423
11 1 Flange 210x14 1.0038 / S235JR (St37-2) 1.85 KG 421030 10012415
C
3 10 3 Flange 210x14 1.0038 / S235JR (St37-2) 1.89 KG 421042 10012424 C
9 1 Front Splash Guard - - 69.1 KG 545133 10044009
8 1 Rear Splash Guard - 68,2 KG 545144 10044020
29 61 7 1 Template - 3,84 KG 541471 10042292
6 1 Fine Adjusting - - 22,8 KG 439261 10016682
5 1 Oscillation Transport Tool - - 27.3 KG 424109 10013212
4 2 Lever - 91,5 KG 541723 10039218
3 1 Bell Crank - 802,6 KG 541799 10039216
2 1 Oscillation Frame - 964,9 KG 542832 10039215
1 1 Oscillation Table - 868,7 KG 541942 10039217
23 Item Qty Description Dimension Basic Material Weight Ut. MM-No. DRW-No. Norm/Remark
260

Modell: 10000261689_IAM_000.iam Modellversion: -

110

48
B B

THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
(75) 540 115 Standard Workshop
ISO 128
Section Weight Main Scale Format
Instructions 9800.4 115.600 3.245 TO 1:5 A0
615 Replaced by

635 740 Mould Oscillation Assembly Released

Approved
22.01.2013

10.01.2013
C603

SCBR

Drawn 05.10.2012 V628

800 Document No. Version

10'039'208 -
A Sheet: 1 of 3 A
Material No.

Index Description of Modification Date Name SMS group

542462
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
EKI Old File Name: File Name: 10039208_DRF_000.idw
 12 11 10 9 8 7 6 5 4 3 2 1

D
H
A-A ( 1 : 10 ) B-B ( 1 : 10 ) 12 D-D ( 1 : 10 )
H

562.5
12 20
C-C ( 1 : 10 )
562.5 16
12 19 1270
13 10 = =
17 10 Z 20
18
19
7
Fixed Bearing Loose Bearing Fixed Bearing Loose Bearing
H
24 24
G 25 25 27 6 G

40
16 H
20 11
10 15 15
15 22
22
21 X 21
Loose Bearing Loose Bearing
Fixed Bearing Fixed Bearing 5
26
( Template For
26 26 26
F Y Transportation)
J F
15 21 22
22
21 14 14
14 J
14

1270
D
= =

E
H-H ( 1 : 2,5 ) E

J-J ( 1 : 2,5 )
E-E ( 1 : 2,5 ) F-F ( 1 : 2,5 ) G-G ( 1 : 2,5 )
79
56 29 45 44 (15) 49 15
14 61
125 58

3 53
47
27
D D

Printed by: C850 on 25. September 2013 - Status: Released RE

80

65
70
30
M12

80

65

70
Z ( 1 : 2,5 )
( Fixed Bearing ) 27
145
35
Y ( 1 : 2,5 ) 53
X ( 1 : 2,5 ) 98

( Fixed Bearing ) ( Loose Bearing ) 2 94 58 2.5 49 2.5 36

12 66
C 96 96
36 C
84
2.5 91 2.5 1 94 1
10 140
14
M10

15 19
M10

14 22 19
21 26 K ( 1 : 10 )
17 60 (17)
60 15.5 67 (15.5)
100
80
70
100
80
70

100
80

Modell: 10000261689_IAM_000.iam Modellversion: -

270

B B
210
15 22
26
33 25 25 THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED

21 33 2.5 2.5 49 UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.

34 53 Standard Workshop
ISO 128
Section Weight Main Scale Format

80 49 80 Instructions 9800.4 115.600 3.245 TO 1:5 A1

Replaced by

145 145
1010
= =
Mould Oscillation Assembly Released

Approved
22.01.2013

10.01.2013
C603

SCBR

Drawn 05.10.2012 V628

Document No. Version

80 10'039'208 -
A A
Sheet: 2 of 3
Material No.
SMS group
542462
12 11 10 9 8 7 6 5 4 3 2 1
EKI Old File Name: File Name: 10039208_DRF_000.idw
 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

L L

K 66 66 66 K

71
72
J
69 J

O
69

71
I 69 I
71
L 70 71 39
71

63 63
40 39
66
74 68

H H

G G

73 Q ( 1 :2,5 )
O ( 1 : 2,5 ) P ( 1 : 2,5 )
S
64 37 R
66 66
66
F F
63 63
63
GREASING ASSEMBLY L-L
69 ( 1:5 ) 38
71
71
a5

66 66

E
65 65 E
N
( 1 : 2,5 ) 70
39 R ( 1 : 2,5 )
68
37 39 65
39 65 39
62 M M 40 62 64
N 66 66

Printed by: C850 on 25. September 2013 - Status: Released RE

D S ( 1 : 2,5 ) 63 63 D

66

73 73

Mould Oil
Greasing

Greasing
67
66
68
68
62 67
C 66 Q C
74
62 68
63 M-M 40
a5
68 ( 1 : 2,5 ) 40
GREASING ASSEMBLY REMARKS:
Mould Oil

MIN. HOLE THREAD DEEP FOR THE FIXATION OF PIPE CLIPS MAT.N 539082,
Greasing
Greasing

AVOIDING TROUGH HOLE IN THE OSCILLATION TABLE MEDIUM PASSAGE

68
66

Modell: 10000261689_IAM_000.iam Modellversion: -

38 64 66
B B
70
THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
Section Weight Main Scale Format
Standard Workshop
ISO 128
Instructions 9800.4 115.600 3.245 TO 1:5 A0
71 69 41 46 42 71 70 Replaced by

Mould Oscillation Assembly Released

Approved
22.01.2013

10.01.2013
C603

SCBR

Drawn 05.10.2012 V628

65 Document No. Version

10'039'208 -
A Sheet: 3 of 3 A
Material No.
SMS group
542462
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
EKI Old File Name: File Name: 10039208_DRF_000.idw
 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

L L

K K

J Air G1/8" J
ISO 1179-1

I I

8 x M12 Air G1/8"

ISO 1179-1 Stroke 30 mm

R8
346.5 2

H H
164

G G

ca. 37.5
P
SAE 6000 PSI
1"
SAE J518
115 ca. 37.5 ca. 37.5
53 165 53
563 150

835 (center position) 82

F F

T
SAE 6000 PSI
1"
SAE J518

E E
70 +- 00.015 70 +- 00.015

0
Piston: 90
49 +- 00.15

49 +- 00.15
55

55
Piston rod: 50

Printed by: C850 on 25. September 2013 - Status: Released RE

Stroke: 50
D D

Load compensation: pulling or pushing

C Specification Data: C

Vendor: Oelhydraulik Hagenbuch AG

Vendor Drawing-No.: M01.3268
Vendor Website: www.hagenbuch.ch

Modell: 10000283911_IAM_000.iam Modellversion: -

B B

THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
Section Weight Main Scale Format
Standard Workshop
ISO 128
Instructions 9800.4 115600 0.000 KG 1:2 A0
Replaced by

Released 17.04.2013 C603

Mould Oscillation Drive Approved 15.03.2013 T088

Drawn 21.12.2012 V628

Document No. Version

10'043'374 -
A Sheet: 1 of 1 A
Material No.

Index Description of Modification Date Name SMS group

543764
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
EKI Old File Name: File Name: 10043374_DRF_000.idw
6. SECONDARY COOLING

6.1 INTRODUCTION
Secondary cooling is provided by water sprayed directly onto the bloom surface.
Heat removal from the billet surface occurs by a combination of the following
processes:
- Spray cooling (heat transfer by film boiling)
- Contact with the supporting rolls (solid – to – solid)
- Heat removal by the excess water (especially above the supporting rolls)
- Radiation (the additional contribution of natural convection can be neglected
in comparison with the others)
Due to the relatively low thermal conductivity of steel, the effect of spray cooling
on solidification diminishes as the shell thickness increases. Finally, at some
distance from the mould, depending on the size of the section being cast and the
casting speed, cooling water is no longer useful for solidification.
The purpose of secondary cooling is to produce a billet free of cracks and without
bulging or other shape defects. This is achieved by applying the correct quantity
of secondary cooling water, with the correct distribution in the casting direction.

6.2 SECONDARY COOLING INTENSITY

The flow rate of the secondary cooling water has a direct bearing on strand
temperature and solidification; therefore, it is very useful to have a relationship or
value for specifying the cooling intensity.
The standard measure of the secondary cooling water intensity that has been in
use for many years is the specific water volume (SWV) representing litres of
cooling water per kg of steel cast (l/kg):
Q
SWV 
w  t  Vc  

Where SWV =Specific Water Volume (litres/kg)

Q = flow rate (l/min)
w = width section (m)
t = thickness of section (m)
Vc = casting speed (m/min)
ρ = density of liquid steel (=7650 kg/m3)

C.4619/401 Chapter 1 Rev0

IVAC0 Page 27 of 44 February 2014
 Another relationship that can be used to more accurately compare cooling
intensities for widely varying strand sizes takes into account the ratio of surface
area to volume. (This measure is not used for normal operations)

Q
I
L  P  VC

Where I = cooling intensity (l/m3)

Q = flow rate (l/min)
P = strand perimeter (m)
Vc = casting speed (m/min)
L = length of cooling zone (m)

The secondary cooling water equipment is designed to give the necessary range
of flows and therefore intensities for the operating parameters of all the section
sizes.

6.3 SHELL THICKNESS

When considering the overall solidification of the strand below the mould, Field's
equation is sufficient to calculate the approximate steel shell thickness:

SK t

Where S = shell thickness (mm)

K = solidification constant (mm•min-0.5)
t = solidification time (min)

The magnitude of K, the solidification constant, is influenced by:

- Heat conductivity of the steel
- Heat of solidification
- Section shape
- Superheat
- Secondary cooling intensity

C.4619/401 Chapter 1 Rev0

IVAC0 Page 28 of 44 February 2014
 - Secondary cooling length

- Secondary cooling spray water distribution

For billets, 160 mm thick, the value of K is approximately 28 mm.min-0.5.

In contrast to mould cooling, secondary cooling is open to a wide range of

adjustment, the effect of which on surface temperature is very obvious. The
secondary cooling distribution and quantity are parameters that can be varied
within the boundaries of the installed equipment e.g. nozzle jet sizes, piping
capacity and pump capacities.

6.4 SECONDARY COOLING LAYOUT

The secondary cooling is divided into several zones. Each zone has a different
water control loop, consisting of flow meter, control valve, and visualisation on
the Level I system.

6.5 CONTROL
Three methods of control are possible:
• Automatic;
• Semi Automatic;
• Manual.
The normal method of control is Automatic: the flow set point of each cooling
zone is calculated based on the casting speed.
In Semi Automatic mode the proportional valve is operated automatically in order
to achieve a certain value of water flow.
In Manual mode, the proportional valve is actuated directly by setting the desired
valve opening.
More information about these three control modes are given in the functional
description.

When Automatic mode is selected, the cooling flow for each zone is defined
according to the mathematical formula for a straight line:

Q  m Vc  C

C.4619/401 Chapter 1 Rev0

IVAC0 Page 29 of 44 February 2014
 WATER FLOW Q in L/MIN

300
250 m
200
150
100
C.O. 50
CASTING SPEED Vc
0
c
-50 0 1 2 3 4 5 6
in M/MIN.

Where: Q = Flow rate (l/min)

m = Gradient
C = offset (l/min) (C is usually set to 0)
Vc = Casting speed

As the cooling flow increases proportionally with the casting speed, the cooling
intensity (l/kg) remains constant. (C is usually set to zero. This function is only
used if there is a very wide range of casting speed.)
The flow rate must not be reduced below the one where the pressure at the
nozzle would be so low that the spray cone fan collapses.
This minimum flow is called cut off point (c.o.).
Thus, a cooling curve is defined and stored in the PLC by the following three
figures: m, C and c.o.

C.4619/401 Chapter 1 Rev0

IVAC0 Page 30 of 44 February 2014
 When AUTOMATIC is selected
[1] the control parameter values
are taken from the recipe stored
in the PLC and the aim flow is
calculated based on the casting
speed, and is indicated at the
3
right hand vertical bar graph and 2
field above [2].

The measured flow will be

adjusted accordingly to the set
point and displayed in the left
vertical bar [3].

The flow control valve will

continuously regulate the flow,
indicated by the horizontal bar
graph and filed above [4].

C.4619/401 Chapter 1 Rev0

IVAC0 Page 31 of 44 February 2014
6.6 SPRAY NOZZLES

6.6.1 RELATIONSHIP BETWEEN WATER FLOW VERSUS WATER

PRESSURE AT NOZZLE TIP – SINGLE FLUID NOZZLE (WATER)

Relationship between Water Flow versus Water Pressure at nozzle Tip – single
fluid nozzle (water)
The relationship between the pressure at the nozzle tip and the flow produced
which is defined as follows;
Q1 Q2
 or Q1  P 2  Q 2  P1
P1 P2

EXAMPLE
Nozzle type = 3.0 l/min
e.g. From the nozzle type it is known that at the reference pressure of 2.8 bar
the reference flow is 3.0 l/min
If the flow is increased to 4.0 l/min

Q1  P 2  Q2  P1
3  P 2  4  2.8
2
4 
P 2    2.8 
3 
P 2  5 bar

Using this formula it is possible to add up the total reference flows of the nozzles
in a zone and from the total flow in the zone, calculate the pressure in the zone.

6.6.2 RELATIONSHIP BETWEEN WATER FLOW VERSUS WATER

PRESSURE AT NOZZLE TIP – DOUBLE FLUID NOZZLES (AIR MIST)

The relation between water flow rate and water pressure for air mist nozzles is
not easily described by a simple equation; moreover the relation is different when
different air pressures are used.
For these reasons air/water flow rates versus air/water working pressures are
given as diagrams.

C.4619/401 Chapter 1 Rev0

IVAC0 Page 32 of 44 February 2014
6.7 DRAWINGS

NOZZLE LAYOUT – SOFT COOLING 95664

NOZZLE LAYOUT – HARD COOLING 95665

AIR MIST NOZZLE AM4R 10035188

WATER ONLY NOZZLES 17968

7. FINAL ELECTROMAGNETIC STIRRER

The CONCAST AG mould stirrer system is developed and manufactured for high
efficiency and reliability. Its working principle is based on the well known mode of
operation of an asynchronous motor.

The alternated current and the magnetic field together form the stirring torque.
These two units are connected according to the law of induction and transferred
contactless into the liquid steel core inside the billet.

The direction of the rotating field can be changed by setting a parameter on the
frequency converter.

The current intensity and frequency need to be adjusted if one of the following
parameters is modified:

 Casting size
 Steel grade
 Casting speed

General description

The EMS-housing is inserted into the mould support. The mould and the stirrer
can be removed and replaced from above the casting platform. Electrical
connections are made from the casting platform via flexible cables.

To generate a rotating magnetic field the stirrer uses a six pole, three phase
circuit operating at Error! Reference source not found.. The field penetrates in
the liquid steel inside the mould. Here it sets up a circular motion of the liquid
steel, so that stirring in the mould up to the meniscus level is achieved.

Due to the location underneath the mould cover, the stirrer is well protected
against steel overflows and other casting problems.

C.4619/401 Chapter 1 Rev0

IVAC0 Page 33 of 44 February 2014
 A-A ( 1 : 5) B-B ( 1 : 5)

400
CL Casting Radius
Zone 1 Row 1&2 Zone 1 Row 3&4
(Water Only) (Water Only)

1 A 95
120
A
2
Zone 1 3 B
4 B

75

70
C
5
C
6
Zone 2a
7
D

95
120
8
D
9

10 75 70

11 CASTING
Zone 2b DIRECTION
12
E

13 C-C ( 1 : 5) D-D ( 1 : 5 )
14 E Zone 2a Zone 2b
15
(Water Only) (Water Only)

16

140
17 F

100
Zone 2c
18
19

F
20

21

100
Zone 3a 140
22

23 CASTING
G DIRECTION
E-E ( 1 : 5 ) F-F ( 1 : 5 )
24 Zone 2c Zone 3a&b
(Water Only) (AirMist)
Zone 3b 25

150
z
26

100
Fixed Side

Printed by: C850 on 04. Oktober 2013 - Status: Released

27

x
28

Zone 4
29

100 150

CASTING
DIRECTION
G-G ( 1 : 5 )
Zone 4
(AirMist)

150
150
 A-A ( 1 : 5) B-B ( 1 : 5)

400
CL Casting Radius
Zone 1 Row 1&2 Zone 1 Row 3&4
(Water Only) (Water Only)

1 A 95
120
A
2
Zone 1 3 B
4 B

75

70
C
5
C
6
Zone 2a
7
D

95
120
8
D
9

10 75 70

11 CASTING
Zone 2b DIRECTION
12
E

13 C-C ( 1 : 5) D-D ( 1 : 5 )
14 E Zone 2a Zone 2b
15
(Water Only) (Water Only)

16

140
17 F

100
Zone 2c
18
19

F
20

21

100
Zone 3a 140
22

23 CASTING
G DIRECTION
E-E ( 1 : 5 ) F-F ( 1 : 5 )
24 Zone 2c Zone 3a&b
(Water Only) (AirMist)
Zone 3b 25

150
z
26

100
Fixed Side

Printed by: C850 on 04. Oktober 2013 - Status: Released

27

x
28

Zone 4
29

100 150

CASTING
DIRECTION
G-G ( 1 : 5 )
Zone 4
(AirMist)

150
150
 6 5 4 3 2 1

Air
Gasket
10 M8x16/20

22
D 38 D

L=Longitudinal

Printed by: C850 on 04. Oktober 2013 - Status: Released RE

14

9
50

12
11

15
Water
14

C C

Nozzle Body Tightening Torque

min. 50 Nm Dimension: Size-2.8-LxT-Length
max. 70 Nm For Example: 2.0-2.8-30x90-L140
5 h8

(not for purchase)

Vendor: Jato

T=Transversal
Material: 2.0401 (CuZn39Pb3) 17660

2 bar Air pressure

Positioning Pin

B B

Modell: 10000227774_IPT_000.ipt Modellversion: -

Length

ALL RIGHTS RESERVED, COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER
Cap Nut Nozzle Tip
THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST
NOT BE MADE PUBLIC OR COPIED UNLESS AUTHORISED BY IT AND IS SUBJECT TO RETURN UPON DEMAND
Section Weight Main Scale Format
Standard Workshop
ISO 128
Instructions 9800.4 175.260 0.91 KG 1 : 1.5 A3
Replaced by

Released 15.06.2012 C603

AirMist Nozzle AM4R Approved 15.06.2012 C603

Drawn . . C603

A Document No. Version

A
10'035'188 -
Sheet: 1 of 1
Material No.

Index Description of Modification Date Name SMS group

6 5 4 3 2 1
Old File Name: AM4R LONG.IDW File Name: 10035188_DRF_000.idw
 A closed water circuit cools the stirrer. The heat is removed by an external
water/water heat exchanger. Flexible hoses connect the stirrer to the supply
pipes. The inlet hose leads first to a strainer which prevents dirt to be transported
into the housing.
Stirrer Design
The stirrer consists of two main parts: the housing and the core. The housing is
made of laminated stainless steel while the core consists of the six copper coils.

The stirrer housing and the cover are made of stainless, non magnetic steel. The
connection hose, the filter housing and the in- and outlet pipes are welded to the
housing. For lifting the complete assembled stirrer three threads M16 in the top
plate of the housing are foreseen (eyebolts shall be screwed in). The stirrer is
placed flat on the mould support.

The core consists of sheet metal rings with six poles to hold the copper coils. The
complete core is held by means of two rings of anti-magnetic steel and the
appropriate connecting rods. The windings of the copper coils are made of a
specially insulated type of copper wire, and after their attachment to the core, the
complete core with coils is impregnated with special resin.

Cooling
The stirrer casing is flowed through by cooling water of specified quality. This
primary water circuit is closed against the environment and run by a water
station. The station consists of circulation pumps, a water tank, a filter, a plate
heat exchanger and several measuring instruments. The piping of the cooling
circuit must be made of antimagnetic (austenitic) stainless steel, in order to
prevent rust form entering into the water circuit.

8. STRAND GUIDE SYSTEM

8.1 INTRODUCTION
The dummy bar and the cast strand are driven and guided by various machine
components. In the direction of casting from the mould are the following: -

 Mould attached foot rolls (dedicated for each section)

 Roller apron supporting rolls
 Withdrawal straightening unit
 Auxiliary Withdrawal unit

C.4619/401 Chapter 1 Rev0

IVAC0 Page 34 of 44 February 2014
8.2 FOOT ROLLS
Foot rolls are dedicated for each sections:
- 130x130: connected with mould cartridge (1 rows, 4 rolls)
- 140x140: connected with mould cartridge (1 rows, 4 rolls)

C.4619/401 Chapter 1 Rev0

IVAC0 Page 35 of 44 February 2014
8.3 STRAND GUIDE ROLLS

The roller apron serves as a support for the cast strand and as guide for the
rigid dummy bar during insertion and withdrawal.
At this plant each strand of the CCM is fitted with 4 strand guiding and strand cooling
containments (segments). The segments are curved, corresponding to the casting radius.

Spray ring and Footroller

Segment 1

Segment 2

Hinged roller

F-EMS

Segment 3

Segment 4

C.4619/401 Chapter 1 Rev0

IVAC0 Page 36 of 44 February 2014
Segment 1:
Along the fixed radius of the strand and dummy bar guide, there are two all
side support roller assemblies mounted. All rollers are combined parallel guide
roller assemblies.

All side support roller

assembly

C.4619/401 Chapter 1 Rev0

IVAC0 Page 37 of 44 February 2014
 Segment 2:

Slide tubes as
strand support
at fixed side

Side guide roller

Roller assembly with

roller at fixed and loose
radius side.

At segment 2 is a
roller assembly
mounted with an
additional roll at loose
side. This roller
assembly allow the
strand and dummy
bar, to pass in a

controlled manner. In case of a so called "frozen"

strand the roll at loose side has to be removed or the
frozen strand must be cut in front of and behind this
roller assembly. The correct distance between the
rollers is given by the radius template.

Segment 3:

C.4619/401 Chapter 1 Rev0

IVAC0 Page 38 of 44 February 2014
 Roller assembly with
Side guide roller roller at fixed and loose
radius side.

F-EMS

Slide tubes as
strand support
at fixed side

At segment 3 is a
roller assembly
mounted with an
additional roll at
loose side. This
roller assembly

allow the strand and dummy bar, to pass in a controlled

manner. In case of a so called "frozen" strand the roll at
loose side has to be removed or the frozen strand must be
cut in front of and behind this roller assembly. . The
correct distance between the rollers is given by the radius
template.

C.4619/401 Chapter 1 Rev0

IVAC0 Page 39 of 44 February 2014
 Segment 4:

Slide tubes as
strand support
at fixed side

Side guide roller

Radius guide roller

Roller assembly with

roller atAt
fixed and loose
segment
radius side.
4 are two

roller assemblies mounted with each an

additional roll at loose side. These roller

C.4619/401 Chapter 1 Rev0

IVAC0 Page 40 of 44 February 2014
 assemblies allow the strand and dummy bar, to pass in a controlled manner.
In case of a so called "frozen" strand the roll at loose side has to be removed
or the frozen strand must be cut in front of and behind this roller assembly.
The correct distance between the rollers is given by the radius template.

8.4 WITHDRAWAL STRAIGHTENING

The Withdrawal & Straightening System is a modular type with 2 modules per strand
located after the cooling chamber. The last module is located before the disconnection
device of the dummy bar.

The Withdrawal & Straightening System fulfils the following tasks:

 It inserts the dummy bar into the mould before casting start.

 It holds the dummy bar head in preparation position above the mould.

 It holds the dummy bar in the start position in the mould up to the casting
start.

C.4619/401 Chapter 1 Rev0

IVAC0 Page 41 of 44 February 2014
  It retracts the dummy bar after the casting start, in casting direction, at
automatically adjusted casting speed from the mould down to
disconnection station.

 It withdraws the casting strand and straight it consecutively.

 The last module is also a straightening module and additional the strand
fixation, when the dummy bar disconnection takes place.
Each MSR-module consists of one driven and one idling roll at the loose side, which
can be hydraulically pressed against the strand and fix rolls at the fix side. For dummy
bar insertion the rolls at the loose side can be lifted and lowered. The upper rolls are
guided in linear guides. The motion is done by the same hydraulic cylinder, which is
used for pressing the roll against the strand. The rolls are internally water cooled.
Additional to their function for transport, the hydraulically actuated rolls can be used as
a future option for soft reduction.
The continuously arranged modules straighten the strand out of the casting radius.
The automatic operation of the Withdrawal & Straightening System needs the co-
operation with the whole CCM. The control of these functions needs a high grade of
software co-ordination. The detailed description of the control you will find in the
electrical function description FD291 in chapter 56.

