Self condition monitoring of continuous casting machines

This report contains the joint contributions of the collaborative ECSC project between Corus UK Ltd, Teesside Technology Centre (Co-ordinator) and Corus NL bv, IJmuiden Technology Centre, Sidenor I+D, IRSID, Aceralia and Labein. The aim of this project has been to develop new and existing techniques of monitoring the condition of continuous casting machines on both an on-line and regular off-line basis, thus giving reliable cost-effective methods to provide an improved maintenance programme, as well as a quality alarm for billet, bloom and slab casters. Work has been carried out on monitoring of critical areas of casters, development of off-line and on-line monitoring techniques, analysis and interpretation of data. Corus UK Ltd has developed methods for improved interpretation of strand condition monitor data, and both on-line and off-line monitoring techniques for mould oscillation and in the strand guide area for monitoring strand support roll geometry and condition. Corus NL by has developed analysis techniques using performance indicators to study trends in surface and internal quality data and indicate machine condition. A feasibility study was carried out on in-chain strand condition monitoring together with the application of "fingerprinting" to interpret spray condition from strand condition monitor spray detector data. Sidenor has studied means of assessing billet caster operation and condition from measurement and analysis of abnormal transitory values related to mould oscillation, heat flux, powder performance and withdrawal units, including analysis of parameters affecting breakouts. IRSID has estimated strand sump position by measurement of solidified shell thickness on low carbon steel grades via the nail shooting method and comparison with modelled data in both pilot plant and on-plant trials. Aceralia/Labein have installed and assessed in-chain roll gap strand condition monitors. They have also developed systems for on-line monitoring and control of strand cooling, an automatic system to monitor and control argon, and strand temperature measurement using laser pyrometers. Improvement of a model using monitored data, based on a quality algorithm, has also been made. All the objectives of this collaborative project have been achieved and a wide range of techniques for off-line and on-line monitoring of continuous casting machines have been developed.