C.4619/401 Chapter 1 Rev0

IVAC0 Page 42 of 44 February 2014
 Future installation of additional modules of the same construction (maximum 6 total per
strand) will allow performing Mechanical Soft Reduction, without need to replace the
two existing modules.
In this future configuration, modules 2 to 6 will perform Mechanical Soft Reduction on
the billet.

8.5 CROP END PINCH ROLL

The crop end pinch roll unit is located before the entry to the cutting machine. It is
used for the extraction of the cast strand in order to support the main withdrawal unit
and to discharge the last cast strand when this has left the main withdrawal unit.
The crop end pinch roll consists of an upper roller which is driven by a gear motor and
a hydraulic cylinder which moves the roll 'UP' and 'DOWN'. The speed of the AC motor
is controlled by a frequency converter.

I
m

The 'UP' position is the inactive position while 'DOWN' is the working position.
With the control pushbuttons mounted on the torch cutting desk, the gear motor
and the hydraulic cylinder can be controlled independently in manual mode. In
automatic mode the movement of the crop end pinch roll rocker arm and the
speed of the roll will be controlled accordingly to the casting speed and the hot

C.4619/401 Chapter 1 Rev0

IVAC0 Page 43 of 44 February 2014
 strand tracking. The speed of the roll must always be absolutely synchronous to
the main withdrawal roll.

8.6 LIST OF DRAWINGS

MSR ASSEMBLY 100471362

MSR SEGMENT 2 10041249

IDLER ROLL 10041308

MSR SEGMENT 1 10041821

C.4619/401 Chapter 1 Rev0

IVAC0 Page 44 of 44 February 2014
 8 7 6 5 4 3 2 1

F F

2
5784

1
Disconnection device
E E
see section
4721

132200-01

Support structure
see section
130100-03
301

Printed by: C850 on 27. September 2013 - Status: Released RE

750 760 750 820 690
D 1300 1300 1300 D

Disconnection
Tangent Axis

Cutting Start
CASTING

16.4
DIRECTION

48.5
-1337.34 -2000
Passline

46.8
C 1 2 3 4 5 6 C

15.9
Strand 4

750 760 750 820 690

3000

Strand 3
4 6 Platform 191,2 KG 539059 10041428
3 3 Idle Roller 2,053 TO 538853 10041308
6000
6480

2 3 MSR Segment 2 10,532 TO 538742 10041249

1 3 MSR Segment 1 10,482 TO 542812 10041821
Strand 2 Item Qty Description Dimension Basic Material Weight Ut. MM-No. DRW-No. Norm/Remark

Modell: 10000272885_IAM_000.iam Modellversion: -

B B
3000

Strand 1
THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
Section Weight Main Scale Format
Standard Workshop
ISO 128
Instructions 9800.4 130100 70,349 TO 1 : 50 A2
Replaced by

MSR Assembly Released

Approved
28.01.2013

28.01.2013
C603

U039
0
480

1510
1990

3020
3500

Drawn 20.11.2012 SCMC

Document No. Version
A A
10'041'362 -
Sheet: 1 of 1
Material No.

Index Description of Modification Date Name SMS group

538942
8 7 6 5 4 3 2 1
CZH Old File Name: File Name: 10041362_DRF_000.idw
 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

L 24 18 L

43 A ( 1 : 10 )
C E B-B ( 1 : 10 ) C-C ( 1 : 10 )
2
49
B
57
K 70 61 K
16
58
57 16
17 10
15
15 29
55
42 a4
26
56
F 52 46
8
J J
41 7 14 6 45
67
22 19 64
71
33 54 A H 23
50
11
G
69
I
H 53
I

53 59
20
4 12
21
11 68
5
CASTING
DIRECTION 3
H H

60
Sheet 1 - Part List
51 Sheet 2 - Dimensions
38 13 73 1 Washer M36_ 37/66X5 8 0.092 KG 368227 ISO7089
72 2 Hex. Nut 0.8d M36 8.0 zinc plated 0.434 KG 306644 ISO4032
71 12 Hex. Nut 0.8d M24 8.0 zinc plated 0.129 KG 306640 ISO4032
70 8 Hex. Nut 0.8d M20 8.0 zinc plated 0.075 KG 306638 ISO4032
69 4 Hex. Nut 0.8d M12 8.0 zinc plated 0.016 KG 306634 ISO4032
39 68
67
4
12
Socket Head Cap Screw
Socket Head Cap Screw
M30X80
M24X180
10.9
8.8 zinc plated
0.75
0.79
KG
KG
349695
317656
ISO4762
ISO4762
66 6 Socket Head Cap Screw M24X160 8.8 zinc plated 0.72 KG 317655 ISO4762
G 65 6 Socket Head Cap Screw M24X90 8.8 zinc plated 0.474 KG 317666 ISO4762
G
32 64 23 Hex. Cap Screw M16X90 8.8 zinc plated 0.18 KG 306709 ISO4017
63 16 Socket Head Cap Screw M16X65 8.8 zinc plated 0.146 KG 317584 ISO4762
62 16 Socket Head Cap Screw M16X25 8.8 zinc plated 0.083 KG 317577 ISO4762
61 8 Hex. Cap Screw M36X300 10.9 2.85 KG 349050 ISO4014
1 60 8 Hex. Cap Screw M24X240 8.8 zinc plated 0.98 KG 307039 ISO4014
59 8 Hex. Cap Screw M24X130 8.8 zinc plated 0.59 KG 307032 ISO4014
58 4 Hex. Cap Screw M24X60 8.8 zinc plated 0.342 KG 306566 ISO4017
57 8 Hex. Cap Screw M20X45 8.8 zinc plated 0.186 KG 306739 ISO4017
36 56 4 Hex. Cap Screw M16X30 8.8 zinc plated 0.085 KG 306699 ISO4017

D 55
54
4
2
Hex. Cap Screw
Hex. Cap Screw
M12X40
M12X30
8.8 zinc plated
8.8 zinc plated
0.052
0.043
KG
KG
306671
306669
ISO4017
ISO4017
44 53 8 Hex. Cap Screw M12X25 8.8 zinc plated 0.038 KG 306668 ISO4017
52 4 Lifting Eye Bolt M36 1.1141 / C15 2.73 KG 369166 DIN580
F F
51 3 Pipe Plug 1" Stainless Steel 0.27 KG 545357 SS-16-P

37 50
49
2
1
Rival Y Ring
Clevis Pin with Head
20-173
12X100
NBR 70
Steel
0.02
0.097
KG
KG
528836
350948
SN 853
ISO2341
48 4 Spring Cotter (Double Coil) 7x130 Standard 00 0.014 KG 476840 DIN 11024
47 3 Precision Dowel Pin 20H8X40 Steel 0.094 KG 339159 ISO2338
C B 46
45
2
2
Sleeve
Sleeve
115x10
115x10
1.0577 / S355J2+N
1.0577 / S355J2+N
0,187
0,162
KG
KG
546864
546862
10044801
10044800
44 4 Shim for Bolt 61x5x26 1.0330 / DC01+LC 0,18 KG 535311 10042457
43 1 Spring cotter 3.2 DIN 11 024 8.5x25.9x61 - 0.000 KG 539023
42 2 Numbering 1.0038 / S235JR+AR 0.211 KG 540306 10041741

E ( 1 : 10 ) F(1:5) 41
40
2
1
Name Plate
Shim Foot
1.5x85x170
68x140x145
3.3535 / AlMg3 (EN AW-5754)
1.4301 / X5CrNi18-10
0.052
6,59
KG
KG
393987
538996
10007717
10041214
48 39 4 Sleeve 23x20 CC493K / CuSn7Zn4Pb7-C 0,037 KG 539010 10041403

E 25 without Protecting Plate G ( 1 : 10 ) 38 4 Sleeve 27x20 CC493K / CuSn7Zn4Pb7-C 0,045 KG 539007 10041401
E
35 37 4 Wedge 14.1x58.5x250 1.0503 / C45 1.37 KG 320814 10000888
7 without Roller Support 36
35
4
4
Bolt
Bolt
50x75x719
36x120
1.7225 / 42CrMo4 + QT
1.0577 / S355J2+N+Z15
7,42
0.92
KG
KG
539000
535218
10040794
10039484
34 1 Bolt 40x80x150 1.7225 / 42CrMo4+QT 1.89 KG 535219 10039139
66 33 1 Protection Plate 1004.1x250x1.5 1.4841 / X15CrNiSi25-20 2.67 KG 538570 10041168
28 32 8 Round 69x60 1.7225 / 42CrMo4+QT 1,47 KG 535217 10039140
65 31 2 Shim Foot 68x140x145 1.4301 / X5CrNi18-10 10.18 KG 535216 10039477

D ( 1 : 10 ) 51
27 30
29
1
1
Shim Foot
Plate
68x140x145
30x300x555
1.4301 / X5CrNi18-10
1.0577 / S355J2+N
6.09
36.7
KG
KG
318468
535220
10000775
10039479

47 62
28
27
4
4
Plate
Plate
41x240x330
28.5x130x220
1.0503 / C45
1.7225 / 42CrMo4+QT
25.3
5.88
KG
KG
539021
537408
10041420
10040732
30 9 26 2 Bolt 102x102x238 1.7225 / 42CrMo4+QT 14.6 KG 535889 10039483

Printed by: C850 on 27. September 2013 - Status: Released RE

40 25 1 Cylinder Cooling 2 351,6x560x615,5 - 37,5 KG 545072 10043965
24 1 Cylinder Cooling 1 351,6x560x615,5 - 37,5 KG 538877 10040988
D D
63 23 1 Protection Plate L 2x871.7x864.7 1.4841 / X15CrNiSi25-20 6,35 KG 538574 10041170
22 1 Protecting Plate R 2x871.7x864.7 1.4841 / X15CrNiSi25-20 6,35 KG 538577 10041172
21 1 Protecting Plate 450x184,8x3 1.4841 / X15CrNiSi25-20 1,92 KG 539015 10041411
20 1 Protecting Plate 450x124,8x3 1.4841 / X15CrNiSi25-20 1,29 KG 539014 10041409
19 1 Lubrication Support - - 9.88 KG 539073 10041458
18 1 Cable Support - 10,8 KG 538997 10039942
17 1 Cable Support - 15,2 KG 538998 10039940
16 1 Support - - 20.4 KG 538561 10041160
15 2 Support - 17,2 KG 538564 10041162
31 14 2 Heat Shield - 22,6 KG 535925 10039905
13 2 Heat Shield - 12,5 KG 538580 10039907
12 1 Holding - 263,1 KG 538586 10039062

C
31 51 H-H ( 1 : 5 ) 11
10
1
2
Holding
Cylinder Assembly
- 259,8
390,4
KG
KG
538583
539040
10039064
10041424 C
9 1 Torsion Compensator 166,1 KG 538743 10038617
8 1 Roller Support - 320,3 KG 538582 10038647
7 1 Guide right 87,8 KG 538747 10039487
6 1 Guide left 87,8 KG 538756 10041255
5 1 Drive Roller 655,9 KG 540048 10041557
4 1 Idle Roller upper 616 KG 539249 10041510
3 2 Idle Roller bottom 695,4 KG 538744 10041509
2 1 Gear and Motor unit 906,1 KG 538999 10040043
1 1 Fixed Frame - 4,383 TO 542689 10039615
Item Qty Description Dimension Basic Material Weight Ut. MM-No. DRW-No. Norm/Remark

Modell: 10000249655_IAM_000.iam Modellversion: -

24
DIRECTION

B B
CASTING

72 73 1 34 2
THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
Section Weight Main Scale Format
Standard Workshop
ISO 128
Instructions 9800.4 10,532 TO 1 : 10 A0
Replaced by

MSR Segment 2 Released

Approved
28.01.2013

28.01.2013
C603

U039

Drawn 16.11.2012 SCMC

Document No. Version

10'041'249 -
A Sheet: 1 of 2 A
Material No.

Index Description of Modification Date Name SMS group

538742
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
CZH Old File Name: File Name: 10041249_DRF_000.idw
 12 11 10 9 8 7 6 5 4 3 2 1

H H
I ( 1 : 15 )
MSR-Modul Nummer - ....

1.0 Pressure test hydraulic

Signature/Date ........................
lifting eye M36 Cylinder 1 MPa Time (min) Result
A 25 10
B 25 10

G
lifting eye M36 G
Position for Segment both Sides
Numbering (track welded) 1.1 Pressure test hydraulic
Signature/Date ........................
5mm Shim Package

Position for Segment Cylinder 2 MPa Time (min) Result

Numbering (track welded) A 25 10
B 25 10

NPT 1/4"

+170 mm Stroke
for Lubrication

3256
I 2.0 Pressure test water
NPT 1" Signature/Date ........................
NPT 1/4" for Water MPa Time (min) Result
F for Lubrication move 0.8 30 F

CASTING
(145) 3.0 Pressure test lubrication
DIRECTION Signature/Date ........................

120 calibration
250
MPa Time (min) Result
20 10
5mm Shim Package
0.25

fix
958

NPT 1/4" NPT 1/4"

for Lubrication for Lubrication
E E
48
26mm (Shim)

water outlet water inlet

469

61
51
L
50

730 816 750 325

900 1175
D D

Printed by: C850 on 27. September 2013 - Status: Released RE

1460 1320

L ( 1 : 15 )
657.5 70
C 207.5 37 C
NPT 1"
for Water
NPT 1"
for Water fix (heat expansion)

K
J
676
516

Modell: 10000249655_IAM_000.iam Modellversion: -

B K(1:5) B
309.5

J(1:5) 70 37 THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
NPT 1" 52.5 1315 Standard Workshop Section Weight Main Scale Format
for Water ISO 128
40 Instructions 9800.4 10,532 TO 1 : 10 A1
Replaced by
32

47 30 MSR Segment 2 Released

Approved
28.01.2013

28.01.2013
C603

U039

Drawn 16.11.2012 SCMC

Drilled together with frame and fixed by dowel pin 47 Document No. Version

10'041'249 -
A Drilled together with frame and fixed by dowel pin A
Sheet: 2 of 2
Material No.
SMS group
538742
12 11 10 9 8 7 6 5 4 3 2 1
CZH Old File Name: File Name: 10041249_DRF_000.idw
 12 11 10 9 8 7 6 5 4 3 2 1

H H

A ( 1 : 10 )
3
CASTING 11
DIRECTION
17
10
Disconnection device 3
G see section G
132200-01 4
16
1
15
A
9

F F

12
13
8

E B E

D D

Printed by: C850 on 27. September 2013 - Status: Released RE

Sheet 1 - Part List
Sheet 2 - Dimensions
18 16 Socket Head Cap Screw M16X65 8.8 zinc plated 0.146 KG 317584 ISO4762
17 4 Hex. Cap Screw M24X240 8.8 zinc plated 0.98 KG 307039 ISO4014
16 4 Hex. Cap Screw M24X100 8.8 zinc plated 0.484 KG 306571 ISO4017
15 4 Lifting Eye Bolt M36 1.1141 / C15 2.73 KG 369166 DIN580
14 3 Precision Dowel Pin 20H8X40 Steel 0.094 KG 339159 ISO2338
C 13 4 Shim for Bolt 61x5x26 1.0330 / DC01+LC 0,18 KG 535311 10042457 C
12 4 Bolt 50x75x719 1.7225 / 42CrMo4 + QT 7,42 KG 539000 10040794
11 2 Sleeve 27x20 CC493K / CuSn7Zn4Pb7-C 0,045 KG 539007 10041401
10 2 Sleeve 23x20 CC493K / CuSn7Zn4Pb7-C 0,037 KG 539010 10041403
9 8 Round 69x60 1.7225 / 42CrMo4+QT 1,47 KG 535217 10039140
B ( 1 : 10 ) 8
7
4
2
Wedge
Shim Foot
14.1x58.5x250
68x140x145
1.0503 / C45
1.4301 / X5CrNi18-10
1.37
10.18
KG
KG
320814
535216
10000888
10039477
6 1 Shim Foot 68x140x145 1.4301 / X5CrNi18-10 6.09 KG 318468 10000775
5 1 Shim Foot 68x140x145 1.4301 / X5CrNi18-10 6.65 KG 318467 10000774
4 1 Heat Shield - 12,5 KG 538580 10039907
5 3 1 Idle Roller bottom 671,3 KG 538884 10041306
6 1 1 Fixed Frame - 1,269 TO 541590 10042150
18 Item Qty Description Dimension Basic Material Weight Ut. MM-No. DRW-No. Norm/Remark

Modell: 10000258176_IAM_000.iam Modellversion: -

B
14 B

THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
Section Weight Main Scale Format
Standard Workshop
ISO 128
Instructions 9800.4 130.100 2,053 TO 1 : 10 A1
Replaced by
7 7 Released 23.01.2013 C603
Idle Roller Approved 21.01.2013 V627

Drawn 20.11.2012 SCMC

Document No. Version

10'041'308 -
A A
Sheet: 1 of 2
Material No.

Index Description of Modification Date Name SMS group

538853
12 11 10 9 8 7 6 5 4 3 2 1
EKI Old File Name: File Name: 10041308_DRF_000.idw
 12 11 10 9 8 7 6 5 4 3 2 1

H
385 690 250 C ( 1 : 10 ) H
232

CASTING
DIRECTION

lifting eye

lifting eye M36

20
753 (+200mm Stroke)

NPT 1"

958
G G
for Water

5mm Shim Package

733
C
NPT 1/4"
for Lubrication

NPT 1/4"
for Lubrication
water outlet NPT 1" water inlet

26mm (Shim)
for Water

469
F F
61
D 51

Cylinder 1
900 A,B 50

730 816

1460 1175
E E

MSR-Modul No - ....

1.0 Pressure test hydraulic

D Signature/Date ........................ D

Printed by: C850 on 27. September 2013 - Status: Released RE

Cylinder 1 MPa Time (min) Result
A 25 10
B 25 10

2.0 Pressure test water

Signature/Date ........................
MPa Time (min) Result
0.8 30

C
D ( 1 : 10 ) 3.0 Pressure test lubrication C

1315 Signature/Date ........................

MPa Time (min) Result
20 10

fix (heat expansion)

F F(1:5)
E(1:5) 70 37
E 5

Modell: 10000258176_IAM_000.iam Modellversion: -

B 6 B
70
676

516

14
THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
Section Weight Main Scale Format
Standard Workshop
ISO 128
Instructions 9800.4 130.100 2,053 TO 1 : 10 A1
Replaced by
Drilled together with frame and fixed by dowel pin
Released 23.01.2013 C603
Idle Roller Approved 21.01.2013 V627
Drilled together with frame and fixed by dowel pin Drawn 20.11.2012 SCMC
Document No. Version

10'041'308 -
A A
Sheet: 2 of 2
Material No.
SMS group
538853
12 11 10 9 8 7 6 5 4 3 2 1
EKI Old File Name: File Name: 10041308_DRF_000.idw
 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

L 23 17 L

E 40 A ( 1 : 10 ) B-B ( 1 : 10 ) C-C ( 1 : 10 )
2
47
C B
54
K 67 57 K
15
55
54 16 10 15

28 14
14 52
39
a4 25 42
F 49
53 8
J J
6 43
38 7 13
77
21 18 60
68
32 51
A H 22
48
11
G
66
I
H 63
50
I

50 56
19
4 71
20
11 65
CASTING 5
DIRECTI
ON
Sheet 1 - Part List different from MSR2
76
H Sheet 2 - Dimensions H
73 3
77 6 Socket Head Cap Screw M24X140 8.8 zinc plated 0.65 KG 317653 ISO4762
76 4 Hex. Cap Screw M24x290 8.8 zinc plated 1.02 KG 500592 10030558 ISO4014
74 64 75 4 O-Ring HITEC 34,5X3,55 NBR 70.5 0.009 KG 327251 DIN3771
74 6 Sleeve 27x20 CC493K / CuSn7Zn4Pb7-C 0,045 KG 539007 10041401
72 12 73 6 Sleeve 23x20 CC493K / CuSn7Zn4Pb7-C 0,037 KG 539010 10041403
72 2 Plate 48x110x460 1.0577 / S355J2+N 18.4 KG 538922 10041352
71 1 Holding - 176,5 KG 542402 10041346
70 1 Washer M36_ 37/66X5 8 0.092 KG 368227 ISO7089
69 2 Hex. Nut 0.8d M36 8.0 zinc plated 0.434 KG 306644 ISO4032
75 68
67
12
8
Hex. Nut 0.8d
Hex. Nut 0.8d
M24
M20
8.0 zinc plated
8.0 zinc plated
0.129
0.075
KG
KG
306640
306638
ISO4032
ISO4032
66 4 Hex. Nut 0.8d M12 8.0 zinc plated 0.016 KG 306634 ISO4032
G 65 4 Socket Head Cap Screw M30X80 10.9 0.75 KG 349695 ISO4762
G
44 31 64 4 Hex. Cap Screw M24X240 8.8 zinc plated 0.98 KG 307039 ISO4014
63 6 Socket Head Cap Screw M24X180 8.8 zinc plated 0.79 KG 317656 ISO4762
62 6 Socket Head Cap Screw M24X160 8.8 zinc plated 0.72 KG 317655 ISO4762
61 6 Socket Head Cap Screw M24X90 8.8 zinc plated 0.474 KG 317666 ISO4762
1 60 23 Hex. Cap Screw M16X90 8.8 zinc plated 0.18 KG 306709 ISO4017
59 16 Socket Head Cap Screw M16X65 8.8 zinc plated 0.146 KG 317584 ISO4762
58 16 Socket Head Cap Screw M16X25 8.8 zinc plated 0.083 KG 317577 ISO4762
57 8 Hex. Cap Screw M36X300 10.9 2.85 KG 349050 ISO4014
35 56 8 Hex. Cap Screw M24X130 8.8 zinc plated 0.59 KG 307032 ISO4014

D 55
54
4
8
Hex. Cap Screw
Hex. Cap Screw
M24X60
M20X45
8.8 zinc plated
8.8 zinc plated
0.342
0.186
KG
KG
306566
306739
ISO4017
ISO4017
41 53 4 Hex. Cap Screw M16X30 8.8 zinc plated 0.085 KG 306699 ISO4017
52 4 Hex. Cap Screw M12X40 8.8 zinc plated 0.052 KG 306671 ISO4017
F F
51 2 Hex. Cap Screw M12X30 8.8 zinc plated 0.043 KG 306669 ISO4017

36 50
49
8
4
Hex. Cap Screw
Lifting Eye Bolt
M12X25
M36
8.8 zinc plated
1.1141 / C15
0.038
2.73
KG
KG
306668
369166
ISO4017
DIN580
48 2 Rival Y Ring 20-173 NBR 70 0.02 KG 528836 SN 853
47 1 Clevis Pin with Head 12X100 Steel 0.097 KG 350948 ISO2341
C B 46
45
4
3
Spring Cotter (Double Coil)
Precision Dowel Pin
7x130
20H8X40
Standard 00
Steel
0.014
0.094
KG
KG
476840
339159
DIN 11024
ISO2338
44 3 Pipe Plug 1" Stainless Steel 0.27 KG 545357 SS-16-P
43 2 Sleeve 115x10 1.0577 / S355J2+N 0,162 KG 546862 10044800
42 2 Sleeve 115x10 1.0577 / S355J2+N 0,187 KG 546864 10044801

E ( 1 : 10 ) 41
40
4
1
Shim for Bolt
Spring cotter 3.2 DIN 11 024
61x5x26
8.5x25.9x61
1.0330 / DC01+LC
-
0,18
0.000
KG
KG
535311
539023
10042457

E
46 F(1:5) 7 G ( 1 : 10 )
39
38
2
2
Numbering
Name Plate 1.5x85x170
1.0038 / S235JR+AR
3.3535 / AlMg3 (EN AW-5754)
0.211
0.052
KG
KG
540306
393987
10041741
10007717
E
24 37 1 Shim Foot 68x140x145 1.4301 / X5CrNi18-10 6,59 KG 538996 10041214
34 without Protecting Plate without Roller Support 36
35
4
4
Wedge
Bolt
14.1x58.5x250
50x75x719
1.0503 / C45
1.7225 / 42CrMo4 + QT
1.37
7,42
KG
KG
320814
539000
10000888
10040794
34 4 Bolt 36x120 1.0577 / S355J2+N+Z15 0.92 KG 535218 10039484
62 27 33 1 Bolt 40x80x150 1.7225 / 42CrMo4+QT 1.89 KG 535219 10039139
32 1 Protection Plate 1004.1x250x1.5 1.4841 / X15CrNiSi25-20 2.67 KG 538570 10041168
61 31 8 Round 69x60 1.7225 / 42CrMo4+QT 1,47 KG 535217 10039140
26
D ( 1 : 10 ) 30
29
2
1
Shim Foot
Shim Foot
68x140x145
68x140x145
1.4301 / X5CrNi18-10
1.4301 / X5CrNi18-10
10.18
6.09
KG
KG
535216
318468
10039477
10000775

45 44 58 28
27
1
4
Plate
Plate
30x300x555
41x240x330
1.0577 / S355J2+N
1.0503 / C45
36.7
25.3
KG
KG
535220
539021
10039479
10041420
29 26 4 Plate 28.5x130x220 1.7225 / 42CrMo4+QT 5.88 KG 537408 10040732

Printed by: C850 on 27. September 2013 - Status: Released RE

37 9 25 2 Bolt 102x102x238 1.7225 / 42CrMo4+QT 14.6 KG 535889 10039483
24 1 Cylinder Cooling 2 351,6x560x615,5 - 37,5 KG 545072 10043965
D D
59 23 1 Cylinder Cooling 1 351,6x560x615,5 - 37,5 KG 538877 10040988
22 1 Protection Plate L 2x871.7x864.7 1.4841 / X15CrNiSi25-20 6,35 KG 538574 10041170
21 1 Protecting Plate R 2x871.7x864.7 1.4841 / X15CrNiSi25-20 6,35 KG 538577 10041172
20 1 Protecting Plate 450x184,8x3 1.4841 / X15CrNiSi25-20 1,92 KG 539015 10041411
19 1 Protecting Plate 450x124,8x3 1.4841 / X15CrNiSi25-20 1,29 KG 539014 10041409
18 1 Lubrication Support - - 9.88 KG 539073 10041458
17 1 Cable Support - 10,8 KG 538997 10039942
16 1 Cable Support - 15,2 KG 538998 10039940
15 1 Support - - 20.4 KG 538561 10041160
30 14 2 Support - 17,2 KG 538564 10041162
13 2 Heat Shield - 22,6 KG 535925 10039905
12 2 Heat Shield - 12,5 KG 538580 10039907

30 44 H-H ( 1 : 5 ) 11 1 Holding - 259,8 KG 538583 10039064

C 10 2 Cylinder Assembly 390,4 KG 539040 10041424 C
9 1 Torsion Compensator 166,1 KG 538743 10038617
8 1 Roller Support - 320,3 KG 538582 10038647
7 1 Guide right 87,8 KG 538747 10039487
6 1 Guide left 87,8 KG 538756 10041255
5 1 Drive Roller 655,9 KG 540048 10041557
4 1 Idle Roller upper 616 KG 539249 10041510
3 2 Idle Roller bottom 695,4 KG 538744 10041509
2 1 Gear and Motor unit 906,1 KG 538999 10040043
1 1 Fixed Frame - 4,383 TO 542689 10039615
Item Qty Description Dimension Basic Material Weight Ut. MM-No. DRW-No. Norm/Remark

Modell: 10000275587_IAM_000.iam Modellversion: -

23
DIRECTION

B B
CASTING

69 70 1 33 2
THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
Section Weight Main Scale Format
Standard Workshop
ISO 128
Instructions 9800.4 10,482 TO 1 : 10 A0
Replaced by

MSR Segment 1 Released

Approved
28.01.2013

28.01.2013
C603

U039

Drawn 28.11.2012 SCMC

Document No. Version

10'041'821 -
A Sheet: 1 of 2 A
Material No.

Index Description of Modification Date Name SMS group

542812
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
CZH Old File Name: File Name: 10041821_DRF_000.idw
 12 11 10 9 8 7 6 5 4 3 2 1

H H
I ( 1 : 15 )
MSR-Modul Nummer - ....

1.0 Pressure test hydraulic

Signature/Date ........................
lifting eye M36 Cylinder 1 MPa Time (min) Result
A 25 10
B 25 10

G
lifting eye M36 G
Position for Segment both Sides
Numbering (track welded) 1.1 Pressure test hydraulic
Signature/Date ........................
5.4mm Shim Package

Position for Segment Cylinder 2 MPa Time (min) Result

Numbering (track welded) A 25 10
B 25 10
NPT 1/4" NPT 1"

+170 mm Stroke
for Lubrication for Water

3256
I 2.0 Pressure test water
NPT 1/4" Signature/Date ........................
for Lubrication
MPa Time (min) Result
48.5

F move 0.8 30 F
CASTING
DIRECTION
(145) 3.0 Pressure test lubrication

122.2 calibration
250 Signature/Date ........................
46.8

MPa Time (min) Result

20 10
51.7mm Shim Package
0.25

fix
1004.7

NPT 1/4" NPT 1/4"

for Lubrication for Lubrication
E E
48
26mm (Shim)

water outlet water inlet

469

61
51
L
50

730 816 750 325

900 1175
D D

Printed by: C850 on 27. September 2013 - Status: Released RE

1460 1320

L ( 1 : 15 )
657.5 70
C 207.5 37 C
NPT 1"
for Water
NPT 1"
for Water fix (heat expansion)

K
J
676
516

Modell: 10000275587_IAM_000.iam Modellversion: -

B B
309.5

K(1:5)
J(1:5) THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
NPT 1" 52.5 1315 70 37 Standard Workshop Section Weight Main Scale Format
for Water ISO 128
10,482 TO 1 : 10 A1
37 Instructions 9800.4
Replaced by
32

45 29 MSR Segment 1 Released

Approved
28.01.2013

28.01.2013
C603

U039

Drawn 28.11.2012 SCMC

Drilled together with frame and fixed by dowel pin 45 Document No. Version

10'041'821 -
A A
Drilled together with frame and fixed by dowel pin Sheet: 2 of 2
Material No.
SMS group
542812
12 11 10 9 8 7 6 5 4 3 2 1
CZH Old File Name: File Name: 10041821_DRF_000.idw
 CHAPTER 2

CASTING OPERATIONS

C.4619/401 Chapter 2 Rev0

IVACO Page 1 of 25 February 2014
CASTING OPERATIONS

TABLE OF CONTENTS

1. TUNDISH NOZZLE PREHEATING 4

1.1. PERMANENT LINING 4
1.2. WORKING LINING 5
2. DUMMY BAR INSERTION AND PACKING 6
3. DUMMY BAR INSERTION 10
4. READY TO CAST 13
5. HANDLING OF LADLE AND TUNDISH ON CASTING FLOOR 14
5.1. INTRODUCTION 14
5.2. OPERATIONAL STEPS 14
5.2.1. GENERAL DESCRIPTION OF LADLE AND TUNDISH OPERATIONS 14
5.2.2. LADLE OPENING 14
5.2.3. LADLE / TUNDISH AREA OPERATIONS 15
5.2.4. LADLE SLIDE GATE OPERATION 15
5.2.5. LADLE STREAM 16
5.2.5.1. LADLE STREAM SHROUDING (OPTIONAL) 16
5.2.5.2. OXYGEN LANCING 17
5.3. SEQUENCE CASTING 17
5.4. LADLE NOZZLE BUILD-UP 17
6 OPEN CASTING 18
A. CHEMICAL PRECONDITIONS 18
B. OPERATIONAL CONCEPT 18
C. TUNDISH PRECAST PREPARATION 18
D. STARTING METHOD 19
I. DISC SEALING METHOD 19
II. CHROMITE SAND SEALING 19
7 READY TO CAST 20
8 START OF CASTING 21
9 DURING CASTING 22
10 END OF CASTING 22

C.4619/401 Chapter 2 Rev0

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11 CASTING IRREGULARITIES 23
12 METERING NOZZLES 24
A. METERING NOZZLE MATERIAL 24
B. METERING NOZZLE SIZES 24

C.4619/401 Chapter 2 Rev0

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1. TUNDISH NOZZLE PREHEATING

1.1. PERMANENT LINING

Normally monolithic permanent linings are used because of the absence of

joints between bricks and the higher duration in service.
Monolithic linings can be applied as either thixotropic mixes, thickened by
vibration, or free-flowing castables. It requires anchors welded to the tundish
to keep it in place.
A newly made permanent lining has to be carefully dried.
Before placing it into the dryer, the new permanent lining must be allowed to
dry in air for 24 hours.
A reference drying cycle is shown in the following diagram. Always apply to
the refractory supplier for the correct curve to use for the specific material!
Mainly two holding times (12-18 hours each, approx. 1 hours each 10 mm of
refractory thickness) are shown in the diagram at 175°C and 450°C. They are
needed to evaporate the moisture. Failure to do this would crack the
permanent lining. Finally the temperature can be raised to 700°C.

A tundish is completely dry if no more steam comes out of the evaporation

holes in the tundish shell.
Refractory supplier’s preparation specifications must be strictly adhered to, to
ensure safe operation and optimum performance.

C.4619/401 Chapter 2 Rev0

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 1.2. WORKING LINING

In most cases a basic gunning mix is used for the working lining, with a
composition that is chemically inert towards liquid steel. (normally, MgO,
which ensures longer casting time).
It is also possible to use dry settling mixes, which are poured in place around
a template. Heating the template makes the mix sinter and form a monolithic
layer.
The working lining facilitates cleaning after use and is to be newly applied
after every cast.
The thickness of the spray-gunned layer is about 30 mm and about 50 mm on
the slag-line.
After spraying the tundish should be dried in the drying station according to
the curve given by the refractory supplier. After drying the tundish can be let
cool down to room temperature without prejudice for the refractory lining.
The typical drying sequence is:
Raise the temperature to 600°C in 1 hour
Hold tundish at 600°C for 2.5-3 hours

600

500

400
Tem perature (°C)

300

200

100

0
0 30 60 90 120 150 180
Time (minutes)

C.4619/401 Chapter 2 Rev0

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2. DUMMY BAR INSERTION AND PACKING

2.1. INTRODUCTION
The Dummy Bar (D/B) is a rigid bar which has the same radius of crvature as
the casting machine. The purpose of the Dummy bar is to seal the mould at
the start of a cast, and after the first liquid steel is poured into the mould, to
withdrawn the solidifying shell.
When the connection between the Dummy Bar and strand reaches the raised
straightener roll, the roll is lowered and the disconnection is made. The
Dummy Bar plays no further part in the casting process, and is raised into its
storage device and parked, ready for the start of the next cast.
The front end of the Dummy Bar has a transition piece, which is changed for
different section sizes.

2.2. DESCRIPTION
The Dummy Bar system consists of a solid bar made up of several sections
and a section dependent transition piece with a permanent Dummy Bar head.
Located behind the Withdrawal / Straightening unit is the storage device
consisting of a cassette with a built in Dummy Bar pinch roll. The cassette can
be lowered and raised by a hydraulic cylinder.

2.3. DUMMY BAR HEAD - CONSEAL IV

The CONSEAL IV is formed by a set of mechanical pieces, which joint
together forming a pyramid, which slots securely onto the D/B head and self-
seals on entering the mould.

The steel plates protect the D/B head from the first steel, which enters the mould during
mould filling. The initial steel poured into the mould melts immediately the plastic material

C.4619/401 Chapter 2 Rev0

IVACO Page 6 of 25 February 2014
that runs down the gap and is quickly cooled by the water-cooled copper walls, to solidify
again at some lower point providing a perfect seal.
With proper application of this system no steel will leak, i.e. no additional sealing or cooling
scrap is required.

In more detail the CONSEAL IV is composed of the following elements:

1 Main cooling plate: in the centre a rectangular slot is machined, through which the
second cooling plate has to be inserted. On its rear part a hook is present that will serve to
fix the CONSEAL 4 to the dummy bar head.
2 Secondary cooling plate: which is inserted in the main plate through the slot. On the
rear side part of both pieces, there are two slots, which besides facilitating the fluent flow of
the steel, they serve as wedges that hold perfectly to the billet and prevent the premature
releasing of the dummy bar from the billet.
3 Sealing and impact plate: manufactured in accordance with the section of each mould
tube (exit side) and with the radius of its corners.
4 Plastic inserts: injection manufactured, which once assembled and thanks to their
accurate machining, fit perfectly to the impact plate guaranteeing a perfect and homogenous
union, a perfect sealing avoiding any filtration. Moreover, they protect the side walls as well
as the copper tube corners during the insertion of the dummy bar.

1
3

After a cast the mould has to be well cleaned and inspected for possible
damage. Before commencing the mould walls must be dry, i.e. free of

C.4619/401 Chapter 2 Rev0

IVACO Page 7 of 25 February 2014
 moisture. However, the walls of a new mould tube should be pre-lubricated
with a suitable oil (vegetable or synthetic oil with a flash point > 250oC) to
prevent sticking of steel during mould filling at the start of the next cast.

2.4. PREPARATION PRIOR TO DUMMY BAR INSERTION

Once the Dummy Bar is introduced up to the middle of the chamber (zone 1), the following
operations have to be carried out:
Hook the CONSEAL in the D/B head;
Place a fixation pin between the CONSEAL and the D/B head;
This pin has two main functions:
Guarantee the perfect fixation of the CONSEAL to the D/B head until the disconnection,
The special machining of the two slots, facilitates the disconnection between the billet and
the D/B head (break of the pin during the disconnection);
Place two small pieces of wire in the holes at the end of the pin.
This operation is VERY important since it prevents the pin from moving (centred slots), which
would cause the non disconnection.

(Conseal IV assembled on D/B head)

Scheme of the Conseal IV Assembled and scheme of the assembled Pin (at
the bottom of the picture)

C.4619/401 Chapter 2 Rev0

IVACO Page 8 of 25 February 2014
 SAFETY PIN

Holes for the insertion of the wire

IMPORTANT: the safety pin should be in Aluminium

C.4619/401 Chapter 2 Rev0

IVACO Page 9 of 25 February 2014
3. DUMMY BAR INSERTION
3.1. Dummy Bar Head is in Park Position.

3.2. The D/B can be driven either in automatic or

manual mode. Automatic insertion cannot be
made if all the necessary conditions are not
present.

3.3. From the parking position the D/B is drawn

back by the Dummy Bar Pinch Roll (D/BPR).

3.4. The Dummy Bar Receiver tilts down.

3.5. The D/BPR drives the D/B into the

Withdrawal unit. From this position the drive
of the Withdrawal unit takes over the task of
D/B insertion.

3.6. The D/B stops automatically in Zone 2 of the

spray chamber where access is possible. The
D/B head should be dried with a hand torch.
Insert the wooden dowel or steel pin to
prevent rotation of the transition piece. Put
Conseal tight over dry head.

3.7. Drive D/B with the local control pendent into

the mould.

C.4619/401 Chapter 2 Rev0

IVACO Page 10 of 25 February 2014
 NOTES ON DUMMY BAR INSERTION
The CONSEAL should be placed firmly over the dummy bar head. It is very
dangerous to put the CONSEAL on top of a wet D/B head, as this could cause
an explosion during mould filling. If the head is still hot from previous usage it
may be cooled with compressed air, otherwise it should be dried using a gas
torch.
The CONSEAL condition should always be checked inside the mould with
flashlight. If it is torn or in any way distorted it should be replaced.

(Insertion into mould)

Some extra chill material is necessary to seal the mould. Scrap may prevent
to form a proper claw and with this cause a premature disconnection of the
D/B and strand of the D/B and strand.

C.4619/401 Chapter 2 Rev0

IVACO Page 11 of 25 February 2014
 (Disconnection)

I
f

t
h
e

D
/
B is inserted too far
inside the mould it must
be removed completely
and another CONSEAL head installed before re-insertion.
The CONSEAL condition should always be checked inside the mould with
flashlight. If it is torn or in any way distorted it should be replaced.

C.4619/401 Chapter 2 Rev0

IVACO Page 12 of 25 February 2014
4. READY TO CAST

Before accepting a first ladle of a sequence onto the Ladle Turret the Casting
Supervisor should check that all the necessary conditions are present to allow
permission to cast.
The correct Section Size and Casting Mode should be selected on the HMI in
the Main Control Room and if Level 1 Recipe control is being used then the
correct Recipe for the Steel Grade should be selected.
A Ready To Cast condition will be given when all the Necessary to Cast
permissives are shown as Green on the Ready to Cast screen shown below.
Should any of the necessary conditions that are mandatory to cast not be met
then the operator can interrogate the fault by using the relevant drop down
dialogues, to rectify it. Obviously the ladle should not be opened without a
Ready to Cast condition.
It is advisable also that all Suggest to Cast conditions are fulfilled also,
however if one of these permissives is not met a Ready to Cast condition is
still fulfilled.

C.4619/401 Chapter 2 Rev0

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5. HANDLING OF LADLE AND TUNDISH ON CASTING FLOOR

5.1. INTRODUCTION

When the liquid steel has been prepared and the casting machine is ready to
cast, the ladle is transferred from ladle treatment to the ladle turret.
This module gives information on the operations concerning the ladle and
tundish. Specific information on the casting technique is given in a separate
module

5.2. OPERATIONAL STEPS

5.2.1. GENERAL DESCRIPTION OF LADLE AND TUNDISH

OPERATIONS

With a preheated tundish practice the most important aim is to retain as much
heat as possible in the tundish refractory from the time the preheat ends to the
time the ladle is opened.
This manual describes the automatic methods available on the casting floor.
Full details of the manual options should be obtained from the functional
descriptions.
Time-consuming operations like tundish transport and preparation at the
casting position (alignment, centring of casting tubes, etc.) must take as short
a time as possible. Automatic cycles are provided to reduce these times to a
minimum, and to reduce the possibility of errors.

5.2.2. LADLE OPENING

After the casting leader has checked that all necessary preparation work has
been done ("ready to cast" status available in the VDU and on the MOP (
Mould operators Panel), protection devices and ladle shrouds in position etc.),
the command is given to open the ladle slide gate. In principle the tundish
should be filled as fast as possible, although in the case of a machine with
many strands it may be necessary (depending on the casting system) to
throttle back the ladle slide-gate such that the tundish does not become
completely full before all the strands have been opened.

C.4619/401 Chapter 2 Rev0

IVACO Page 14 of 25 February 2014
 The tundish insulation powder should be added to the tundish as soon the
ladle shroud is submerged from the rising steel melt, although this may be
adjusted to suit a particular plant depending on the local conditions, such as
tundish design, access to the tundish etc.
Slide gate technology and operating techniques have been well refined over
the past years to ensure regular full bore openings. But occasionally steel
does not follow the initial run-out of sand and oxygen lancing must be used.
For a successful operation it may be necessary to first ignite the steel tube
with a hand torch.

5.2.3. LADLE / TUNDISH AREA OPERATIONS

The following duties are usually the responsibility of the ladle operator.
 Connection and disconnection of hydraulic and pneumatic
couplings for the slide gate, and mounting and removing of
the slide gate hydraulic cylinder
 Ladle car operation
 Tundish filling by manual or automatic slide gate control
 If the slide gate is manually controlled, maintaining the
tundish steel working level to +/- 1.0 t steel weight
 Executing tundish temperature measurements and taking
steel samples
 Liaison with the casting foreman and the mould operators
 Checking that steel bath insulation is maintained
 Maintaining a safety watch for slide gate oil leakage’s and for
hot spots on the ladle shell

5.2.4. LADLE SLIDE GATE OPERATION

Using a slide gate, the opening position can be chosen so that an equilibrium
between steel quantity flowing out of the ladle and being cast into the moulds
can be achieved, e.g. the slide gate remains at a constant setting and its

C.4619/401 Chapter 2 Rev0

IVACO Page 15 of 25 February 2014
 position is only altered in order to compensate for the decreasing throughput
due to the reduction of the ferrostatic pressure in the ladle.
A problem that can sometimes occur with a slide-gate is that steel does not
follow the initial run-out of sand, and oxygen lancing must be used. For a
successful operation it may be necessary to first ignite the lancing pipe with a
hand torch.

5.2.5. LADLE STREAM

5.2.5.1. LADLE STREAM SHROUDING (OPTIONAL)

For using the ladle shroud the following actions have to be performed.
 Start of cast
 Put Ladle Shroud Tube in the manipulator
 Bring tube with the manipulator into tundish after tundish lowered into
casting position
 Turn ladle into casting position
 Attach ladle shroud
 If ladle opens lower ladle into normal casting height
 If not, put ladle shroud side-ways and lance open
 Cast approx. 2 min with open stream, close slide gate, connect shroud,
open slide gate and lower ladle

End of casting from ladle can be noticed by two means.

1. If ladle weight indication near the closure weight, raise ladle, close
slide gate shortly, remove shroud, open slide gate and observe
stream for slag coming
2. Raise ladle so that shroud exit is just about at meniscus level and
watch steel bath, close slide gate immediately when slag appears

Note1: the tundish weight drops quickly when only slag is teamed
Note2: the value of the closure weight of the liquid steel remaining in ladle at
the empty ladle time is considered as in the customer official procedures
(usually 3-6 tons)

After closing ladle slide gate and swinging ladle away:

 Lift and tilt shroud

C.4619/401 Chapter 2 Rev0

IVACO Page 16 of 25 February 2014
  02-lancing of inlet cone of shroud
 Bring shroud into position for attaching to ladle slide gate of next ladle
 Bring ladle in raised position into casting position and attach the
shroud

5.2.5.2. OXYGEN LANCING

The oxygen lancing of the slide gate nozzle at start or during teeming has to
be performed from the area between ladle car support and tundish just below
the ladle, i.e. at the hot metal side where no protection guard against
splashing steel can be installed.

5.3. SEQUENCE CASTING

Sequence casting is the casting of more than one ladle through the same
tundish increasing the yield and the machine utilisation. Ideally the following
conditions need to be fulfilled:
Only similar steel qualities should be cast in sequence;
The ladle changing time, i.e. the time between emptying one ladle and opening
the slide gates of the next ladle must be such that the tundish weight never
drops below a critical level at which quality problems can occur (A critical
aspect of successful sequence casting is that the ladle opens without the need
for lancing).

5.4. LADLE NOZZLE BUILD-UP

If the ladle nozzle becomes blocked by cold steel or inclusion build up it can
be opened again by oxygen lancing. The level in the tundish should, as in the
case of a sequence casting ladle changeover, not drop below a critical level
for quality reasons.

Any oxygen lancing will have a negative influence on the level of steel
cleanness.
If the ladle requires repeated lancing to maintain the necessary flow, it may be
necessary to decide to stop the cast depending on the quality requirements of
the steel being cast.

C.4619/401 Chapter 2 Rev0

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 6 OPEN CASTING
This module describes the operation of Open casting, that is an open stream
of steel passing through a metering nozzle into the mould.
The Billet Caster is also equipped to cast with the CONCAST NOZZLE
MANIPULATOR (CNM), which is described earlier, however the principles of
Open Casting as described here are the same.

A. CHEMICAL PRECONDITIONS
Open casting is normally used for non-demanding Si-killed commercial steels.
Aluminium total content must be minimised to prevent alumina deposits on the
metering nozzles, which interfere with the open stream and eventually block
the nozzles. Generally, the following limits are applied;

C  0.20 % Altot  0.006 %

C > 0.20 % Altot  0.004 %

The steel must be sufficiently killed with Si to prevent pinholes

B. OPERATIONAL CONCEPT

Flow rate from the tundish is a function of the nozzle diameter and the liquid
steel level in tundish
Automatic mould level control is achieved by control of withdrawal speed.
Mould lubrication is achieved by vegetal oil or suitable mineral oil.

C. TUNDISH PRECAST PREPARATION

The tundish nozzles have to be properly aligned with the moulds. To shorten
the preparation time immediately before casting, it is recommended to pre-
align the tundish before preheating by driving it over the moulds to check the
alignment. Visual nozzle alignment checking can be achieved using the simple
tool shown in the appended drawing 16244.4.
During handling and preheating, the tundish nozzles are susceptible to
becoming blocked with loose refractory material and/or low melting point
materials, which have melted during preheating.
Difficulties, particularly during the start of casting, will thus result, unless some
precautions against blockage are taken.
In addition to this problem, reliable self-opening of the nozzles after steel flow
from the ladle commences is not guaranteed, particularly on the outer nozzles

C.4619/401 Chapter 2 Rev0

IVACO Page 18 of 25 February 2014
 of larger tundishes unless some measures are taken to prevent the initial cold
steel and any associated tundish debris from entering the nozzle bores.

D. STARTING METHOD

The key to successful starting is to have a method, which is secure enough so

that it cannot start without the action of the operator, but can be opened easily
to give a reliable stream
Two methods for sealing the nozzles are given below.

I. DISC SEALING METHOD

This sealing method is generally used in combination with the CNM, because
the design of the fixed nozzle in this case allows reliable positioning of the disc
(see drawings).
A steel disc is placed flat on the nozzle prior to start tundish preheating:
Thickness 2 – 2.5 mm
Diameter Depending on nozzle design (normally 40 mm)
This disc should be fixed by mortar to ensure a good seal. The disc should
not be covered with the mortar, since this will make strand opening much
more difficult. The disc can be positioned before preheating, but care must
be taken to avoid burning it open with the nozzle preheater flames.
Normally, the disc needs a short blow with the oxygen lance to be opened.

II. CHROMITE SAND SEALING

This method is predominantly applied when casting with metering nozzles,

especially when emergency launders are available.
After the preheated tundish is centred above the moulds an asbestos
substitute cord, or steel plug, is forced inside the nozzle and the cavity above
filled with a preheated chromite sand / carbon mixture.
This method has the advantage that the individual nozzles can be opened at
will. The possibility of self-opening is practically non-existent compared to the
disc sealing method.
However, in the absence of the launder, when the rope is pulled the sand
must be collected in a shovel to reduce the breakout risk and avoid making
dirty steel high in sand inclusions.
With a proper technique (correct amount of sand, even nozzle preheating) the
steel will flow by itself. As soon as a compact stream is observed the launder
can be swung out.

C.4619/401 Chapter 2 Rev0

IVACO Page 19 of 25 February 2014
 7 READY TO CAST
The tundish and nozzle preheating should be stopped only when the other
casting machine elements are “Ready To Cast”. A specific page on the
Control Room VDU displays all the necessary conditions and gives details of
any conditions, which are not ready.

25
READY TO CAST A RUN OUT BILLET LENGTH
OPTIMIZATION
MODE SELECTOR

CASTING
PREPARE
RUN-OUT
DUMMY
BAR
POURING TUBE MOULD SLAG NOT SPECIFIED OFF
FAULT FAULT FAULT
BILLET ACTUAL LENGTH

STOPPER MOULD LEVEL CASTING SPEED

ROD POSITION (mm) ACTUAL % SET-POINT % ACTUAL m/min

MAX. LEVEL
FULL CALIBR.

1 6 14
SET-POINT m/min
SOURCE
OPEN

7 12 13 15
ALARM READY MIN. LEVEL DECREASE INCREASE
CALIBRATION SET-POINT SET-POINT

2 3 8 16 17
CLEANING LOCAL REMOTE
CLOSE MANUAL AUTOMATIC MOULD FILL
CYCLE CONTROL CONTROL

4 5 9 10 11 18 19
STOP START
WITHDRAWAL WITHDRAWAL

MOULD LUBRICATION EMERGENCY SLIDE GATE

POWDER
OFF
POWDER
ON
CONTROL
ON/OFF 20 21

MOULD OSCILLATION
22
STOP START

SLIDE GATE CLOSE

AMOUNT

23 LAMP TEST

24

Hand box
connector

From To MOP
CC = 0÷30mm

C.4619/401 Chapter 2 Rev0

IVACO Page 20 of 25 February 2014
 8 START OF CASTING
Ladle and Tundish operations are described earlier.
On arrival of the Ladle on the turret, connection of services, and rotation of the
ladle to the casting position, the end of preheating and tundish movements
can proceed according to the automatic sequence as described in Module 3A.
The main aim of the initial opening is to achieve a compact stream from the
tundish to the mould, and to avoid the entry of excessive foreign material into
the mould. All strands should be opened within 5 minutes of opening the ladle
to avoid freezing.
The mould filling times are determined by the nozzle throughput, and as the
nozzles are non-throttled, the time will be a function of the nozzle diameter
and the head of steel in the tundish.

Before opening the strands:

After arrival of the tundish to the mould ensure, the alignment is correct.
Switch the selector on the MOP to “Casting”.
Select "Automatic" on the MOP. (Auto button flashing on MOP). No operator
input will then be required to start the withdrawal drive.
Check if "Ready" lamps are on and "Alarm" lamps are off. If these conditions
are not available it is necessary to check on the VDU screen in the control
room.
Open the Ladle.
When the correct tundish level has been reached, open the strands.
If the stream is not compact, the flow is too slow, or in the worst case, it freezes
completely, the emergency launder must be swung in position.
With the Oxygen lance the nozzle shall be burned free and, after a good steel
stream is steady, the emergency launder can be swung out so that casting can
actually start in Automatic mode.

As soon as a steel level of approx. 20 % has been detected, the control

system will start the withdrawal drive and set the mould level controller into
automatic mode.

C.4619/401 Chapter 2 Rev0

IVACO Page 21 of 25 February 2014
 9 DURING CASTING
The casting process is essentially automatic, however the operating personnel
must pay attention to various items.
Splashes from the mould can collect around the oiler plate and restrict the flow
of oil to the mould. These should be removed by knocking off with a bar before
they build up into large pieces, as the pieces would end up in the mould and
result in a mould hanger (the thin solid steel shell is held back and cracks)
which leads finally to a breakout.
If splashing is for some reason excessive, the mould level setpoint can be
reduced during casting in the Control Room VDU. Care must be taken to
ensure that the level is not lowered too much, as the effective mould length for
steel solidification is also reduced.
Occasional checks on the flow of oil to the mould should be made visually. A
simple oil can should be available in case of, for example, a blocked oil
passage or a pump failure.
Build up around the nozzle can occur and must be removed either by
knocking off with a bar or GENTLY melting with an oxygen lance.

10 END OF CASTING
After the ladle has been emptied, the casting speed steadily decreases due to
the dropping metal level in the tundish.
When casting with metering nozzles, the pouring must be stopped at the latest
when the steel stream becomes unstable.
This is achieved by inserting a copper plug into the nozzle bore. (see
appended drawing 15156.4). If available, the emergency launder must be
swung in position just before plugging the strand.
This operation must be performed before the steel stream becomes too
unstable, as this signifies that slag could enter the mould very soon.

Note: when casting with CNM the strand is stopped by firing in a blind block. If
this is not available for some reason, the strand should be stopped
manually as described above.

For multi-strand machines producing long billets, length optimisation is very

important to avoid unnecessary production of scrap at the end of a cast. One
strand after the other should be closed at the moment the length of the billet in
the machine is a multiple of the specified cutting length plus approx. 1 m for
crop end and safety allowance. This length optimisation is indicated on the
MOP. Ideally, the last steel from the tundish is cast with only one of the centre
strands.

C.4619/401 Chapter 2 Rev0

IVACO Page 22 of 25 February 2014
 When the stream has been stopped, the strand will continue casting at slow
speed to a point where the strand is outside the mould level measuring range.
When the strand stops, the machine can be put in Run-Out mode on the MOP
and the run out started by pushing the Run Out push button on the MOP.

11 CASTING IRREGULARITIES

A. OPEN-NOZZLE LANCING

Oxygen is a valuable tool for the mould operator if used carefully. Only skilled
operators should perform this operation. Lances must be free of oil or grease.
Oxygen lancing should be applied only as a "last measure" due to the adverse
effect on steel internal cleanness and the erosion of the refractory metering
nozzle.

B. MOULD OVERFLOW

If the strand becomes stationary for any reason, an overflow can result. The
mould level control system detects this event and fires in the blind block. If this
is not available for some reason, the action to be taken is the same described
above (with open casting without CNM).
If the steel has overflowed over the top of the mould, no attempt should be
made to withdraw the strand, as the shell could be torn resulting in metal
spillage beneath the mould area.
If there is no way to remove the strand quickly, it must be cut beneath the
mould, so that the rest of the strand can be withdrawn from the machine. The
mould can be changed later and the shell removed in the mould shop.
If the strand solidifies fully in the mould, the machine (oscillation) geometry
can be distorted.

C. BREAKOUTS

A strand breakout is a spillage of liquid steel from the cast strand anywhere
beneath the mould area, mostly just beneath the mould in the top zones.
Its severity depends on the point of rupture, and usually those occurring far
down the metallurgical length are the most damaging due to the amount and
pressure of liquid steel above.

C.4619/401 Chapter 2 Rev0

IVACO Page 23 of 25 February 2014
 An abrupt mould level drop indicates a breakout. This is detected by the CNM

system and the blind block will be fired in. If there is no blind block, or the

CNM is not in use, the first action must be to swing the emergency launder in

position and to plug the strand with a copper plug.

D. MOULD HANGER

If the steel stream is not compact, it is possible that sparks or small splashes
can build up on the mould walls, mould top plates or cover-plates. This can
slowly increase in severity and grow downwards toward the liquid level in the
mould. This build up must be removed with a steel bar or in the worst case
oxygen lance before it becomes a critical size.
If the hanger is allowed to progress down to the meniscus level it will become
connected to the steel shell and a tear will occur possibly resulting in a
breakout.

12 METERING NOZZLES

A. METERING NOZZLE MATERIAL

Zirconia is now widely used for metering tundish nozzles and gives long and
reliable service without significant erosion.
Where increased erosion and chemical attack resistance is required, i.e. long
term casting, low-carbon steels with high oxygen content, free cutting Si-Mn
steels etc., zirconia provides the necessary properties.

B. METERING NOZZLE SIZES

The formula for calculating the flow through a nozzle is as follows:

h 6
G   2 g   F  
1000 100

C.4619/401 Chapter 2 Rev0

IVACO Page 24 of 25 February 2014
 where:
G nozzle throughput in kg/min
 factor
F area of the nozzle bore in mm2
h total ferrostatic height mm ( meniscus to nozzle exit )
 density of liquid steel at 1550 °C
60 conversion factor sec ↔ min
g earth acceleration factor

Values:
= 0.90 ÷ 1.0
g = 9.81 m/sec2
 = 7.2 kg/cm3

The factor  is dependent on the fluidity of the steel. A commonly used value
for  is 0.92, however it may be found that after some experience the value
can be optimised due to local conditions.
When open casting, the casting speed can be changed to a certain degree by
increasing or decreasing the bath level in the tundish. This is not
recommended as a regular practice due to the adverse effect on the product
quality caused by the unstable conditions in the tundish.

C.4619/401 Chapter 2 Rev0

IVACO Page 25 of 25 February 2014
 CHAPTER 3

OPERATION IN CASTER AUXILIARY AREAS

C.4619/401 Chapter 3 Rev0

IVACO Page 1 of 13 February 2014
 TABLE OF CONTENTS

1. TUNDISH PREPARATION (STOPPER CASTING) 3

2. MOULD TUBE CHECK 10
3. MOULD ATTACHED FOOTROLLS 11
4. DRAWINGS 13

C.4619/401 Chapter 3 Rev0

IVACO Page 2 of 13 February 2014
1. TUNDISH PREPARATION (STOPPER CASTING)

After De-sculling the Tundish should be cleaned of any remaining steel, slag or
adhered refractory material. The permanent lining should then be visually
inspected and repairs effected if necessary.
The Tundish furniture can then be installed e.g. Turbostoppers, Dams and Weirs
etc.
If required new well blocks can also be installed at this stage.
Once the Tundish has cooled down to approximately 90°C, the sprayed working
lining can be applied, ensure that a sealing cone is inserted into the well block to
prevent spray mass sticking to its internal surfaces.
Generally a coating thickness of 30mm over the whole surface is sufficient with
the area of the slag line increased to approx. 50mm depending on the intended
sequence length.

When spraying is complete ,the cones should be removed and the tundish
transferred to the drying station, and dried in accordance with the refractory
supplies drying curves.
Once dried the SEN or Tundish Nozzle can be installed and fixed with refractory
mortar.

1.1 Stoppers installation

The stopper installation takes place with the covers and tundish nozzles / SEN’s
in place and with the stopper already fitted with its threaded rod.
The threaded rod with all its bolts and washers must be secured to the stopper
rod before mounting the latter into the cross arm. The following drawing displays
the correct position of all the needed parts.

C.4619/401 Chapter 3 Rev0

IVACO Page 3 of 13 February 2014
1.2 Installation Sequence:

IMPORTANT: Before installing the stopper rod, bring the cross arm in the
intermediate position by turning the hand wheel. The position of the cross arm is
indicated by the arrow in the viewing window of the stopper box. The
intermediate position is necessary for the correct installation.

C.4619/401 Chapter 3 Rev0

IVACO Page 4 of 13 February 2014
 Before installing the stopper rod, bring the cross arm in the
intermediate position by turning the hand wheel. The position of
the cross arm is indicated by the arrow in the viewing window
of the stopper box. The intermediate position is necessary for
the correct installation.

 Unfix the cross arm bolt: this bolt blocks the cross arm horizontal movement
around the stopper arm (vertical).
 Move the cross arm sufficiently to insert the stopper rod.
 Insert the stopper rod through the cover hole taking care that the rod tip does
not enter the SES/SEN bore.
 Using the hand wheel on the stopper control box, move the cross-arm up or
down until it is approximately in the middle of the stroke. This is indicated in the
window of the stopper box.
 Put the stopper tip in the SEN top and the Rod End in the fork of the cross-
arm, hand tighten the cross-arm nut.
 Align the cross-arm such that it is aligned vertically over the SEN bore.

 Raise the stopper with the hand wheel and tighten the cross-arm nut with a
spanner.
 Hand tighten the stopper rod top and bottom nut and the align stopper such
that it is vertical over SEN. Check by opening and closing.
 Close stopper and hold closed, tighten top nut with spanner.
 With the hand-wheel, open and close for final check stopper to verify that:
 the stopper can move vertically
 the Stopper tip can enter and block the opening of the SES / SEN without any
lateral movement of the stopper when entering or leaving the closed position. No

C.4619/401 Chapter 3 Rev0

IVACO Page 5 of 13 February 2014
 obstacles or debris should interfere with the stopper movement This is a key-
factor for the correct starting procedure of casting strands
 For manual stopper movement the latch bolt must be turned clockwise. For
locking the stopper arm the latch bolt must be turned counter-clockwise.
 The stoppers must always be locked in the closed position during tundish
transportation by crane or car to avoid damage.

C.4619/401 Chapter 3 Rev0

IVACO Page 6 of 13 February 2014
 5
STOPPER SETTING 1
1 Move the cross arm to the middle position 4 3
with the handwheel
2
2 Put stopper in nozzle and crossarm

3 Hand tighten top nut

4 Align stopper vertically over nozzle

5 Raise stopper with handwheel

and tighten top nut with spanner 1
5

STOPPER SETTING 2
8

6 Hand tighten bottom nut

and check alignment

7 Check opening and closing

8 Close stopper, tighten top nut

C.4619/401 Chapter 3 Rev0

IVACO Page 7 of 13 February 2014
1.3 Preparation of Tundish before casting

 Drive tundish car over moulds and align the tundish “front to back” and check
the alignment of the SEN “side to side” with the moulds.
 Return to preheating position.
 Final check of stopper alignment by opening and closing the stopper with the
hand wheel.
 Raise to fully open position and lock the hand wheel.
 Connect cooling air and nitrogen pipes to stopper box.
 Plug power and signal cables for stopper control to sockets in stopper box.

 Check the guides of emergency slide gates

 Attach hydraulic cylinders for emergency S/G
 Bring tundish pre-heater into position.
 Start preheating tundish according to the refractory supplier specification
 Start preheating SEN according to the refractory supplier specification

C.4619/401 Chapter 3 Rev0

IVACO Page 8 of 13 February 2014
 1.4 Handling after End of Cast

On Casting Floor:

 After casting move tundish in transfer car over emergency box

 Disconnect power and signal cables for stopper control and cooling gas
supply hoses. NOTE: if stopper mechanics are exposed to heat for a long time
without being connected to the cooling gas supply they can be damaged.
 Take off hydraulic cylinders of emergency slide gate
 Open stoppers and lock in position
 Remove SEN/SES, (can also be removed later at tundish preparation area)
 Crane transport of tundish from tundish car to the tundish preparation area
(insert in tilting station if not occupied)

On Tundish preparation area

 Removing of stopper box and fork arm from the tundish (and SEN/SES and
slide gates if not already removed)
 Remove tundish lids.
 Bring tundish to tundish tilting station and tilt for dismounting emergency slide
gates and removal of slag, skull, working lining and rest of nozzles. This work is
usually done within 1 hour after end of casting
 Transport tundish to parking or lining stands
 Cool down with ventilator unit to a temperature that allows stepping into
tundish
 Check impact area (change impact bricks if damaged)
 Mount the intermediate walls
 Set new SEN’s/SES’s, ensuring proper alignment
 Cover the SEN tops
 Apply the working lining
 Drying according to the refractory supplier specification
 Position tundish lids

C.4619/401 Chapter 3 Rev0

IVACO Page 9 of 13 February 2014
2. MOULD TUBE CHECK

2.1. MAINTENANCE

New moulds rarely give problems initially, although it is always a good practice to
record the mould cavity dimensions when new as a basis for subsequent
evaluation of the mould's condition.
The mould geometry is of greatest importance to the achievement of a perfect
cast product. The steel plant needs to keep a check on the actual dimensions of
the mould tube and of the taper throughout its service life. This should be
measured in the new condition and during the life of the tube at periodic intervals,
such checking enables the engineer to establish criteria for replacement by
setting up lifetime records.
Inspection record sheets should be used for keeping track of the mould history by
entering number of strand, date and cast numbers the mould has been used for
and to note incidents like breakouts and possible strand defects.
Cavity checks approximately every 100 casts when casting open and every 50
heats when casting submerged will provide a picture of mould performance and
be the basis for re-ordering and re-conditioning.
Mould life depends upon many factors:
• Cooling water quality
• Handling care (physical damage)
• Lubrication medium
• Breakout and overflow rate (physical damage)
Correct assembly of the moulds is very important. Particular care must be taken
when installing a new tube in a water jacket to ensure that the lower seal permits
the mould to expand during casting.

2.2. CRITERIA FOR MOULD TUBE EVALUATION

Besides routine inspections, a tube must be carefully checked after casting

incidents, especially for scratches, which are more harmful in the upper half of
the tube and cannot be tolerated in meniscus area.
Max. Admitted scratch depth 1 – 2 mm
Protruding scratch edges must be ground off and the scratch blended into the
surface.

Decisive for scrapping a mould tube are:

C.4619/401 Chapter 3 Rev0

IVACO Page 10 of 13 February 2014
 • Bloom surface quality (especially longitudinal corner cracks)
• Bloom section dimensions (especially rhomboidity)
• Breakouts that cannot be related to casting parameters or steel analysis

The limit for the mould wear in the bottom part is approximately 1 mm (compared
with the new tube), measured 25 mm above the tube exit (measure between
curved faces must be taken in the radial direction).

3. MOULD ATTACHED FOOTROLLS

3.1. DESCRIPTION

The foot rolls are attached to the mould bottom flange. Their purpose is to
support the solidifying shell of the bloom as it leaves the mould, so that the risk of
breakouts is minimised.
In addition, the foot rolls keep the bloom in the centre of the mould.
These two actions contribute to reduce the wear of the mould plates in the lower
part of the mould.

3.2. SETTING

The foot rolls must be accurately aligned with reference to the actual dimensions
of the mould (at its bottom end).
An alignment template is provided for this purpose. It gives the possibility to
align the rolls with the mould pass-line.
Foot rolls alignment is performed with the mould and the template placed on the
mould alignment stand.
The position of the foot rolls compared to the strand can be changed by acting on
two alignment bolts for each roll.
Generally the foot rolls are aligned flushed with the mould exit, i.e. they are
placed on the theoretical prolongation of the mould faces. Alignment starts from
the outer radius, where the foot rolls are aligned on the machine radius (16500
mm.)
The reference surface of the template in the foot rolls area is 0.5 mm inside the
pass-line. Intermediate settings from 0 to -0.5 mm (for each side) can be
obtained by inserting a feeler gauge between the template and the roll.
The following instructions must be followed for foot rolls alignment:

C.4619/401 Chapter 3 Rev0

IVACO Page 11 of 13 February 2014
 - The rolls must turn freely. Blocked rolls must be dismantled and repaired.
- Take care that the alignment template is in close contact with the copper wall
of the mould. If necessary, block the template against the mould with a wooden
wedge.
- Act on the alignment bolts until the roll is in good contact with the template
(plus feeler gauge) on both sides. The roll does not need to be blocked against
the template and should still be possible to turn it by hand easily.
- Take care that the foot rolls do not change position when locking the
alignment screws.
After alignment, the gap between rolls must be measured accurately (in both
directions) and compared with the measured gap between mould walls at mould
exit (excluding worn areas). Both measures, at mould exits and between rolls,
must be written down in a protocol. Such a protocol is very important to track
operation or quality problems.
The foot rolls must be checked at regular intervals to ensure correct positioning,
and always after an incident, such as when a bloom stopped inside the mould, as
the removal of the bloom may alter the roll position.
Properly trained and qualified operators must do the alignment of the foot rolls. A
maintenance report should be issued after each alignment operation.

C.4619/401 Chapter 3 Rev0

IVACO Page 12 of 13 February 2014
 Template

Feeler Gauge

Foot Roll

4. DRAWINGS

MOULD TEMPLATE ASSEMBLY 10043539

TEMPLATE PARALLEL SIDE 10043543
TEMPLATE FIXED & LOOSE SIDE 10043540

C.4619/401 Chapter 3 Rev0

IVACO Page 13 of 13 February 2014
 12 11 10 9 8 7 6 5 4 3 2 1

H H
CASTING
DIRECTION

C/L RADIUS

G G

F F
600

600
E E

D D

Printed by: C850 on 26. September 2013 - Status: Released RE

2
1
361.36

360

R9834.8
C C
R10000
0.5 0.5 0.5
R9999.5
0.5 R9835.3

2 1 Template Assembly 3,48 KG 544683 10043543

1 1 Template Assembly 3,6 KG 544678 10043540
Item Qty Description Dimension Basic Material Weight Ut. MM-No. DRW-No. Norm/Remark

Modell: 10000284909_IAM_000.iam Modellversion: -

B B

(164.2)
THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
(165.2) UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
Weight
0.5 162.2 0.5 Standard Workshop
ISO 128
Section Main Scale Format
Instructions 9800.4 115.912 7,08 KG 1 : 2,5 A1
Replaced by
163.2

243.2 Foot Roll Template SQ.160-TA Released

Approved
18.04.2013

18.04.2013
C603

C603

Drawn 27.12.2012 V628

Document No. Version

10'043'539 -
A A
Sheet: 1 of 1
Material No.

Index Description of Modification Date Name SMS group

544694
12 11 10 9 8 7 6 5 4 3 2 1
EKI Old File Name: File Name: 10043539_DRF_000.idw
 8 7 6 5 4 3 2 1

2 1
12 2
F 5 F
A-A ( 1 :2 )
9
15 7
6 4

1
12

30
1
2 3
55

E E

B
D-D ( 1 : 2 )
B-B ( 1 : 2 ) 30.9

1
18
B 30

47
9

30
227.4

43 43
15
3

1
4

Printed by: C850 on 26. September 2013 - Status: Released RE

15.5
15
D D

7 8
775

8
798.5

2
6 8 4 5

11

12 1 Spring Pin 3X18 Spring Steel 0.001 KG 328356 ISO8752

11 1 Clampling Knob GG-50-M10-E EN-JL1040 / EN-GJL-250 0.108 KG 372918 DIN6335
C C
(GGL-25)
10 1 Washer M10 Steel 0.004 KG 353488 ISO7089
9 6 Retaining Ring for Shaft 14X1 Spring Steel 0.001 KG 326789 DIN471
C ( 1:2 ) 10
8
7
6
1
Washer 25x2
30x47x83.5
3.2315 / ALMgSi1 (EN AW-6082) 0.002
0.113
KG 442140
433871
10018133
10015046
Clevis 3.2315 / ALMgSi1 (EN AW-6082) KG
6 1 Clevis 30x30x83.5 3.2315 / ALMgSi1 (EN AW-6082) 0.095 KG 433870 10015043
360

5 1 Pin 18x50 CC764S / CuZn34Mn3Al2Fe1-C 0.098 KG 433836 10015041

10
3 4 3 Pin 15x45 1.4301 / X5CrNi18-10 0.062 KG 433834 10015039
3 1 Threaded Rod - 0,418 KG 544677 10043608
2 1 Template-Parallel Side Left - 1,36 KG 544682 10043544
1 1 Template-Parallel Side Right 12x60x775 3.2315 / ALMgSi1 (EN AW-6082) 1,07 KG 544681 10043545
Item Qty Description Dimension Basic Material Weight Ut. MM-No. DRW-No. Norm/Remark

Modell: 10000284913_IAM_000.iam Modellversion: -

B 12 11 B
D
A A
THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
34

UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.

ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
Section Weight Main Scale Format
Standard Workshop
ISO 128
Instructions 9800.4 3,48 KG 1 : 2.5 A2

C Replaced by

50
Template Assembly Released

Approved
18.04.2013

18.04.2013
C603

C603

For Parallel Side Drawn 27.12.2012 V628

Document No. Version
A 162.2 A
10'043'543 -
Sheet: 1 of 1
D Material No.

Index Description of Modification Date Name SMS group

544683
8 7 6 5 4 3 2 1
EKI Old File Name: File Name: 10043543_DRF_000.idw
 8 7 6 5 4 3 2 1

1 2 1 2

F 12 5 F
A-A ( 1 : 2 )
6 7

12
30
8

1
1 3
11
E 7 D-D ( 1 : 2 ) E
46.8

B B-B ( 1 : 2 ) 30.9

47
18 30

30
60
8
B 15
11

15.5
3

15
233.9

Printed by: C850 on 26. September 2013 - Status: Released RE

D D
5 4 4
2
775

42 42 6
11
775 8 4

801.21 10

12 1 Spring Pin 3X18 Spring Steel 0.001 KG 328356 ISO8752

C C ( 1:2 ) 11
10
6
1
Retaining Ring for Shaft
Clampling Knob
14X1
GG-50-M10-E
Spring Steel
EN-JL1040 / EN-GJL-250
0.001 KG 326789
0.108 KG 372918
DIN471
DIN6335
C
(GGL-25)
R9835.3 9 9 1 Washer M10 Steel 0.004 KG 353488 ISO7089
8 6 Washer 25x2 3.2315 / ALMgSi1 (EN AW-6082) 0.002 KG 442140 10018133
7 1 Clevis 30x47x83.5 3.2315 / ALMgSi1 (EN AW-6082) 0.113 KG 433871 10015046

3
6 1 Clevis 30x30x83.5 3.2315 / ALMgSi1 (EN AW-6082) 0.095 KG 433870 10015043
5 1 Pin 18x50 CC764S / CuZn34Mn3Al2Fe1-C 0.098 KG 433836 10015041
R9999.5
361.36

4 3 Pin 15x45 1.4301 / X5CrNi18-10 0.062 KG 433834 10015039

10
3 1 Threaded Rod - 0,418 KG 544677 10043608
2 1 Template-Loose Side 12X82.9X775 3.2315 / ALMgSi1 (EN AW-6082) 1,24 KG 544669 10043542
-
12 10 1 1 Template-Fixed Side
Item Qty Description Dimension Basic Material
1,33 KG 544667
Weight Ut. MM-No.
10043541
DRW-No. Norm/Remark

Modell: 10000284910_IAM_000.iam Modellversion: -

B B
D
A A
THIS DRAWING AND ALL INFORMATION THERE ON IS THE PROPERTY OF CONCAST AND IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED
UNLESS AUTHORISED BY CONCAST AND IS SUBJECT TO RETURN UPON DEMAND.
ALL RIGHTS RESERVED COPYRIGHT AS PER DRAWN DATE SHOWN IN DRAWING HEADER.
32

Section Weight Main Scale Format

Standard Workshop
ISO 128
Instructions 9800.4 3,6 KG 1 : 2.5 A2
Replaced by

C 59 Template Assembly Released

Approved
18.04.2013

18.04.2013
C603

C603

For Radius Side Drawn 27.12.2012 V628

Document No. Version
A A
10'043'540 -
Sheet: 1 of 1

D Index Description of Modification Date Name SMS group

Material No.

544678
8 7 6 5 4 3 2 1
EKI Old File Name: File Name: 10043540_DRF_000.idw
 CHAPTER 4

CASTING PARAMETERS

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CASTING PARAMETERS

TABLE OF CONTENTS

1.1 GROUPING OF STEEL GRADES 3

1.2 ALLOCATION OF STEEL GRADES TO GROUPS AND FAMILIES 4
1.2.1 GROUPS 4
1.2.2 ORGANISATION OF STEEL GRADES INTO FAMILIES 4
1. LIQUIDUS TEMPERATURE 7
2. SPECIFICATION OF LIQUID STEEL TEMPERATURES FOR CASTING 9
2.1 TUNDISH SUPERHEAT 9
2.2 CHANGES OF CASTING SPEED WITH TUNDISH SUPERHEAT 10
2.3 AIM SUPERHEAT 10
3. CASTING SPEED 12
3.1 CASTING SPEEDS FOR SECTION 160X160 13
4. TUNDISH COVERING POWDERS 14
5. MOULD COOLING 14
6. MOULD LEVEL CONTROL 14
7. HYDRAULC MOULD OSCILLATION 15
7.1 MECHANICAL DATA (DESIGN LIMITS) 15
7.2 MOULD OSCILLATION PARAMETERS 15
8. MOULD POWDER 16
8.1 METALLURGICA SCORIALIT SPH-C 16
8.2 STOLLBERG ACCUTHERM ST-SP 16
9. SECONDARY COOLING 17
9.1 CURVE PARAMETERS 18
9.1.1 SECTION 160X160 18
9.2 SELECTION OF SPRAY COOLING CURVES FOR ALL STEEL FAMILIES 19
10. WITHDRAWAL AND STRAIGHTENING UNITS 20
10.1 160X160 20
11. TUNDISH METERING NOZZLE SIZES 21
12. CROP END 22
13. DATA SHEETS 22

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Definition of steel groups

1.1 GROUPING OF STEEL GRADES

In continuous casting, it is common practice to group several steel grades

together as long as they have similar composition, and to cast them with the
same process parameters. This simplifies the operation and is justified by the
fact that grades with similar composition generally have similar behaviour upon
solidification.
The steel grades to be cast are stored in a database known as the Recipe
System. Within the database, the grades are stored in a series of groups and
families.
The recipe system is accessible from both the Level 1 system and the Level 2
system when available.

CONCAST defines “group” and “family” in this way:

Group. A group of steel grades with basically the same steelmaking

practice and the same casting method.

Family. A set of grades within a group with exactly the same casting
parameters (cooling, mould level, mould powder etc) and event handling.
Effectively all steel grades in a family can be cast in exactly the same way.

A Group is denoted by a letter from A to Z, and a family by the group letter and a
number from 01 to 99.
A casting recipe is allocated to each family and all steel grades in the family are
cast using this same recipe.
A casting recipe is a full set of parameters (machine set-points) needed to cast
the family with optimum metallurgical results.
To simplify data entry recipes or parts of recipes can be inherited.
This is explained in detail later in this module.

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 1.2 ALLOCATION OF STEEL GRADES TO GROUPS AND FAMILIES

1.2.1 GROUPS

The table below lists the steel groups according to CONCAST subdivision.

A Structural steels, C-Mn-Si

B Special Si-killed carbon steels

C Rimming steel substitute

Al-killed special steels, not alloyed or with
D
total alloy content ≤ 2.5 wt%
Al-killed and Si-killed alloyed steels with
E
total alloy content > 2.5 wt%
F Free cutting steel

This subdivision reflects several concepts:

- Steelmaking process, especially deoxidation method. Steels in groups A and
B are silicon-killed, while steels in group D and E are aluminium-killed. Rimming
steel substitutes and free cutting grades are considered separately because of
their peculiar properties. The deoxidation method and the residual
concentration of aluminium determines the casting method (open or submerged).
- General quality level expected for the steel products. For this reason,
structural steel for general purposes (group A) is divided from silicon-killed steels
that have requirements on internal cleanness and/or inclusion composition (group
B). This difference influences both the steelmaking process and the casting
method (group B may require protection of the casting streams from reoxidation).
- Casting-related physical properties; the high alloyed grades (group E) are
separated from the low-alloy ones (group D) because their different mechanical
properties may require special care in casting and cooling.

1.2.2 ORGANISATION OF STEEL GRADES INTO FAMILIES

Within each group, the families are allocated mainly based on the carbon content
(rows of the following tables).

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 The limits of carbon content that define families have been chosen considering
the effect on the continuous casting process, and not on the base of the
properties of the end product. Example: the carbon range corresponding to the
peritectic reaction corresponds to one separate family because peritectic steels
have very peculiar solidification behaviour. The subdivision of high carbon steels
in several families corresponds to the limits of formation of cementite, which
affects segregation in continuous casting semi-products.
The presence of other elements that have a considerable effect on the
mechanical properties of steel at casting temperature, i.e. boron and sulphur, is
also considered and the relevant grades are allocated to special families as
shown in the table.
This difference is required because sulphur, for example, reduces the ductility of
steel at high temperature and makes the billet more prone to cracking. For this
reason, some parameters, especially casting speed and cooling curves, will be
different for resulphurised grades compared to the equivalent grades without
sulphur.
The complete subdivision is shown in the table in the next page.

This table can also be used as a template to attribute any new steel grade to a its
family.
This method of organisation is designed to simplify the allocation of new steel
grades into existing families, avoiding the need to create new casting parameters
and eliminating the risk of loosing control over the structure of the recipes
actually used in the plant.
The system is not rigid and the database structure will allow expansion of the
classification or to increase the number of families or even sub-families as
desired. Therefore, the database can adapt to different customer’s needs and
does not limit customer’s freedom to classify steel grades according to internal
uses.

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 TABLE FOR ALLOCATION OF STEEL GRADES TO FAMILIES

Families (according to carbon content)

< 0.09 0.10-0.17 0.18-0.25 0.26-0.42 0.43-0.59 0.6-0.69 0.70-0.79 0.80-0.94 > 0.94

A Structural steels, C-Mn- (Open

A10 A20 A30 A40 - - -
Si Cast)
Mn/S≥28 B10 B20 B30 B40 B50 B60 B70 B80 B90
Special Si-killed carbon Mn/S≥28
B B52 B62 B72 B82 B92
steels Special uses

Mn/S<28 B15 B25 B35 B45 B55 B65 B75 B85 B95

C Rimming steel
C10 - - - - - -
substitutes
Mn/S≥28 D10 D20 D30 D40 D50 D60 D70 D80 D90
Al-killed special steels,
D not alloyed or with total Boron - D22 D32 D42 - - -
alloy content ≤ 2.5 wt%
Mn/S<28 D15 D25 D35 D45 D55 D65 D75 D85 D95

Al-killed and Si-killed Mn/S≥28 E10 E20 E30 E40 E50 E60 E70 E80 E90
E alloyed steels with total
alloy content > 2.5 wt% Mn/S<28 E15 E25 E35 E45 R55 E65 E75 E85 E95

F Free cutting steels F10 F20 F30 F40 F50 - - -

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1. LIQUIDUS TEMPERATURE

The correct temperature in the tundish is specified in terms of superheat, that is

to say the difference between the temperature of the liquid steel and its liquidus
temperature.
The liquidus temperature calculation is based on the steel analysis.
The CONCAST formula used for this purpose is displayed here below.

Carbon <= 0.51 Wt% Carbon >= 0.51 Wt%

O O
1534 C 1521 C

%C x 90.4 %C x 65

%Si x 8 %Si x 8

%Mn x 5 %Mn x 5

%P x 34 %P x 34

%S x 40 %S x 40

%Sn x 10 %Sn x 10

%As x 14 %As x 14

%Cr x 1.5 %Cr x 1.5

%Ni x 4 %Ni x 4

%Nb x 7 %Nb x 7

%V x 2 %V x 2

%B x 60 %B x 60

%Mo x 2 %Mo x 2

%Ti x 17 %Ti x 17

%W x 1 %W x 1

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 Calculation examples are given below for two steel grades:

Grade C Mn Si P S Cr Ni Mo
A 0.15 .47 .19 .025 .020 .10
B .84 .55 .22 .020 .025 .10 .10 .05

Reduction of liquidus temperature (°C) for grade A due to the presence of:

Element Wt% Factor Reduction

C 0.15 x 90.4 = 13.56
Mn 0.47 x 5 = 2.35
Si 0.19 x 8 = 1.52
P 0.025 x 34 = 0.85
S 0.020 x 40 = 0.80
Cr 0.10 x 1.5 = 0.15
O
Total = 19 C
O
Subtract from 1534 C
O
Liquidus Temperature = 1515 C

Reduction of liquidus temperature (°C) for grade B due to the presence of:

Element Wt% Factor Reduction

C 0.84 x 65 = 54.6
Mn 0.55 x 5 = 2.75
Si 0.22 x 8 = 1.76
P 0.020 x 34 = 0.68
S 0.025 x 40 = 1.0
Cr 0.10 x 1.5 = 0.15
Ni 0.10 x 4 = 0.4
Mo 0.05 x 2 = 0.10
O
Total = 61 C
O
Subtract from 1521 C
O
Liquidus Temperature = 1460 C

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2. SPECIFICATION OF LIQUID STEEL TEMPERATURES FOR CASTING

The actual steel temperatures required in the ladle and the tundish will be finally
established on site by the CONCAST engineer responsible for hot
commissioning. This provision is taken to allow for the prevailing on-site
conditions and actual analysis.
The following is given as a guide to give an understanding of the principles
behind the selection of tundish temperatures. However the final tundish
temperatures will not deviate substantially from those mentioned.
The steel temperature in the tundish can be, according to specification, in the
range of approximately 15 - 60 °C above liquidus. The effect of casting conditions
such as section size and distribution, tundish to mould teeming technique and the
steel grade will influence the optimum tundish steel temperature for a particular
grade of steel.
Operating at higher temperatures than necessary to compensate for poor
operating technique is not only bad "castmanship" but can be dangerous. From
most aspects, high superheat in the mould is deleterious to billet quality.
One exception to this basic principle occurs when low carbon steels are cast.
Due to the solidification behaviour of this steel it is necessary to cast with a high
temperature in the tundish to ensure fluidity of the steel into the mould. This is
even more necessary when casting Aluminium killed steels where nozzle
clogging may be an issue.
From the safety viewpoint, a serious emergency such as a total power failure will
require that the steel flow from tundish to mould is promptly terminated. In open
casting this operation proceeds far more comfortably and safely with "on-spec."
steel temperatures.
Exceeding the upper limit increases the potential for breakouts exponentially.
Poor casting machine condition is accentuated by high superheat due to the
hotter and thus weaker steel shell emerging from the mould. Slight imperfections
in mould geometry, as a result of use, will cause defects in the cast strand at high
superheats. These defects may be absent or insignificant at specification
temperatures, but coupled with a hot weak shell, they may become breakout
initiators. Non-perfect alignment between the mould and the foot rolls, or a less
than optimum mould oscillation characteristic - which would otherwise pass
unnoticed, may break a weak, sensitive strand shell.

2.1 TUNDISH SUPERHEAT

The difference between the temperature of the liquid steel in the tundish and the
liquidus temperature is called “tundish superheat” or simply “superheat”.
The optimum value of superheat is a function of steel composition, casting mode
and operational considerations.

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2.2 CHANGES OF CASTING SPEED WITH TUNDISH SUPERHEAT

Reducing casting speed can to some extent compensate the effects of high
superheat. In the same way, one can increase casting speed to compensate for
low superheat.
This is especially important because both superheat and casting speed concur to
determine the length of the liquid pool and therefore the optimal position of the
soft reduction.
The dynamic spray cooling and the dynamic control of MSR can compensate the
effect of superheat and speed changes but the best practice is to keep these two
parameters as constant as possible.
The induction heating system in the tundish has the function to keep superheat
constant when the conditions of the steel arriving from the ladle vary.

2.3 AIM SUPERHEAT

- The indicated value of the superheat is based on the liquidus temperature

calculated with the Concast formula.
- For the first ladle of each sequence add 5 - 10°C to the values shown in this
table (to account for the drop in temperature during the initial tundish fill)
- The normal tolerance for the superheat is + 10°C, however for the high
carbon grades where segregation is critical, the tolerance is + 5°C.
- Values may be adjusted during commissioning, based on the observed
temperature losses in tundish and ladle and on the sampling procedure.
- The ladle last temperature in the Ladle Furnace must take in account all the
above mentioned issues plus the temperature loss due to the ladle itself that
is in the range of 35-45°C calculate as ( Ladle T° – Tundish T°)
- For the Controlled Sulphur steel grades ( S = 0.020  0.040 %) 10°C to the
aim Tundish superheat might be added in order to guarantee the castability
against TD nozzle clogging phenomena

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 AIM TUNDISH SUPERHEAT ( °C )

Carbon Content < 0.09 0.10-0.17 0.18-0.25 0.26-0.42 0.43-0.59 0.60-0.69 0.70-0.79 0.80-0.94 > 0.94
A10 A20 A30 A40 A50 A60 B70 B80 B90
A Structural steels, C-Mn-Si 40 40 35 35 35 30 25 25 25
B10 B20 B30 B40 B50 B60 B70 B80 B90
Mn/S≥ 28
35 30 30 30 25 25 25 25 25
Special Si-killed Mn/S≥28 B62 B72
B
carbon steels Special uses 25 25
B15 B25 B35 B40 B55 B65 B75 B85 B95
Mn/S<28
35 30 30 30 25 25 25 25 25
D10 D20 D30 D40 D50 D60 D70 D80 D90
Mn/S≥ 28
Al-killed special 35 35 30 30 25 25 25 25 25
steels, not alloyed or D22 D32 D42 D52 D62
D Boron
with total alloy content 35 30 30 25 25
≤ 2.5 wt%
D25 D35 D45 D55 D65
Mn/S<28 35 30 30 25 25

GENERAL RULE TO CALCULATE THE TEMPERATURE AND SUPEHEAT IN LADLE:

LAST LADLE FURNACE SUPERHEAT (°C) = AIM TUNDISH SUPERHEAT (°C) + LADLE LOSS (40°) + 1ST HEAT LOSS (cold Tundish)
Example calculation for D40 grade:
LAST LADLE FURNACE SUPERHEAT (°C) = 30° + 40 ° (+10° if 1st heat of sequence) = 70°C (or 80°C if 1st heat of sequence).

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3. CASTING SPEED

The caster should always operate at the indicated casting speed, which constitutes the optimum value for each steel grade.
Too high casting speed results in:
- Face bulging that may exceed tolerances
- Increased degree of centre porosity and segregation
Too low casting speed results in:
- Rougher surface and increased frequency of bleeds

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3.1 Casting Speeds For Section 160x160

0.10-
Carbon Content < 0.09 0.18-0.25 0.26-0.42 0.43-0.59 0.60-0.69 0.70-0.79 0.80-0.94
0.17
A10 A20 A30 A40 A50 A60 A70 A80
A Structural steels, C-Mn-Si 3.4 3.4 3.4
B10 B20 B30 B40 B50 B60 B70 B80
Mn/S≥ 28 3.0 3.0 3.0
Special Si-killed Mn/S≥28 B12 B22 B32 B42 B52 B62 B72 B82
B 2.5 2.5 2.4
carbon steels Special
B15 B25 B35 B40 B50 B60 B70 B80
Mn/S<28 3.0 3.0 3.0
D10 D20 D30 D40 D50 D60 D70 D80
Mn/S≥ 28
Al-killed special 3.0 3.0 2.9 2.8 2.8 2.7 2.7 2.6
steels, not alloyed or D12 D22 D32 D42 D52 D62
D Boron
with total alloy 2.8 2.7 2.6 2.5 2.5 2.5 2.4
content ≤ 2.5 wt% D15 D25 D35 D45 D55 D65 D75 D85
Mn/S<28 2.8 2.8 2.7 2.6 2.5 2.5 2.5 2.4

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4. TUNDISH COVERING POWDERS

The liquid steel in the tundish must be covered with insulating powder to protect it
from reoxidation.
The recommended powder types, based on MgO and suitable for all the steel
grades of the production mix are:

Metallurgica Repartect SPH-B 775/BGN

Stollberg T-715-G2

Powder characteristics are listed in the appended data-sheets.

5. MOULD COOLING

Section 160x160

Nominal Flow l/min 1950

Alarm flow l/min 1550
Emergency flow l/min 1200

6. MOULD LEVEL CONTROL

Section 160x160

Total Measuring Range (mm) 201

Top of Measuring Range to top of Cu

76
Tube (mm)

Meniscus set-point level (%) 70%

Top of Copper tube to Meniscus (mm) 137

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7. HYDRAULC MOULD OSCILLATION

7.1 MECHANICAL DATA (DESIGN LIMITS)

Oscillation stroke Max +/- 10 mm

Oscillation frequency 20 to 400 cpm

Acceleration Max. 4 m/s2

Asymmetry +/- 11°

7.2 MOULD OSCILLATION PARAMETERS

The table below shows the mould oscillation parameters selected

Submerged Open
Section
Casting Casting
Casting Speed Aim (m/min) 2.5-3.0 3.0-3.6
Quadratic Frequency Factor – n f - -
Linear Frequency Factor – m f 55 65
Constant Frequency Factor – c f - -
Frequency Cut Off – C fo 60 60
Frequency 165-198 163-195
Quadratic Stroke Factor – n h - -
Linear Stroke Factor – m h - -
Constant Stroke Factor – c h 12 11
Stoke Cut Off – C ho 2 2
Negative Strip Time (secs) 0.10-0.12 0.11-0.13
Negative Strip % -32 -43

Note: the oscillation parameters are calculated over a realistic range of casting
speed around the aim speed value.
This design provides flexibility of operation by maintaining optimum oscillation
parameters when casting speed is changed for any reason (unless the change is
too large).
The initial oscillation waveform will be of the sinusoidal type. Mould acceleration
will be kept below 3 m/s/s.

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 8. MOULD POWDER

8.1 METALLURGICA SCORIALIT SPH-C

Carbon Content < 0.09 0.10-0.17 0.18-0.25 0.26-0.42 0.43-0.59 0.60-0.69 0.70-0.79 0.80-0.94
D10 D20 D30 D40 D50 D60 D70 D80
*** SPH-C411- SPH- SPH-C411- SPH- SPH- SPH- SPH- SPH-
Al-killed special steels, not alloyed or with 81/E C176/ALS 9 81/E C189/E 1 C189/E 1 C189/V3 C189/V3 C189/V3
D
total alloy content ≤ 2.5 wt% D22 D32 D42 D52 D62
Boron SPH- SPH-C411- SPH- SPH- SPH-
C176/ALS 9 81/E C189/E 1 C189/E 1 C189/V3

8.2 STOLLBERG ACCUTHERM ST-SP

Carbon Content < 0.07 0.07-0.20 0.21-0.60 >0.60

ST-SP/521-GL1A- ST-SP/521-GL1A-
*** ST-SP/512-SV-DC ST-SP/817-C
C C
Al-killed special steels, not alloyed or with total alloy
D <0.30%C
content ≤ 2.5 wt%
Boron
ST-SP/511-C

For grade AISI 1215 use ST-SP/512SAG-C

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9. SECONDARY COOLING

The generic cooling curve are named: 150Axxx Where 150 stands for the section
size and “xxx” is the value of the specific water volume applied; for example:
160A140 the specific water volume is 1.40 l/kg
Parameter values for each zone (M, C, C.0.) are given in the following tables; the
picture below shows their meanings:

Q  M VC  C
Where:
Q = Flow rate (l/min)
M = Gradient / proportional factor
C = offset (l/min) (C is usually set to 0)
Vc = Casting speed (m/min)
C.O. = cut-off (minimum water flow rate admitted in l/min)

In next tables list of the “M, C, C.o.” coefficients values are given for the foreseen
specific water volumes.

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9.1 CURVE PARAMETERS

9.1.1 SECTION 160X160

ZONE1 ZONE2 ZONE3 ZONE4

Cut Off Cut Off Cut Off Cut Off
Cooling Curve M C M C M C M C
[l/min] [l/min] [l/min] [l/min]
160A06 40 49 19 13
160A07 47 57 22 15
160A08 54 65 25 17
160A09 61 73 28 19
160A10 67 81 31 22
160A11 58 120 30 13
160A12 63 123 131 151 33 14
160A13 69 142 36 15
160A14 74 - 153 - 38 - 65 16 - 29

160A15 79 163 41 18
160A16 84 174 44 19

160A17 90 185 47 13
16022 167 201 52 26
16023 175 210 54 27
243 213
16024 182 219 56 28
16025 190 228 59 29

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9.2 Selection of spray cooling curves for all steel families

(Hard Cooled Grades)

0.10- 0.18- 0.26- 0.43- 0.60- 0.70- 0.80-

Carbon Content < 0.09
0.17 0.25 0.42 0.59 0.69 0.79 0.94
A10 A20 A30 A40 A50 A60 A70 A80
A Structural steels, C-Mn-Si 160A17 160A15 160A13
B10 B20 B30 B40 B50 B60 B70 B80
Mn/S≥ 28 160A16 160A14 160A13

Mn/S≥28 B12 B22 B32 B42 B52 B62 B72 B82

B Special Si-killed carbon steels Special (160A23) (160A23) (160A23)
uses B15 B25 B35 B40 B50 B60 B70 B80

Mn/S<28 160A15 160A13 160A12

D10 D20 D30 D40 D50 D60 D70 D80

Mn/S≥ 28
160A09 160A08 160A08 160A08 160A08 160A08 160A07 160A07
Al-killed special steels, not alloyed or with D12 D22 D32 D42 D52 D62
D Boron
total alloy content ≤ 2.5 wt% 160A08 160A06 160A06 160A06
D15 D25 D35 D45 D55 D65 D75 D85
Mn/S<28 160A09 160A08 160A08 160A08 160A08 160A08 160A07 160A07

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10. WITHDRAWAL AND STRAIGHTENING UNITS

Pressures and Force for Withdrawal / Straightening Unit and Auxiliary Withdrawal Unit

The Withdrawal/Straightening unit has four settings, corresponding to the following

operation modes:

1 Insertion and extraction of the Dummy Bar

2 Disconnection
3 Hot billet in the withdrawal roll
4 Hot billet in the withdrawal roll and in the auxiliary pinch roll

10.1 160X160

Auxiliary Pinch
Withdrawal Roll Straighten roll
roll
Mode
P F P F P F
(bar) (kN) (bar) (kN) (bar) (kN)
1 130 180 - - - -
2 18 31 100 140 - -
3 18 31 20 32 - -
4 15 27 17 28 40 28

Legend: p = Hydraulic pressure

F = Force on the billet

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11. TUNDISH METERING NOZZLE SIZES

Casting Speed 3.1 3.3 3.4 3.6 3.7

Nozzle Diameter 21.0 21.5 22.0 22.5 23.0

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12. CROP END

Section Front Crop Tail Crop

160x160 800 1500

13. DATA SHEETS

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TECHNICAL DATA SHEET Accutherm ST-SP/511-C
Preliminary Product Description: Granular

Chemical Analysis (wt%) Typical Values

Typical Min Max wt%

Basicity 0.80 0.74 0.86 TiO2 0.61

SiO2 21.69 19.69 23.69

CaO 17.43 15.43 19.43

MgO 2.49 1.49 3.49

Al2O3 13.01 11.51 14.51 B2O3 0.36

Fe2O3 4.77 3.77 5.77

Na2O 5.35 4.05 6.65

3
F 4.58 3.28 5.88 Bulk Density (Kg/dm ) 0.87

23.95 21.95 25.95 Melting Characteristics

C-total
Softening Point (deg. C) 1185

Moisture 0.60 Melting Point (deg. C) 1200

Flowing Point (deg. C) 1210

o
IRSID Viscosity @ 1300 C (Pa-s) 0.86

Note: The range values listed above are tested and Calculated Break Point (deg. C) 922
controlled as required by our quality control
Note: The items listed above are typical values
system. These values are certified by
determined during our development process.
Stollberg Inc.

The data presented in this document is in accordance with the present state of our knowledge. We reserve the right
to modify product specifications within the scope of technical progress, new developments and policies of
continuous improvement.

STOLLBERG Inc. Phone (716) 278-1630

4111 Witmer Road Fax (716) 284-8753
2/22/2012 / UGS-01223
Niagara Falls, NY 14305 Website www.stollberg.com
TECHNICAL DATA SHEET Accutherm ST-SP/512SAG-C
Preliminary Product Description: Granular

Chemical Analysis (wt%) Typical Values

Typical Min Max wt%

Basicity 0.70 0.64 0.76 TiO2 0.92

SiO2 28.24 26.24 30.24

CaO 19.80 17.80 21.80

MgO 2.42 1.62 3.22

Al2O3 14.45 12.95 15.95

Fe2O3 3.66 2.66 4.66

Na2O 3.73 2.73 4.73

3
F 2.59 1.59 3.59 Bulk Density (Kg/dm ) 0.82

13.89 12.59 15.19 Melting Characteristics

C-total
Softening Point (deg. C) 1190

Moisture 0.60 Melting Point (deg. C) 1200

Flowing Point (deg. C) 1210

o
IRSID Viscosity @ 1300 C (Pa-s) 4.10

Note: The range values listed above are tested and Calculated Break Point (deg. C) 946
controlled as required by our quality control
Note: The items listed above are typical values
system. These values are certified by
determined during our development process.
Stollberg Inc.

The data presented in this document is in accordance with the present state of our knowledge. We reserve the right
to modify product specifications within the scope of technical progress, new developments and policies of
continuous improvement.

STOLLBERG Inc. Phone (716) 278-1630

4111 Witmer Road Fax (716) 284-8753
9/30/2011 / UGS-01183
Niagara Falls, NY 14305 Website www.stollberg.com
TECHNICAL DATA SHEET Accutherm ST-SP/512-SV-DC
Preliminary Product Description: Granular

Chemical Analysis (wt%) Typical Values

Typical Min Max wt%

Basicity 0.70 0.64 0.76 TiO2 0.47

SiO2 35.92 33.42 38.42

CaO 25.10 23.10 27.10 K2O 1.10

MgO 2.87 2.07 3.67

Al2O3 12.22 10.72 13.72

Fe2O3 1.60 1.10 2.10

Na2O 4.64 3.64 5.64

3
F 4.00 3.00 5.00 Bulk Density (Kg/dm ) 0.90

6.57 5.57 7.57 Melting Characteristics

C-total
Softening Point (deg. C) 1115

Moisture 0.60 Melting Point (deg. C) 1130

Flowing Point (deg. C) 1155

o
IRSID Viscosity @ 1300 C (Pa-s) 2.12

Note: The range values listed above are tested and Calculated Break Point (deg. C) 1026
controlled as required by our quality control
Note: The items listed above are typical values
system. These values are certified by
determined during our development process.
Stollberg Inc.

The data presented in this document is in accordance with the present state of our knowledge. We reserve the right
to modify product specifications within the scope of technical progress, new developments and policies of
continuous improvement.

STOLLBERG Inc. Phone (716) 278-1630

4111 Witmer Road Fax (716) 284-8753
2/8/2012 / UGS-01212
Niagara Falls, NY 14305 Website www.stollberg.com
TECHNICAL DATA SHEET Accutherm ST-SP/521-GL1A-C
Preliminary Product Description: Granular

Chemical Analysis (wt%) Typical Values

Typical Min Max wt%

Basicity 0.60 0.54 0.66

SiO2 31.69 29.19 34.19

CaO 19.04 17.04 21.04

MgO 1.73 0.93 2.53

Al2O3 5.36 4.36 6.36

Fe2O3 1.44 0.44 2.44

Na2O 7.82 6.52 9.12

3
F 5.76 4.46 7.06 Bulk Density (Kg/dm ) 0.80

20.88 18.88 22.88 Melting Characteristics

C-total
Softening Point (deg. C) 1010

Moisture 0.60 Melting Point (deg. C) 1060

Flowing Point (deg. C) 1110

o
IRSID Viscosity @ 1300 C (Pa-s) 0.55

Note: The range values listed above are tested and Calculated Break Point (deg. C) 1028
controlled as required by our quality control
Note: The items listed above are typical values
system. These values are certified by
determined during our development process.
Stollberg Inc.

The data presented in this document is in accordance with the present state of our knowledge. We reserve the right
to modify product specifications within the scope of technical progress, new developments and policies of
continuous improvement.

STOLLBERG Inc. Phone (716) 278-1630

4111 Witmer Road Fax (716) 284-8753
11/15/2011/ UGS-01194
Niagara Falls, NY 14305 Website www.stollberg.com
TECHNICAL DATA SHEET Accutherm ST-SP/817-C
Preliminary Product Description: Granular

Chemical Analysis (wt%) Typical Values

Typical Min Max wt%

Basicity 0.59 0.53 0.65

SiO2 31.66 29.16 34.16 MnO2 3.83

CaO 18.77 16.77 20.77

MgO 4.00 3.00 5.00

Al2O3 4.82 3.82 5.82

Fe2O3 1.40 0.40 2.40

Na2O 8.51 7.01 10.01

3
F 4.70 3.70 5.70 Bulk Density (Kg/dm ) 0.75

15.49 13.99 16.99 Melting Characteristics

C-total
Softening Point (deg. C) 980

Moisture 0.60 Melting Point (deg. C) 1020

Flowing Point (deg. C) 1060

o
IRSID Viscosity @ 1300 C (Pa-s) 0.39

Note: The range values listed above are tested and Calculated Break Point (deg. C) 990
controlled as required by our quality control
Note: The items listed above are typical values
system. These values are certified by
determined during our development process.
Stollberg Inc.

The data presented in this document is in accordance with the present state of our knowledge. We reserve the right
to modify product specifications within the scope of technical progress, new developments and policies of
continuous improvement.

STOLLBERG Inc. Phone (716) 278-1630

4111 Witmer Road Fax (716) 284-8753
11/15/2011/ UGS-01193
Niagara Falls, NY 14305 Website www.stollberg.com
 Stollberg

TECHNICAL DATA SHEET Accutherm T-715-G2

Preliminary Product Description: Tundish

Chemical Analysis (wt%) Typical Values

Typical Min Max wt%

Basicity 2.02 1.62 2.42 TiO2 0.33

SiO2 15.06 12.56 17.56 MnO2 0.11

CaO 30.38 27.88 32.88 K2O 0.17

MgO 18.42 16.42 20.42

Al2O3 14.48 12.48 16.48

Fe2O3 0.36 1.50

Na2O 0.19 1.00

3
F 2.70 2.20 3.20 Bulk Density (Kg/dm ) 0.74

15.01 13.51 16.51 Melting Characteristics

C-total

Moisture 0.50 Melting Point (deg. C) 1320

Note: The range values listed above are tested and

controlled as required by our quality control
system. These values are certified by Note: The items listed above are typical values
Stollberg Inc. determined during our development process.

The data presented in this document is in accordance with the present state of our knowledge. We reserve the right
to modify product specifications within the scope of technical progress, new developments and policies of continuous
improvement.

STOLLBERG Inc. Phone (716) 278-1630

4111 Witmer Road Fax (716) 284-8753
8/2/2004 / UPA-00049
Niagara Falls, NY 14305 Website www.stollberg.com
 CHAPTER 5

GUIDELINES FOR

QUALITY EVALUATION

C.4619/401 Chapter 5 Rev0

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Guidelines for quality evaluation

Table of Contents Page

1 Introduction 3

2 Shape defects and dimensional accuracy 5

Rhomboidity 7
Bulging 8
Corner Depression 9

3 Surface defects and Surface Quality 10

Longitudinal Corner Cracks 11

Deformed Oscillation Marks 12
Transverse Corner Cracks 13
Transverse Face Cracks 14
Surface Pinholes 15
Bleeds 16
Laps and Double Skin 17
Slag Inclusions on the surface 18
Craze Cracking 19

4 Internal defects and Internal Quality 20

Macro inclusions 21
Sub-surface cracks (off corners) 22
Diagonal cracks 23
Halfway cracks 24
Center cracks 25
Segregation 26
V-type center segregation 27
Ghost Lines 28
Hair Cracks 29

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1. Introduction

The purpose of this chapter is to list the criteria for quality evaluation of the
blooms cast.
The object of routine inspection and quality control is:

 To detect by means of irregularities on the blooms, faults on mould,

secondary cooling and withdrawal/straightener unit settings which can result
in defective blooms or disturbances to casting i.e. breakouts.
 To detect substandard casts which would result in a defective final product
that has to be downgraded.

The inspection of blooms to detect defects is done taking different kind of sample
depending on the information requested. This in turn depends on what the end
product will be and how confident the customer is in their process control.
It is not often necessary to do a full inspection of the cast product. A random
check provides all the required information.
The number and type of samples taken for different grades is commonly referred
to as a sampling plan.
These sampling modalities, together with causes and corrective actions required
for the elimination of various defects will be described.

Defects can be divided in two groups according their origin:

 Strand specific (only occur on 1 strand due to mechanical or machine set-up

problems, such as defective mould tubes, faulty secondary cooling, faulty
straightener settings)

 Heat specific (which are related to the properties of the liquid steel and
normally caused by problems with superheat, trace element control,
deoxidation practice during secondary metallurgy).

Each group of defects (strand specific or heat specific) can furthermore be

classified as:

 Shape defects ( for dimensional accuracy);

 Surface defects ( for surface quality);
 Internal defects ( for internal quality).

During blooms inspection three type of samples are usually considered:

 Transverse cross section – slice (indicated by A);

 Entire bloom surface (indicated by B);
 Longitudinal cross section (indicated by C);

Transverse cross section slice can be inspected immediately after cutting, (still in
rough machined condition, indicated by A1) for dimensional accuracy.
A Sulphur-print (condition A2) or a chemical macroetching (condition A3) can be
performed on the slice after grinding for assessment of internal defects.

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 It is not always necessary to prepare slices both in A2 and A3 condition, the
choice being dependent on the quality of the steel grade cast and the quality
requirements of the final product.
The internal quality can be inspected also from Sulphur print taken on
longitudinal cross section (condition B1).
Surface defects are detected visually on the entire bloom surface after local
cleaning with wire brush (condition B1) or after test scarfing 2 mm deep
(condition B2). Surface can also be inspected in longitudinal cross section after
pickling (condition C2) or after pickling and spot ground to detect defect depth
(condition C3).

Table 1 summarised the different types of defects that can be revealed by

different sample preparation.

Table 1 – Sample types

Sample type Sample Processing Used to check for

Transverse Rough machined section Check for cross section shape and
slice (A1) (saw cut / milling) dimensional accuracy

Transverse Macro etching Macro inclusions, internal cracks, %

slice (A2) Equiaxed, pipe.

Transverse Ground & S-printed %Equiaxed, internal cracks,

slice (A3) segregation

Entire surface Visual inspection, local Cold welds, transverse depressions,

bloom (B1) cleaning with wire brush longitudinal corner crack, irregular
oscillation marks

Entire surface Test scarfing 2mm deep Subsurface slag entrapment. Pinhole
bloom (B2) porosity

Longitudinal section Longitudinal cut and S- Segregation, pipe (for higher C grades
(300mm) (C1) printed subject to possible bridging)

Longitudinal section Surface pickled and Pinholes, intergranular network

(300mm) (C2) inspected cracking, transverse corner crack

Longitudinal section Surface pickled and Concealed transverse corner crack

(300mm) (C3) inspected, spot ground to (mould level fluctuation) that did not
detect defect depth showing on sample C2

The most common of these samples are described in detail below along with the
defects that may be seen.

IMPORTANT: Routine samples should be taken from blooms cast under normal
conditions i.e. exclude blooms from the beginning and end of a cast. Of course if
an unforeseen event occurs.

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2. Shape defects and dimensional accuracy

Shape defects can be observed on transverse slice cut from a bloom, which
should be taken at least 150 mm away from any torch cut.
The slice in this condition is used to assess the following parameters:

 Difference of Diagonals (Rhomboidity) (see Fig 1);

 Side length of bloom (Bulging) (see Fig 1);
 Corner depression (see Fig.1);
 Difference of Diameters (Ovality) (see Fig.2);
 Macroscopic inclusions (see section: internal defect).

Fig 1 – Measurements for dimensional accuracy (square sections)

A
B

W1

D1 D2

X1 X2

W2

 measure D1 and D2 Long and short diagonals

 measure W 1 and W 2: width between curved sides
 measure X1 and X2: thickness between parallel sides

(W and X to be measured approx. 20 mm from corner)

 The measures of the diagonals are used to calculate the Rhomboidity

according to the following equation:

2   D1  D 2
R hom boidty %   100 Where D1 = long diagonal
D1  D2

C.4619/401 Chapter 5 Rev0

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 D2 = short diagonal

 The degree of bulging on one or more sides can be determined by making

measurements W and X as follows:

(W 1 + W 2) / 2 = Average width of the bulged sides

(X1 + X2) / 2 = Average width of the parallel sides

(W – X) = Degree of bulging in mm

C.4619/401 Chapter 5 Rev0

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 Defect Rhomboidity

Primary Worn mould – leads to uneven primary solidification. Solidifying shell

Cause can touch one side of mould and leave a large air gap on the opposite
face. The shell is thicker and stronger on one side compared to the other
and rhombic distortion occurs when the shell exits the mould.
If the rhomboidity is mould related it is quite common to see the
rhomboidity increase and decrease in severity within one or two heats. It
is also possible for the rhomboidity to change from right handed to left-
handed. This normally a strand specific defect.
Secondary Badly adjusted foot rolls – will mechanically force the strand shell into a
Cause (1) rhombic shape.
Secondary Bad spray alignment – if severe enough can cause such uneven cooling
Cause (2) that a rhombic shell is formed in a similar way to a worn mould i.e.
uneven shell formation.
Other Steel Chemistry – will affect the strength of the solidifying shell. The
Contributing presence of Cu, Sn and S will all weaken the shell and allow distortion to
Factors occur more easily.
Additional Rhombic distortion may have an internal crack associated with it. This
Info can open up in the rolling mill and cause cobbles or seams. If the
rhomboidity is severe the crack can reach the surface during casting and
cause a breakout.
Severity of 0 – 3 % Good
Rhombic 3 – 4 % Tolerable
deformation > 4% Serious risk of breakout and or defective blooms
Corrective Change the mould if worn. Reset the foot rolls correctly. Realign sprays
Actions especially zone 1. Ensure Mn:S ratio > 28:1. Cu,Sn < 0.25

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 Defect Bulging

Primary High casting Speed – leads to a thinner shell on exit from the mould.
Cause The shell is not strong enough to resist the ferrostatic forces above it and
is distorted and may even breakout. Secondary causes may increase this
effect. As section size increases the ferrostatic pressure increases and
bulging tendency will increase. This is normally a strand specific defect.
Secondary Badly adjusted foot rolls or containment rolls – will allow the strand to
Cause (1) bulge on exit from the mould or along the segments. They must always
be set correctly to provide the correct amount of support for the strand
shell
Secondary Worn mould – will allow bulging to occur in the worn section of the mould
Cause (2) especially if the casting speed is high.
Other Steel Chemistry – will affect the strength of the solidifying shell. The
Contributing presence of Cu, Sn and S will all weaken the shell and allow distortion to
Factors occur more easily.
Severity of The normal bloom dimensional tolerance is 1.5 %.
Bulging Deviations larger than 3 % could cause possibly problems in a pushes-
type reheat furnace, while are not relevant in case of walking beam
furnaces.
Corrective Reduce the casting speed. Reset the foot rolls correctly. Change the
Actions mould if worn.. Ensure Mn:S ratio > 28:1. Cu,Sn < 0.25

C.4619/401 Chapter 5 Rev0

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 Defect Corner Depression

Primary Rhomboidity – a rhomboid bloom often has a longitudinal off corner

Cause depression. This appears as a trough running parallel with the corner
along the entire length of the bloom. It can also be intermittent and
contain bleeds. In severe cases there can be a crack under this
depression.
Secondary Worn mould – can allow intermittent contact with the mould wall and a
Cause (1) strong corner can twist in the mould causing a depression even if there is
no rhomboidity. There is likely to be a crack underneath and therefore a
possibility of a breakout.
Secondary Bad spray alignment – a badly twisted riser on a spray ring will allow
Cause (2) undercooling on a corner and reheating followed by distortion.
Other Distorted moulds – even if new will behave like old moulds. If a new
Contributing mould has had a bloom pulled out of it the taper may have been
Factors destroyed. This will also cause similar problems to a worn mould. Steel
chemistry i.e. low Mn:S ratio will also reduce shell strength.
Severity of 0 – 1 mm No action required
surface 1 – 3 mm Check mould tube age and/or presence of deposits
depression > 3 mm Breakout risk and risk of internal cracks below the depression
Corrective Change the mould if worn or distorted. Check the upper sprays (spray
Actions ring) for any gross misalignment of spray risers.

C.4619/401 Chapter 5 Rev0

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3 Surface defects and Surface Quality

Surface defects (or External defects) are found by inspection of the entire bloom
surface removing any scale with a sand blaster (condition B1 and B2).
Local areas can be cleaned using a wire brush.
Surface defects that can be seen are described below.

 Longitudinal Corner Cracks

 Deformed Oscillation Marks
 Transverse Corner Cracks
 Transverse Face Cracks
 Surface Pinholes
 Bleeds
 Laps and Double Skin
 Slag Inclusions on the surface
 Craze Cracking

Note: even if the following description is dealing with square cross section,
features, causes and corrective actions related to surface defects are also valid
for round cross section.

C.4619/401 Chapter 5 Rev0

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 Defect Longitudinal corner cracks

Primary Worn mould – These cracks are formed in the mould and often due to a
Cause worn profile in the corner either knicked or key-holed. This causes a
thinner shell to form and allows reheating lower in the mould. This
reduces the strength of the corner allowing a crack to form.
Secondary Bad secondary nozzle alignment – in case of bad spray jet alignment of
Cause (1) upper zones a rhombic-wise shell contraction can generate a longitudinal
corner crack.
Secondary Variable heat transfer – can allow reheating and crack formation. Mould
Cause (2) powder lubrication however normally reduces the chances of this
happening.
Secondary Superheat – has a strong effect on cracking. A hot shell has less
Cause (3) strength to resist thermal stresses set-up in the mould.
Other Carbon content – influences the occurrence of cracks. Cracks are more
Contributing likely above 0.15 C and approach a maximum at 0.40 wt% C. Cu, Sn and
Factors S all weaken the shell and increase crack probability.
Corrective Change the mould if worn. Change mould powder to reduce heat
Actions transfer. Decrease superheat to minimum possible. Check the alignment
of secondary sprays

C.4619/401 Chapter 5 Rev0

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 Defect Deformed Oscillation Marks

Primary Worn mould – in the meniscus area in particular will cause the marks to
Cause look smeared in the middle of the face. High tensile stresses can lead to
a breakout.
Secondary Wrong mould lubrication – in case of wrong powder viscosity selection
Cause (1) sticking between newly formed shell and mould wall can take place
Secondary Severe taper – If the taper is too strong for the steel grade deformed
Cause (2) oscillation marks will result. This is accompanied with a high tensile
stress that can pull the bloom shell apart.
Secondary Casting Speed – If the casting speed is too slow the taper shall become
Cause (3) excessive and will generate a lot o stress in the shell as it moves into the
lower part of the mould.
Other If the mould life is low but meniscus area is deformed check the water
Contributing side of the mould in case the water hardness has risen and deposited an
Factors insulating layer of lime scale on the copper;
Scarce lubrication in the mould or mould powder incorrect;
Oscillation parameters incorrect.
Corrective Change the mould if worn.
Actions Cast at the correct speed for section and steel grade.
Improve the mould lubrication.
Check the oscillation parameters (frequency and stroke).

C.4619/401 Chapter 5 Rev0

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 Defect Transverse Corner Cracks

Primary Steel Chemistry – high levels of P, S and other tramp elements can
Cause greatly weaken the shell and in combination with a mechanical stress
cause the cracks to form, normally in oscillation marks.
High amount of Al, Nb and V which decrease the hot ductility in the
temperature range of 600-900°C.
Secondary Mechanical stress – Any mechanical stress coupled with poor chemistry
Cause (1) may cause cracks. Severe mould taper, worn oscillator bearings or a
badly aligned machine can cause stresses. Also poor lubrication alone
can cause enough stress to generate cracks
Secondary Unbending – stresses can be high enough to generate cracks especially
Cause (2) if the grade is crack sensitive and the corner temperature is lower than
900°. The cracks will appear on the top side of the bloom.
Other A severe mould taper or slow casting speed will generate stress. Casting
Contributing parameters that give positive strip will generate stress and negative strip
Factors must always be used.
Corrective Reduce residuals, eliminate mechanical stress, increase straightening
Actions temperature, have negative strip and a short stroke, use low viscosity
lubricant.

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 Defect Transverse face cracks

Primary Steel Chemistry – Unusually high levels of P, S and Cu will cause a

Cause problem instantly.
Secondary Mechanical stress – Any mechanical stress coupled with poor chemistry
Cause (1) may cause cracks. Severe mould taper, worn oscillator bearings or a
badly aligned machine can cause stresses. Also poor lubrication alone
can cause enough stress to generate cracks
Secondary Unbending – stresses can be high enough to generate cracks especially
Cause (2) if the grade is crack sensitive and the bloom temperature is low. The
cracks will appear on the top side of the bloom.
Other Normally this problem is chemistry related but if the chemistry is normal
Contributing then all the factors that cause transverse corner cracks must be
Factors considered.
Corrective Check the steel chemistry especially Cu. Follow corrective actions for
Actions transverse corner cracks, i.e. reduce mechanical stresses.

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 Defect Surface pinholes and subsurface blow holes

Primary Steel Chemistry – high levels of gaseous elements H, N and CO will

Cause combine to give a pressure > 1 bar and cause a pinhole. Problem is
worse if Si is low and C is high.
Secondary Wet Tundish – can add significant quantities of H and O to an otherwise
Cause (1) non problematic steel.
Secondary Stirring Gas – At the LMF stirring with N for a long period can cause a
Cause (2) sudden and rapid increase in dissolved N content.
Secondary Gas pick up / reoxidation – O, N can be absorbed from Ladle to
Cause (3) Tundish shroud, from the uneven slag coverage in Tundish and from the
Tundish to mould shroud. The sealing from air contact during all the
mentioned steps must be assured.
Secondary Argon sealing – If the protective Ar flow-rate in TD nozzle/slide-gates is
Cause (4) to high, Ar bubbles will be dragged from the molten steel in the mould and
appear like small pinholes and blow holes.
Other This problem is always chemistry related and all sources of H, N and CO
Contributing must be minimised. Certain steel chemistries are impossible to cast
Factors without first degassing the steel or aluminium killing.
Steel reoxidation, use of excessive oil lubricant or wet casting powder in
the mould have an influence.
Corrective Check the steel chemistry and reduce gases. Do not add damp Ferro
Actions alloys especially FeSi as H content increases. Check that tundish and
the casting powder are properly dried. Check the sealing of the shrouds

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 Defect Bleeds

Primary Defective mould – This defect is a small breakout that has occurred in
Cause the mould and then solidified again. That is why the teardrops have a
flattened appearance. The breakout is normally caused by another
defect i.e. subsurface crack etc.
Secondary Surface Slag – Slag from the meniscus area can be trapped in the
Cause (1) solidifying shell and on exit from the mould be pushed out of the shell but
ferrostatic pressure. The steel that follows is quenched by the spray
water and leaves a bleed. The slag is normally alumina or solid
manganese silicates.
Secondary Scarce lubrication - mould powder incorrect.
Cause (2)
Other This problem is either a faulty mould or poor chemistry control of the
Contributing steel. Reoxidation in the ladle, tundish or mould can create solid
Factors inclusions if the chemistry is sensitive to this.
Wrong oscillation parameters.
Corrective Change the mould. Adjust the steel chemistry to avoid solid inclusions.
Actions Prevent reoxidation of steel in the tundish and mould.

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 Defect Laps and Double Skin

Primary Lubrication – This problem is caused by poor or intermittent lubrication.

Cause The steel sticks to the side of the mould and is then dragged down by the
oscillation motion and instead of forming a normal oscillation mark a lap is
created.
Secondary Variation of the mould level – an uneven variation of the mould level
Cause (1) and/or a meniscus perturbation can lead to skin overlapping.
Secondary None
Cause (2)
Other If mould powder absorbs a lot of alumina the viscosity and melting point
Contributing of the powder and slag can change. This can affect the ability to lubricate
Factors the mould and consequently cause sticking and laps.
Corrective Ensure correct mould powder is used. Check the level variation and the
Actions oscillating bank

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 Defect Slag Inclusions on the surface

Primary Slag - Excessive amount of slag in the steel.

Cause Slag containing high amount of Al2O3 and low Si2O, MnO and FeO.
Secondary Variable mould level that pulls the slag rim down into the bloom when
Cause (1) submerged casting; excessive turbulence into the mould.
Secondary Reoxidation of the liquid steel.
Cause (2) Deoxidation with Ca or CaSi, low Mn/Si ratio and open casting (Mn and Si
are oxidised and their oxides are trapped into the solidified steel)
Other Erosion of the refractory materials;
Contributing Low level of steel into the tundish.
Factors
Corrective Minimised the slag quantity in the mould;
Actions Check the content of Mn, Si, Ca, Al during secondary metallurgy
treatment;
Check the mould level variation.

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 Defect Craze Cracking

Primary A segregation of low melting point elements i.e. Cu to the grain

Cause boundaries is usually the main reason for craze cracking occurring
around the grain boundaries.
Secondary High levels of B, Al and N2 in boron steels
Cause (1)
Secondary Precipitation of AlN in Al-killed steels
Cause (2)
Other
Contributing
Factors
Corrective Lower quality applications can tolerate a certain amount of craze cracking
Actions but products requiring 0.5% defect depth on the rolled bar or coil cannot
tolerate any craze cracking and corrective action must be taken.
Change the mould powder to lower the mould heat flow;
Add Ni to achieve a Cu/Ni ratio of 1:1.

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4 Internal defects and Internal Quality

Internal defects can be observed in Sulphur prints of transversal and longitudinal

cross sections (A2 and C1 respectively) or after chemical macroetching (A2).
Internal defects that can be seen are described below.

 Macro inclusions
 Sub-surface cracks (off corners)
 Diagonal cracks
 Halfway cracks
 Center cracks
 Segregation
 Piping and Bridging
 V-type center segregation
 Ghost lines
 Haircracks

Note: even if the following description is dealing with square cross section,
features, causes and corrective actions related to internal defects are also valid
for round cross section.

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 Defect Macro inclusions

Primary Reoxidation – anywhere in the system will produce a large macro

Cause inclusion. On the CCM the 3 places for reoxidation are between ladle and
tundish, in the tundish and between tundish and mould.
Secondary Mould powder – can be drawn into the steel if SEN is not immersed
Cause (1) deeply enough below the meniscus.
Secondary Steelmaking - can generate or remove large numbers of inclusions.
Cause (2) Numerous factors exist. Accurate control of the entire secondary
steelmaking process is required to produce clean steel.
Other Refractory erosion can lead to inclusion problems. This can be from
Contributing anywhere in the system. Preheating of SEN’s and tundish must be
Factors excessive or material breaks down and is washed into steel.
Corrective Ensure no reoxidation occurs. Have correct SEN immersion depth.
Actions Ensure secondary steelmaking is correct.

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 Defect Off corners cracks

Primary Rhomboidity - This crack is an indication of uneven mould cooling and it

Cause is usually associated with depression or rhomboidity. If the crack
propagates to the surface during casting there will be a breakout. During
rolling cracks may be opened up in the roughing stands.
Secondary Uneven secondary cooling (upper zones)– non symmetric section
Cause (1) spray cooling in the very first zones can provoke corner contraction hence
cracks starting from the hotter solidified steel below the solidification front
Secondary Uneven containment rolls gap – containment rolls not properly set can
Cause (2) allows face bulging with subsequent arising of cracks in the off corner
area.
Secondary W/S unit – low ductility at high temperature during bending and
Cause (3) ??? strengthening of the strand may give arise in this kind of cracks.
Secondary High casting temperature, high casting speed.
Cause (4)
Corrective Check mould tube for deformation and/or deposits if the crack is
Actions propagated very close to the surface and a pronounced depression on
the surface exists; change mould tube at once, risk of breakout and
defective blooms, if the cracks are propagated until the surface or
connecting to a diagonal crack.

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 Defect Diagonal cracks

Primary Rhomboidity - This is usually associated with a strong rhombic

Cause deformation of the bloom of more than 5 %. This long crack is an
indication of very uneven mould cooling. It is likely that the crack will
propagate to the surface. During rolling these cracks are more likely to
open up in the roughing stands.
Secondary Bad spray alignment – the secondary cooling is not uniform an all 4
Cause (1) bloom’s sides.
Secondary Oscillation marks at the corners deeper than at the face’s centre: the
Cause (2) bigger corner air gap developed by deeper marks in these position
reduces the heat transfer leading to thin shell formation.
Other Steel composition: Mn/S < 25-30
Contributing
Factors
Corrective If these long diagonal cracks ending close to the bloom corners the
Actions corrective action must be to immediately change the mould;
Check the secondary cooling system for correct alignment;
Reduce formation of deep oscillation marks around corners;
Steel composition with Mn/S > 25-30;
In low carbon steel with low Mn/S ratio, keep S<0.018%.

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 Defect Halfway cracks

Primary Secondary cooling – is the main reason for these cracks. The change
Cause in cooling intensity between spray zones allows reheating which
generates stresses in the bloom. The solid shell cracks at the solid liquid
interface. The depth of the crack determines how far down the machine
the stress was first developed.

Secondary W/S unit pressure too high

Cause (1)
Secondary None
Cause (2)
Other Blocked spray risers or nozzles will allow reheating and crack generation.
Contributing
Factors
Corrective The cracks formed are normally far enough under the surface so they do
Actions not cause rolling problems. They are not oxidised and normally weld up
during rolling.
Use the correct cooling curve and avoid large changes of intensity
between zones.
Check all spray nozzles are unblocked.
Modify cooling curve in order to reduce reheating between cooling zones
or at the end of cooling.

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 Defect Center cracks

Primary Secondary cooling – excessive secondary cooling reduces the skin

Cause temperature drastically, which is reheated up from the core still liquid
when the bloom exits from the cooling system
Secondary Low C steels (C < 0.10 – 0.12wt%) are very prone to this type of crack
Cause (1) even when the spry cooling is O.K.
Secondary Trace elements like S, P and Cu, Sn
Cause (2)
Other High casting speed, high tundish superheat
Contributing
Factors
Corrective Decrease the secondary cooling intensity;
Actions Decrease the casting speed;
Decrease the casting temperature.

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 Defect Segregation

Primary Superheat – if high, extends the length of columnar grains growing

Cause towards the centre of the bloom. This causes more C, S and Mn to be
concentrated in the remaining liquid ahead of the solidification front.
Secondary Secondary Cooling – Hard cooling will generate equiaxed grain growth
Cause (1) in the centre of the bloom, ahead of the columnar crystal growth front.
This will stop the concentration of solute in the remaining liquid and
spreads the final liquid to solidify over a wider area
Secondary Casting Speed – A high speed leaves less time for heat removal and
Cause (2) less chance for equiaxed crystals to form in the centre
Other MEMS, FEMS can be used to reduce the effects of segregation but
Contributing FEMS is placed on the machine at a point of maximum affect for a given
Factors casting speed. Cannot therefore change the casting speed.
Corrective Reduce superheat, increase cooling, reduce casting speed. Use MEMS
Actions and FEMS if possible.

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 Defect “V” type center segregation

Primary High Superheat – an high superheat promotes formation of columnar

Cause solidification structure at expense of the equiaxed one, promoting centre
segregation of alloy elements such as C, S, P and Mn.
Secondary Too low secondary cooling
Cause (1)
Secondary
Cause (2)
Other Steel chemistry: high S, P, C and Mn content
Contributing
Factors
Corrective Corrective actions, such as reduce the superheat, increase the water
Actions cooling and use EMS, should be taken if the size of the V segregates
exceeds the standard acceptable for the final application. High levels of C
can be found in V segregates and these can cause hard brittle phases in
the rolled product. Knowledge of what he end product can tolerate is
required before a decision can be made as to whether the blooms must
be scrapped or not.

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 Defect Ghost lines

Primary Rhomboidity /depressions - This crack is an indication of uneven mould

Cause cooling and it is usually associated with depression or rhomboidity. When
the crack propagates to the solidification front it can be partially or
completely filled from the low melting products, forming a structural
discontinuity in which MnS is highly concentrated.
Secondary Uneven secondary cooling (upper zones)– non symmetric section
Cause (1) spray cooling in the very first zones can provoke corner contraction hence
cracks starting from the hotter solidified steel below the solidification front
Secondary Uneven containment rolls gap – containment rolls not properly set can
Cause (2) allows face bulging with subsequent arising of cracks in the off corner
area.
Other Steel chemistry: high S, P, C and Mn content, high superheat
Contributing
Factors
Corrective Check mould tube for deformation and/or deposits if the crack is
Actions propagated very close to the surface and a pronounced depression on
the surface exists; change mould tube at once, risk of breakout and
defective blooms, if the cracks are propagated until the surface or
connecting to a diagonal crack.

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 Defect Haircracks

Primary Hydrogen content over 2-2.5 ppm

Cause
Secondary Wet Tundish – the H contained in the H2O of a tundish lining not
Cause (1) completely dried can be picked up and cause the formation of hair line
crack
Secondary None
Cause (2)
Other Wet alloys and lime earlier in the process
Contributing
Factors
Corrective Degassing
Actions

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 CHAPTER 6

STARTUP AND COMMISSIONING

C.4619/401 Chapter 6 Rev0

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Startup and Commissioning

Table of contents

1. INTRODUCTION 3
2. COLD COMMISSIONING & INTEGRATED TESTS 3
3. PERFORMANCE GUARANTEE TESTS 4
4. ANNEXES 4

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1. INTRODUCTION

The purpose of this Chapter is to define the requirements, and procedures

necessary to enable the objectives of following project phases to be successfully
been met.
 Cold Commissioning and Integrated Tests
 Hot Tests
 Performance Guarantee Tests
Concast has in the past twenty years successfully started up over 150 casting
machines, all the advice and recommendations in this chapter are a result of
these experiences, and to disregard them will only increase the risk of failure.

2. COLD COMMISSIONING & INTEGRATED TESTS

The objective of this phase is to initially test that all the units of the Caster are
functioning correctly as individual units, it is important that activities during this
phase are coordinated to ensure that all utilities necessary to operate that unit
are available and other outstanding erection activities to not interfere with these
test activities.
To assist Concast personnel and to aid training it is recommended that Control
Room Operators assist in these activities to both familiarise themselves with the
machine movements and controlling them from the HMI and Local Control boxes.

Man Power Requirements – Cold Tests

Control Room Operators 4
Automation Engineer 1+

The Integrated Test Phase is a precursor to the first cast and the start of the Hot
Test Phase. During the Integrated Test the operation of individual units of the
machine will be consolidated until the machine functions faultlessly as one
integrated unit.
In the later stages of Integrated Tests the Casting Operators are introduced to
the machine, and Operator training begins. The objective of the Operator training
will be for them to successfully operate (with assistance from Concast) the
Casting Machine for the First Cast without causing damage to the equipment or
injury to personnel. The minimum requirement for the end of the integrated test
phase is to conduct 3 casting simulations during which both machine and
operators function faultlessly.

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 Man Power Requirements – Integrated Test
Casting Operators 8
Control Room Operators 4
Automation Engineer 1+

During Integrated tests it is essential that the all Commissioning Check Lists are
completed and any deficiencies are recorded, all equipment and materials should
be present and correct, and all vulnerable areas of the machine are protected
from liquid metal and heat damage Annex 3.
To monitor the performance of the initial start up phase a Start Up Curve as
should in Annex 4 should be developed during the project liaison meetings to
which actual data can be added during the Hot Test phase.

3. PERFORMANCE GUARANTEE TESTS

To enable the Performance Guarantee Tests to proceed smoothly, it is

recommended to have all the necessary facilities available on site, use of outside
agencies to make the relevant tests can often result in a slow turnaround of
samples outside of the contractually agreed time frame. The necessary
equipment required to conduct the sample testing on site is given in Annex 2

4. ANNEXES

Annex 1 Cold Commissioning Check Lists

Annex 2 Tools, Equipment and Materials
Annex 3 Machine Protection

C.4619/401 Chapter 6 Rev0

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ANNEX 1 Cold Commissioning Check Lists

Description of Test Relevant Functional Descriptions

CASTING FLOOR GENERAL
ROTATION OF LADLE TURRET FD 111, 112
LADLE TURRET OPERATION FD 111, 112
TUNDISH PREHEAT STATION FD 152
TUNDISH CAR FD 131, 132
BELLOWS FD 177
MOULD LEVEL CONTROL FD 233
MOULD OIL SYSTEM FD 213
MOULD COOLING WATER AND FD511, 514
EMERGENCY SYSTEM
MOULD OSCILLATION FD 211
DUMMY BAR FD 291
SPRAY COOLING FD 512
LEVEL 1 VDU
LEVEL 2 SYSTEM
INTEGRATED TEST OF CASTING
PREPARATION SEQUENCE (open
casting without tundish)
INTEGRATED TEST OF CASTING
SEQUENCE (stopper casting with
tundish)
FULL INTEGRATED COLD TEST (OPEN
CASTING)
MOULD PREPARATION AREA
TUNDISH PREPARATION AREA

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Annex 2 Tools, Equipment and Materials
Open Casting

Equipment / Material Quantity Units Location Comments

O2 Lance Holder for Ladle Lancing 1 pcs At Ladle Lancing Out Position
High Pressure Oxgen Gun or Shower Device 1 pcs At Ladle Lancing Out Position Cleaning Shroud during ladle changes
Hose Reel For Oxygen Hoses 2 pcs At Ladle Lancing Out Position
Lancing Pipes 20 pcs At Ladle Lancing Out Position Larger Quantities to be kept in stores
Hand Burning Torch 1 pcs At Ladle Lancing Out Position To ignite O2 lances
Mould Level Calibration Block 1 per section Casting Floor Mould Area To Calibrate MLC
Long Handled Brush 1 pcs Casting Floor Mould Area For Cleaning Mould Tube at end of Cast
Long Handled Mop 1 pcs Casting Floor Mould Area For Pre lubricating Mould Tube
Mould Chill Scrap 500 pcs Casting Floor Mould Area For Mould Prreparation Before Start of Cast
Turnings/Punchings/Nail Heads 100 Kg Casting Floor Mould Area For Mould Prreparation Before Start of Cast
Oil Cans 8 pcs Casting Floor Mould Area For manual oil application into moulds
O2 Lance Holder for Tundish Nozzle Lancing 2 pcs Casting Floor Mould Area
Hose Reel For Oxygen Hose 2 pcs Casting Floor Mould Area
Hand Burning Torch 1 pcs Casting Floor Mould Area To ignite O2 lances
Lancing Pipes 100 pcs Casting Floor Mould Area
Copper Cones 8 pcs Casting Floor Mould Area For plugging strands
Steel Discs for Nozzle sealing 100 pcs Casting Floor Mould Area To seal Tundish Nozzle before start of cast (preferred method)
Ceramic Rope 50 m Casting Floor Mould Area To seal Tundish Nozzle before start of cast(Alternative Method)
Slag Fishing Rods 50 pcs Casting Floor Mould Area To remove slag from mould during casting
Graphite Spray 50 cans Casting Floor Mould Area To lubricate CNM Nozzles
CNM Hand Tools 1 set Casting Floor Mould Area Used during nozzle changing
Selection of CNM Nozzles and Blanks 50 pcs Casting Floor Mould Area
Storage Rack for CNM Nozzles 1 pcs Casting Floor Mould Area
Torque Wrench to check CNM assembly 2 pcs Casting Floor Mould Area Nominal torque 40Nm
Hand Torches/Lamps 4 pcs Casting Floor Mould Area
Crow Bars 2 pcs Casting Floor Mould Area & Tundish Prep Area
General Hand Tools, Spanners, Sockets, Hammers etc 1 set Casting Floor
Samplers 200 pcs Casting Floor
Thermocouples 200 pcs Casting Floor
Tundish Insulation Powder 1000 kgs Casting Floor
Tool Locker 1 Casting Floor
Shackles, chains and strops Casting Floor Lifting Moulds, launders etc
Conseal Assemblies 100 pcs Intermediate Floor If specified
Racks to Store Spray Risers Intermediate Floor
Work Bench with Vice 2 pcs Tundish CNM Area & Casting Floor
Well Block Setting Tool 1 per Strand
Upper Nozzle Setting Tool 1 per Strand
Emergency Torch Cutters 2 pcs Run Out Roller Table after TCM For Cutting Billets in event of TCM failure

C.4619/401 Chapter 6 Rev0

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Performance Guarantee Tests

Equipment / Material Location Comments

Burning Gun Billet Yard
20m Tape Measure Billet Yard
Vernier Calipers Laboratory For section Measurement
Mechanical Hack Saw / Band Saw Laboratory Workshop To cut sample in preperation for Milling
Milling Machine Laboratory Workshop Sample surface Preparation
Macro Etch Facilities Laboratory Macro Etch if Required- Refer to ASTM E340
Fume Cupboard Laboratory Macro Etch if Required- Refer to ASTM E340
Hot Plate Laboratory Macro Etch if Required- Refer to ASTM E340
Laboratory Glassware eg Beakers, Measuring Cylinders Laboratory Macro Etch if Required- Refer to ASTM E340
Dark Room Laboratory Sulphur Print if Required- Refer to ASTM E1140
Print Drier Laboratory Sulphur Print if Required- Refer to ASTM E1140
Photographic Paper Laboratory Sulphur Print if Required- Refer to ASTM E1140
Fixer Laboratory Sulphur Print if Required- Refer to ASTM E1140
Trays Laboratory Sulphur Print if Required- Refer to ASTM E1140
Tongs Laboratory Sulphur Print if Required- Refer to ASTM E1140
Squeegee Laboratory Sulphur Print if Required- Refer to ASTM E1140
Dark Room Light Laboratory Sulphur Print if Required- Refer to ASTM E1140
Laboratory Glassware eg Beakers, Measuring Cylinders Laboratory Sulphur Print if Required- Refer to ASTM E1140
Clock Laboratory Sulphur Print if Required- Refer to ASTM E1140
Chemical Storage Cabinets Laboratory If required

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ANNEX 3 Machine Protection
Areas particularly vulnerable to liquid metal splashes and ingress and requiring protection
are as follows, along with typical protection solutions used on other sites.
1) Ladle Turret and Mould Canopy

C.4619/401 Chapter 6 Rev0

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 2) Casting Floor Support Columns

3) Spray Chamber

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IVACO Page 9 of 11 February 2014
C.4619/401 Chapter 6 Rev0
IVACO Page 10 of 11 February 2014
5. STARTUP CURVE (REQUIRED TO BE FINALISED)
CCM Start Up Curve Ivaco C.4619/401
Average Heat Size 68 t
Planned Heats Actual Heats
Percentage of Planned Planned Actual Actual
Section Total Section
Nominal Weekly Total Cummulative Cummulative Cummulative Cummulative
160sq Heats 160sq
Production Heats Tonnes Heats Tonnes
Day 1 0 0 0
Day 2 0 0 0
Day 3 0 0 0
Day 4 0 0 0
Day 5 0 0 0
Day 6 0 0 0
Day 7 0 0 0 Week 1 0 0 0 0
Week 2 0 0 0 Week 2 0 0 0 0
Week 3 0 0 0 Week 3 0 0 0 0
Week 4 0 0 0 Week 4 0 0 0 0
Week 5 0 0 0 Week 5 0 0 0 0
Week 6 0 0 0 Week 6 0 0 0 0
Week 7 0 0 0 Week 7 0 0 0 0
Week 8 0 0 0 Week 8 0 0 0 0
Week 9 0 0 0 Week 9 0 0 0 0
Week 10 0 0 0 Week 10 0 0 0 0
Week 11 0 0 0 Week 11 0 0 0 0
Week 12 0 0 0 Week 12 0 0 0 0

Start Up Curve
100
Cummulative Production

140 1

90
140000
Section160sq
0.9
Total Heats
120 80
Percentage of Nominal
Weekly Production 120000 0.8

70
100
0.7

100000
Planned
Percentage of Nominal Ouput

60
Cummulative
Tonnes
0.6
80
Actual
Heats

50 80 000
Cummulative
Tonnes

Tonnes

Heats
0.5

Planned
Cummulative Heats
60 40
60 000 0.4
Actual
Cummulative Heats

30
0.3
40
40 000

20
0.2

20
20 000
10 0.1

0 0 0 0
Day 1

Day 2

Day 3

Day 4

Day 5

Day 6

Day 7

Week 2

Week 3

Week 4

Week 5

Week 6

Week 7

Week 8

Week 9

Week 10

Week 11

Week 12

1 2 3 4 5 6 7 8 9 10 11 12

Week

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LADLE TURRET OPERATION FD111, 112

Customer Concast
Representative Representative

CHECKS DATE COMMENTS

General
• Ensure all “System Ready “ requirements are understood, and how to obtain
is known.
• Check “Hydraulic Ready”, and how to obtain
• Check Lamp test.

Rotation in Manual mode

• Perform from LCB both CW and CCW.
• Check this is only possible with selector in Manual
• Check interlock with turret arm raised/lower position. Should only rotate if
both arms are up.
• Check speed of rotation in fast and slow in both directions. Should be smooth
to avoid steel spillage or stress on turret
• Check acceleration/deceleration is OK. Check “Arm in Casting Position”
lamps are lit correctly in all modes of operation.

Rotation in Automatic mode

• Check interlock with turret arm raised/lower position.
• Check this is only possible with Control Mode selector in Auto
• Check speed of rotation, acceleration/deceleration. Should be smooth to
avoid steel spillage or stress on turret
• Check ladle arms automatically stop in correct position.
• Check ladle arms stop when "auto Rotation Stop" button is pressed

CHECKLIST_001.doc Page 1
LADLE TURRET OPERATION FD111, 112

CHECKS DATE COMMENTS

Emergency Rotation by Electric Motor
• Initiate Emergency rotation from both the Main Emergency mushroom and
the Emergency pushbutton on the LCB.
• Check this can be done with the arms in the up and down position.
• Check this can be done with the Control Mode selector in all positions (Off,
Auto or manual )
• Check that rotation ends with ladle in emergency position.

Emergency Rotation By Pneumatic Drive

• Ensure that the operation of the Pneumatic motor is understood. Check that
when the pneumatic motor is activated, the electric system is deactivated.
• Check the rotation speed. Ensure the procedure for stopping the rotation is
understood. (Manual positioning of ladle in Emergency position).

Safety
• Check clearance of handrails etc, and possible danger areas for operators.
• Check horn sound during all rotations (Auto, Manual and Emergency).

Integrated with Ladle, Tundish and Tundish Car

Ladle lifting lowering
• Arm in Casting position should not be able to be lowered if tundish is not
lowered below intermediate position. Check this interlock is present and safe
clearance is available.
• Check for safety issues with ladle and tundish in place, operator access the
slide gate connections, access to other functions (tundish powder addition,
sampling etc ).

CHECKLIST_001.doc Page 2
LADLE WEIGHING SYSTEM FD114

Ccustomer Concast
Representative Representative

CHECKS DATE COMMENTS

• Check output of Ladle weighing system on scoreboard
• Check indication on VDU
• Check system of taring, (PLC controlled tare weight of each ladle in VDU).
• Check ladle lid tare adjustment system is available.

CHECKLIST_002.doc Page 1
TUNDISH PREHEAT STATION FD 152

Customer Concast
Representative Representative

CHECKS DATE COMMENTS

• Understand the controls of the preheat station control panel
• Be able to program the automatic heating cycles according to refractory
suppliers recommendations
• Check manual up and down movement.
• Check ignition of burners.

Integrated with Tundish

• Check alignment of burners with holes in tundish lid.
• Check temperature rise at full power of burners. ( degrees per minute )
• Check temperature curve relative to programmed curve

CHECKLIST_003.doc Page 1
TUNDISH CAR FD 131, 132

Customer Concast
Representative Representative

CHECKS DATE COMMENTS

• Run the tundish cars in manual mode at slow and fast speed. Ensure the limit
switches function properly (slow down and stop) at the ends of the track.
• Check that each tundish car cannot move out of the preheating position if the
burners are not fully up.
• Ensure that fine adjustment is possible (inching) important for SEN/ nozzle
alignment.
• Check that accelerations and decelerations are smooth, and changes of
direction are possible and smooth.
• With the car in cast position, check that the lowering speed is slow, and
position of stopping is controllable, (important for SEN centring / immersion
depth.)
• Ensure there are no safety problems/collisions etc for lift/lower at all positions
along the track.
• Check that each tundish car cannot move when the other one is out of the
preheating position (interlock). Check that the “By-pass” button on the TCB
overrides this interlock.
• Check the anti-collision limit switch on tundish car 1, by engaging it manually
during its travel.
• Move the tundish in the casting direction with the hydraulic hand pumps
several times backwards and forwards. Check for leaks.

Emergency Operation
• Check the emergency operation from the Emergency pushbutton.
• Check the position in which the tundish car stops.
• With emergency slidegate cylinders attached and in Submerged casting
mode, check the cylinders actuate when the tundish Emergency button is
pressed.

CHECKLIST_005.doc Page 1
CASTING FLOOR GENERAL

Customer Concast
Representative Representative

CHECKS DATE COMMENTS

• Check that all necessary tools are available and positioned for easy access
(only operational tools are included, maintenance tools should be arranged
separately );
• Open/ CNM . Small lancing pipes, shovels, oxy lancing equipment,
copper plugs, steel plugs, 2 centring tools for aligning outer strands with
moulds, alignment tools for checking upper and lower nozzle alignment,
starter disc for putting in tundish before preheating if not installed in TD prep
area, graphite spray, torque wrench, spare metering nozzle of correct size,
family, squirt can for auxiliary oil, slag fishing rod ( 4 – 6mm )n nozzle
handling tools ( insertion and removal)
• Stopper .Spanner in case stopper need retightening, manual feeding
trays for powder for start up or in case of failure of auto feeder. Powder
pusher. Powder feeder parts ( tubes etc)
• General . Starter pieces ( if used ), ladle lance pipes, refractory
blanket for general protection, cutting torches, compressed air for
cleaning/drying; mop for cleaning moulds, general tools such as spanners,
hammers, crow bar, good lights for mould inspection etc.
• Check position of spill box and tundish, is it safe in case of tundish overflow
emergency? Can it be removed? Ensure that the spill box is empty and
especially that there is no water in it (danger of explosions).
• Check accessibility of fire extinguishers, type of extinguishers, proper
brickwork protection around columns, heat protection for cables and hoses,
safety equipment (eye wash etc)
• Check all communications are working, particularly from control room to
casting area.

CHECKLIST_008.doc Page 1
MOULD LEVEL CONTROL FD233

Operator Responsible Concast

Representative

CHECKS DATE COMMENTS

• Check the access to, and the operation of the shutter for the mould level
control source.
• During the tundish transport cycle, determine the optimum time to open the
sources, not too early (safety issue), not too late, risk of delaying the
transport, or safety issue with moving car.
• Understand the procedure for calibration of the mould level control with the
steel block. Calibrate.
• Check the mould level range. Place to steel block at set distances down the
mould (measured from the top of Cu tube) and from VDU read of the % level.
Plot graph of mm vs % for all strands, compare with each other and with
drawing.
• Check empty calibration procedure.

CHECKLIST_011.doc Page 1
MOULD OIL SYSTEM FD213

Customer Concast
Representative Representative

CHECKS DATE COMMENTS

• Check that the temperature control system is OK, and where to observe the
temperature (bar graph) and level. Understand the VDU page for oil
lubrication.
• With the MOP in “Prepare Mode” start the oil pumps by switching to “Oil” and
“Manual”. Check for even distribution of oil around the mould, and look at the
flow rate with different settings on the potentiometer. Determine at what point
the potentiometer sets the flow to zero.
• Calibrate each mould oil supply. Remove the mould cover and remove the oil
supply pipe from the distributor. Set the potentiometer to 10%, 20% etc up to
100%. Collect the oil in a measuring vessel for a set time (2 minutes) and plot
the ml/minute for each mould. If there are significant differences report.

CHECKLIST_012.doc Page 1
CASTING FLOOR GENERAL

Customer Concast
Representative Representative

CHECKS DATE COMMENTS

• Check that all necessary tools are available and positioned for easy access
(only operational tools are included, maintenance tools should be arranged
separately );
• Open/ CNM . Small lancing pipes, shovels, oxy lancing equipment,
copper plugs, steel plugs, 2 centring tools for aligning outer strands with
moulds, alignment tools for checking upper and lower nozzle alignment,
starter disc for putting in tundish before preheating if not installed in TD prep
area, graphite spray, torque wrench, spare metering nozzle of correct size,
family, squirt can for auxiliary oil, slag fishing rod ( 4 – 6mm )n nozzle
handling tools ( insertion and removal)
• Stopper .Spanner in case stopper need retightening, manual feeding
trays for powder for start up or in case of failure of auto feeder. Powder
pusher. Powder feeder parts ( tubes etc)
• General . Starter pieces ( if used ), ladle lance pipes, refractory
blanket for general protection, cutting torches, compressed air for
cleaning/drying; mop for cleaning moulds, general tools such as spanners,
hammers, crow bar, good lights for mould inspection etc.
• Check position of spill box and tundish, is it safe in case of tundish overflow
emergency? Can it be removed? Ensure that the spill box is empty and
especially that there is no water in it (danger of explosions).
• Check accessibility of fire extinguishers, type of extinguishers, proper
brickwork protection around columns, heat protection for cables and hoses,
safety equipment (eye wash etc)
• Check all communications are working, particularly from control room to
casting area.

CHECKLIST_008.doc Page 1
MOULD COOLING WATER AND EMERGENCY SYSTEM FD511, 514

Customer Concast
Representative Representative

CHECKS DATE COMMENTS

• Set mould water flow at the VDU to the setpoint flow in the casting
parameters. Check the flow meters and pressure gauges at the valve stand.
The outlet pressure should be around 2.5 bar.
• Check visually from below the mould (spray chamber) for any obvious leaks
• Understand the VDU control system. Set different flows in Auto and Semi
auto and in Manual mode
• Check that the temperature measuring instruments are working (inlet & outlet
should be the same)
• Reduce the mould water flows in semi-auto or auto below the minimum limit.
Check the emergency water arrives at minimum limit. Time the emergency
water supply, check the flow rate (l/min). Does it last long enough the stop
casting? Check the audible alarm on the casting floor.

CHECKLIST_014.doc Page 1
MOULD OSCILLATION FD211

Customer Concast
Representative Representative

CHECKS DATE COMMENTS

• The mould oscillation can be tested using the pushbuttons start and stop
when the MOP is in Prepare mode. The withdrawal will run at a fixed slow
frequency.
• Measure the stroke of the oscillation using a dial gauge or similar.
• Organise the tools required for a stroke change and practice stroke change.
• Understand the control page for oscillation in the VDU. With the
necessary preconditions, (MOP in casting mode) check the automatic
oscillation reacts to changes in speed (measure the frequency at
different speeds) .

CHECKLIST_015.doc Page 1
MEMS and FEMS FD271, 273

Customer Concast
Representative Representative

CHECKS DATE COMMENTS

• Understand the VDU page for MEMS and FEMS
• Understand the cooling water systems, how to control, fill, etc.
• Determine how to turn on the stirrers manually, and how to check if the
stirrers are working (both from instrumentation and by placing a steel bar in
the mould (MEMS only).
• Automatic starting of the stirrers during casting simulation is introduced later.

CHECKLIST_016.doc Page 1
DUMMY BAR FD291

Customer Concast
Representative Representative

CHECKS DATE COMMENTS

• Understand the discharge control desk MCD. Understand necessary
conditions for control of dummy bar (“ready to insert”). Operate all the
functions individually, ( rolls up/down, tilter up/down, drive in/out)
• After checking for safety (men in spray chamber), fitting wooden pin, and
with “Ready to Insert” on the VDU, initiate automatic insertion cycle. Dummy
bar travels to zone 2a. Follow dummy bar through spray chamber and watch
for possible collisions and safety problems.
• Fit Conseal onto head. Check that the wooden pin is still in proper position
and unbroken.
• Take control of dummy bar with HCB and drive into mould. Measure insertion
depth from casting floor. (Should be inserted 50-70 mm inside mould)..
Record the position of the dummy bar when properly inserted.
• Make an automatic retraction from the mould.
• Make a manual insertion of the Dummy bar to zone 2a.
• This requires Dummy bar drive out, tilter down, drive in, lower withdrawal
drive roll, drive in. Check for acceptable visibility from control room.
• Make manual extraction from zone 2.
• Understand the tracking system, how to reset the tracking, etc

CHECKLIST_017.doc Page 1
SPRAY COOLING FD512

Customer Concast
Representative Representative

CHECKS DATE COMMENTS

• Check the alignment of the nozzles using the dummy bar as a guide in 3
ways:
• Direction of sprays (i.e. pointing perpendicular to face of dummy bar?)
• Distance of each nozzle from dummy bar (should be the same for every
nozzle on every side up and down the riser).
• Alignment of nozzle with assumed centre of billet (i.e. riser offset left or right)
• Although it is not normally done, it is possible to make a set of gauges to
assess the distance and position of the nozzles relative to the dummy bar
(but not the direction). Details of this can be provided if requested.
• With the water on, check visually the sprays zone by zone, strand by strand
for obvious leaks.
• Check the flow meters and pressure gauges give the same readings as the
VDU.
• From the VDU, check the secondary cooling conditions across the strands as
follows;
• Understand the places where filters can be blocked, and know how to clean
the filters.

CHECKLIST_019.doc Page 1
LEVEL 1 VDU

Operator Responsible Concast Representative

CHECKS DATE COMMENTS

Navigation
• Be familiar with the basic layout of the Level 1 screens, and how to navigate.
• Practice changing parameters on some key screens, e.g .secondary cooling
page.
• Practice making trends.

Recipe system
• Understand how the casting parameters are stored in the recipe system and
how to change.
• Understand how the steel grades are stored in the families.
• Transfer the casting parameters to the PLC.

CHECKLIST_020.doc Page 1
LEVEL 2 SYSTEM

Operator Responsible Concast Representative

CHECKS DATE COMMENTS

In the early part of commissioning the Level 2 system will be a secondary

function compared to Level 1. In cold commissioning it is necessary only to be
familiar with certain functions;

• Understand how the casting parameters are stored in the recipe system and
how to change.
• Understand how data is received from the steel shop ( e.g. next heat details)
• Understand how to look at casting data, and how to detect “out of limits” data.
• Understand how to produce reports
• Understand how to insert data, such as mould tube number.

CHECKLIST_021.doc Page 1
INTEGRATED TEST OF CASTING PREPARATION SEQUENCE (open casting without tundish)

Operator Responsible Concast Representative

CHECKS DATE COMMENTS

This test can be skipped if fully equipped tundish is available –
see next section

• Ensure “Ready to Insert” is available on VDU

• Insert Dummy Bar as described earlier.
• Open Radioactive sources.
• Check “Ready To Cast” screen, it may be necessary to bring in the tundish
car into position, or to simulate tundish car by occupying limit switch, or within
PLC.
• Obtain Ready to Cast with all systems functioning and available and
Automatic cast start selected.
• Simulate mould filling by closing gradually closing the shutter of the
radioactive source. As the signal reduces, the mould level increases. At the
20% level the withdrawal drive will start, and the automatic speed ramp will
be performed. The casting speed will attempt to keep the level at 70%, but
obviously the shutter position is actually controlling the level signal, not the
speed.
• Change over to manual control, and set the speed to normal casting value.
• Check the following:
• Oscillation starts when withdrawal starts
• Oil flow starts
• Spray water starts, particularly zone 1 must start not more than 2-3 seconds
from withdrawal starting, visual check. Check that water flow and oscillation is
controlled according to casting speed, and follows speed changes.
• MEMS starts approx 30 secs after withdrawal.
• FEMS starts after certain time ( when dummy bar has passed )
• Disconnection sequence should occur at the correct time, and should operate
properly at full range of casting speeds (e.g. 1m/min to 5m/min )
• Check pressures change at correct time.
• Check dummy bar parks in parking position

CHECKLIST_022.doc Page 1
INTEGRATED TEST OF CASTING PREPARATION SEQUENCE (open casting without tundish)

CHECKS DATE COMMENTS

• Check all systems are ok (mould cooling water etc).
• At end of test, lower mould level signal below 20% level with shutter.
• Drive should carry on for several seconds, then stop.
• Switch MOP selector to Runout, then push Runout button.
• Check that secondary cooling water, mould oil etc follows correct runout
procedure
• Test related to emergency situations (break-outs):
• If the level drops suddenly below 20% (open shutter) the CNM should fire. .
(This function may not be enabled until after the disconnection)
• If the level rises above 95% (close shutter) the CNM should fire. (This
function may not be enabled until after the disconnection)
• Check that the bellows lowers when the CNM operates.

CHECKLIST_022.doc Page 2
INTEGRATED TEST OF CASTING SEQUENCE (stopper casting with tundish)

C. S. Huachipato Concast
Representative Representative

CHECKS DATE COMMENTS

• With a fully equipped tundish (stopper boxes, emergency slidegate inc.
hydraulics), make a simulated start of cast.
• With “Ready to Cast”, make auto mould filling. Do not close the shutter, and
wait until the alarm comes (60 seconds?)
• Close the shutter to simulate mould level rising. The stopper should react to
keep the level at the setpoint.
• Simulate breakout by opening the shutter quickly, check for alarm and
observe stopper closing. (This function may not be active for a certain time)
• Simulate overflow by closing the shutter.
• Test the Emergency close function (close emergency knife by pressing the
pushbutton on the MOP).

CHECKLIST_024.doc Page 1
FULL INTEGRATED COLD TEST (OPEN CASTING)

Customer Concast Representative DATE

Representative

OPERATOR ACTION COMMENTS

PREPARATION PHASE - 2-3 hours before ladle arrival

3 men on casting floor, 1 in the pulpit

Pulpit • Ensure that power and services are available.

• Bring fully prepared refractory lined tundish.
• Check the alignment of the tundish nozzles
• Move the tundish to casting position.
Foreman • Adjust position of tundish in the car over the moulds (in casting
Operator 1 direction), centring the nozzles. Use the hydraulic cylinders for this.
Operator 2 • Return the tundish to the preheat position.
• Put nozzle preheat burners in position.
• Preheat (simulate) preheating of the tundish.
• 45-60 minutes before expected ladle arrival, ignite (simulate) nozzle
preheat burners

START CASTING - 30 minutes before ladle arrival

5 men on casting floor, 1 in pulpit, 1 at ground level

Operators 2-4 • Insert wooden pin into the dummy bars using the local DBRCP
pendant
Operators 1-3 • Clean and pre-lubricate the moulds.
Pulpit • Insert dummy bars (automatic cycle) – MOP selector must be in
DUMMY BAR position – The dummy bar will stop below the mould
Operators 2-4 • Dry the dummy bar head (use torches), put the Conseal on, leave
cooling chamber and close the doors.
Operators 1-3 • Select PREPARE on MOP, insert the dummy bar into mould. Check
that the Conseal enters smoothly in the mould and is not torn or

CHECKLIST_025.doc Page 1
FULL INTEGRATED COLD TEST (OPEN CASTING)

damaged (in this case, replace Conseal and repeat). Use the
aligning tool to introduce the dummy bar into mould exactly at the
specified level. Leave MOP in PREPARE after completing this
operation.
Pulpit, foreman • Check READY TO CAST conditions on VDU
All • All operational personnel put on necessary protection clothes.
Foreman • Open radioactive sources
(Crane) • Place ladle onto ladle turret arm at loading position.
Operators 1-2-3 • Connect hydraulic cylinder and air to CNM as soon as the ladle has
left the LF (Foreman to give proper timing).
Foreman • Swing ladle into casting position (ladle arm must be UP)
• Operator 4 connects hydraulic cylinder to ladle slide gate
Operator 4
Ladleman • Ladleman helps with slide gate pendant
• Operator 4 reaches the casting floor immediately after this operation
Foreman • Gives the instruction to switch tundish preheater off
Operator 3 • Switch tundish preheater off and lift preheater arm
Operator 1 • Switch nozzle preheaters off
Foreman • Drive tundish to casting position
• Align tundish with moulds
Foreman
Operator 1 • Lower tundish
• Lower turret arm
Operators 2-3 • Put ladle shroud in position
• For each strand, perform following actions:
• Select CASTING on MOP
A strand, which has no ready to cast, does not
• CHECK THAT THE STRAND IS READY TO CAST (LIGHT
prevent casting on the other strands. For
STEADY ON – a blinking light gives NO ready to cast) – REPORT
safety reasons, the strand nozzle must be
Foreman to Foreman if the strand is not ready
plugged. Leave MOP on CASTING and leave
Operator 1 • Check that the level indicator (red bar) on MOP displays ZERO (= dummy bar in the mould.
radioactive source is open) The strand can be opened later if the problem
• Push CALIBRATE EMPTY button on MOP to calibrate the level has been solved.
control system
• Push the AUTO button of the mould level control (green light

CHECKLIST_025.doc Page 2
FULL INTEGRATED COLD TEST (OPEN CASTING)

flashes)
• Select OIL and AUTO (for the simulation, selector can remain in
MANUAL) – adjust oil potentiometer on the specified level
• Must check the correct execution of the procedure described under
Foreman the previous point, especially the ready to cast on all strands, then
give the order to open the ladle
Operator 4 • Position himself ready to lance open the ladle
Ladleman • Opens ladle
Operators 2-3-4 • Simulate oxygen lancing
Ladleman • Simulates quick filling of tundish.
Operators 2-4 • Add powder to tundish.
• Place themselves in front of the strands
Operators 1-2-
3-4 • Operators 1-2 are responsible for strands 1-2-3, operators 3-4 for the
strands 4-5
• After five minute (tundish fill) simulate opening with oxy-lance pipe as • Strand opening sequence: 2 and 4, then 1
follows: and 5, last 3
Operators 1-2- • Operator 1: opens Strand 2 and Operator 2 helps with burner (to • Foreman gives the order to open the strands
3-4 ignite oxylances) and keep ready to plug the nozzle if necessary • Foreman (or Concast during commissioning)
• Operator 3 opens Strand 4 approximately at the same moment and gives the order to plug a strand when
Operator4 keeps ready to plug the nozzle needed

(Concast) • Simulate filling of the mould using the source shutter, manual will be
required to control the speed.
Operators 1-2-
3-4 • Start remaining strands in sequence: 1 and 5, then 3.

Pulpit, Foreman • Check disconnection on all strands. Check parking of the dummy
bars.
Three operators are required on the casting
• One operator must observe disconnection and first cut of all strands. floor until the head cuts has been completed
Operators 1-2-3 The others are ready to plug and stop any strand if disconnection Later, 2 operators (or operator and foreman) on
fails. casting floor are enough
Operator 4 • Go downstairs, ready to help the ground floor operator with the torch
in case of missed cuts

CHECKLIST_025.doc Page 3
FULL INTEGRATED COLD TEST (OPEN CASTING)

• Check water values:

- mould cooling
Pulpit, Foreman
- secondary cooling
• Check casting speed.
Operators 1-2-3 • Check mould oil flow (after checking turn off).
• Simulate tundish temperature and oxygen measurement and sample
taking.
Additional personnel is required to rotate the
• Simulate first cut of front crop with torch cutting units, and subsequent upper straightening roll manually for the
cutting of billets. simulation
Pulpit • Simulate discharge and removal of billets
Operators 1-2-3 • Simulate a breakout on one strand and plug the relevant nozzle as
fast as possible.
Ladleman • Simulate empty ladle by closing slide gate.
Ladleman • Disconnect slide gate hydraulic cylinder
Operator 1-2 • Remove ladle shroud and place it in parking position
• Raise turret arm
Foreman
• Swing ladle over to loading position.
• Remove ladle by ladle crane.
Foreman
Operators 1-2-3 • Simulate end of casting from tundish by closing nozzles one by one.
(Concast) • Lower level in each strand with shutter.
• Perform runout sequence:
• when the steel level in the mould drops, the withdrawal machine
will stop and RUNOUT button on MOP will flash – wait until this
Foreman happens
Operators 1–2- • Switch MOP selector to RUNOUT
3
• Press the RUNOUT illuminated button. The lamp in the button will
then remain steady, and the withdrawal machine will start with a
pre-selected speed. Do not move the MOP selector until the
runout sequence is terminated (last cut done)
• Lift tundish car
Foreman
• Remove tundish car from casting position.

CHECKLIST_025.doc Page 4
FULL INTEGRATED COLD TEST (OPEN CASTING)

• Bring back the tundish to casting position, start the strands again and
All simulate ladle and tundish removal in emergency. Memorise the
EMERGENCY CLEAR procedure and the escape routes from the
casting floor.

CHECKLIST_025.doc Page 5
MOULD PREPARATION AREA

Customer Concast
Representative Representative

CHECKS DATE COMMENTS

• This area is not covered in detail, however the setting of the foot rolls is
included as it is an important operational.
• Foot roll alignment should be checked using the provided gauge.
• Understand how the foot rolls are released, how the position is adjusted, and
the rolls fixed in place.
• The foot rolls should set 0.2 mm inside the pass line.

CHECKLIST_026.doc Page 1
TUNDISH PREPARATION AREA

Customer Concast
Representative Representative

CHECKS DATE COMMENTS

• This area is not covered in detail, as the refractory lining of the tundish is not
the responsibility of the Operational Personnel. However the setting of the
stopper is included as it is an important operational issue and may be
checked on the casting floor.
• Check the verticality of the stopper rod, and the proper seating of the rod in
the SEN seat.
• With the hand wheel, check the up and down movement is free (no
mechanical interference) and the stopper seats correctly.
• The top nut tightness can be checked

CHECKLIST_027.doc Page 1