Ladle Turret

PROJECT REPORT FUNCTIONING OF LADLE TURRET IN CONTINUOUS CASTING SHOP, SMS II

A Project Project report report submitted submitted in partial partial fulfillment fulfillment of the Requirem Requirements ents for Management Development Development Program Program for MT MT (Tech) (Tech) Prepared By BRAHMANANDA REDDY SAGILI MT (TECH) EMP. EMP. NO. : 123140, SMS II (CCD)

Under the esteemed Guidance of SRI K.V. SIVAPRASAD AGM (CCD-MECH), SMS II

TRAINING AND DEVELOPMENT CENTRE VISAKHAPATNAM STEEL PLANT VISAKHAPATNAM.

1

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CERTIFICATE This is to certify that the Project titled “FUNCTIONING OF LADLE TURRET IN CONTINUOUS CASTING SHOP SMS

II”

is fulfillment as a part of training

program imparted by RINL/VSP during the year 2013 is a bonafide work carried on by BRAHMANANDA BRAHMANANDA REDDY SAGILI,

Emp.No.123140, Emp.No.12314 0, MANAGEMENT TRAINEE

(TECHNICAL), SMS-II under my guidance.

K.V. SIVAPRASAD AGM CCD (MECH) SMS II VISAKHAPATNAM Date:













ACKNOWLEDGEMENT I acknowledge my profound profound gratitude & thanks to Sri K.V.SIVAPRASAD, AGM, CCD (MECHANICAL) for advising me to take up this project project work on “FUCTIONING OF LADLE TURRET IN CONTINUOUS CASTING SHOP SMS II ”

under his able guidance & support extended to prepare this project report. I express express my deep sense of gratitude to Sri K.V.SIVAPRASAD, AGM (CCD -MECHANICAL) for his valuable advice and help extended to me in preparing preparing this project project in spite of his busy office schedule. schedule. BRAHMANANDA REDDY SAGILI MT (T) Emp.No.123140













INDEX

INTRODUCTIO N TO CCD, SMS II 1. INTRODUCTION

5-8

2. LADLE TURRET FUNCTIONS

9 - 11

3. LADLE TURRET TECHNICAL SPECIFICATIONS

12 – 13 13

4. SYSTEM EQUIPMENTS

13 - 16

5. LADLE TURRET DRIVE UNIT 6. LADLE TURRET BEARING FUNCTIONING

7. ARM LIFTING CYLINDER 8. TURRET LOCKING CYLINDER

17 - 18 19 20 - 21 22

9. ROTARY JOINT

23 - 24

10. EMERGENCY ROTATION

24 - 25

MANIPULATOR 11. LADLE COVER MANIPULATOR

12. LADLE TURRET MAJOR ALARM SIGNALS 13. DIFFERENCES BETWEEN LADLE TURRET OF SMS 2 & SMS 1

26 26 - 27 28













1. INTRODUCTION TO CONTINUOUS CONTINUOUS CASTING MACHINE, MACHINE, SMS II The expansion phase of Vizag Steel from present 3.3 MT to 6.3 MT boasts a new SMS unit namely SMS II which consists of 3 Continuous Casting machines against the 6 machines of the present production phase all of which are still yet to be commissioned soon. The 3 machines are supplied and erected by Danieli Centromet, Italy. A photo of one of the casting machines namely CCM#1 is shown below in fig: 1.1.The casting machines in the expansion phase has 6 strands instead of the available 4 strands in SMS I. The machine radius is 10 m instead of the 12 m radius of all the machines in SMS I. The products formed are billets and rounds in SMS II cater instead of the blooms formed in SMS I caster. CCM#1 produces billets of size 150X150 and 200X200 and rounds of 220,280 and 350 mm diameters. Similarly CCM#2 and 3 produces only billets of sizes 150X150 and 200X200.

Fig : 1.1: View of the Casting machine (CCM#1) while casting













Given below are the main characteristic of the Casting Machine in SMS II:

Machine type

3BLC1006

Number of strands

6

Machine radius

10

m

Unbending radii

19

m

Strand distance

1,5mm

Outfit sections

Squares of 150x150 and 200x200 and rounds of Ф220,Ф280

and Ф350

Ladle capacity

160 t max -150 t nominal

Ladle support

Butterfly fork type, 2 independent lifting and lowering system,

Load capacity

250 t

Ladle cover manipulator

Hydraulic type

Ladle shroud manipulator

Pneumatic type

Tap to tap time

50 min average

Tundish car

Cantilever with electro-mechanical drive

Tundish capacity

35 t

Mould tube

Multitaper, Curved 780 mm long for Ф 220- Ф 280- 350mm Multitaper, Curved 1000 mm long for 150x150 mm

Mould lubrication

Oil and Powder for 150x150 mm Powder for round sections(Closed Casting)

Tundish to mould flow control

Slide gates for rounds















Mould level control

Radioactive

Electromagnetic stirrer

Mould EMS external + Final EMS

Oscillating unit

Hydraulic actuated

Dummy bar

rigid

Containment Containment for each strand

2 rows of foot rolls for round sections 3 rows of foot rolls for 150x150 mm and 200x200 mm

Secondary cooling system

First zone (foot rollers): water cooling Zone 2 mist cooling Zone 3 mist cooling Zone 4 mist cooling

Straightening

Modular type (5 module per strand) with shaped rolls

Max metallurgical length

24.4 m approx

Withdrawal speed range

0.25-4 m/min

Billet cutting

Oxy cutting

Torch Cutting length

6-12 m for billets, 4-6.5mfor rounds

Discharge system

Liftable transfer system, turnover cooling bed













2. LADLE TURRET FUNCTIONS

Turret is designed to support the steel ladles and rotate them from the charging side, where the overhead crane delivers the ladle, to the casting position, just in above of the tundish. Turret is fixed with one rigid ladle support arm, designed in a “H” shape shape to accept ladles delivered perpendicular to the caster axis. The arm rotates on a central bearing. Compressed air, inert gas and electrical signals are conveyed to the arm through a rotary joint installed in the supporting base, this allows a continuous revolving of the turret (360°).Turret is equipped with a sturdy base frame, rigidity of the structure allows for negligible deflection of the arm. Main components of the Ladle Turret are: a) Supporting Structure, made of welded steel sections, anchored via flange and anchoring bolts to a reinforced concrete base. b) Central steel body, designed to accommodate the thrust bearing and the armdriving unit. Bearing, three – three – row row cylindrical roller type. c) Rotating joint to distribute all utilities. d) “H” shape ladle arm, made of welded steel sections and and dimensioned to handle ladle of the rated capacity. At each end of the arm, a supporting fork with two ladle holding saddles is installed. Each saddle is lift able via a hydraulic cylinder. A total of four cylinders are supplied. Saddles are suitable for installation of weighing cells. e) AC motor driving unit equipped with inverter, encoder and brake. The variable speed motor guarantees a progressive acceleration and deceleration without any jerking of the arm motion. Motor is coupled with a gearbox and motion is transmitted through a rack and pinion Gear system. f) Pneumatic motor for emergency drive, installed on the opposite side of the main motor and connected connected through the same shaft of the gearbox, gearbox, operation is switched automatically in case of power failure.













LADLE TURRET













Fig : LADLE TURRET AT CCD SMS-II













3. LADLE TURRET TECHNICAL SPECIFICATIONS: SPECIFICATIONS:

Main Characteristics: • Shape One Arm

: “H“ Type

• Radius

: 5500 mm

• Full Ladle weight weight max.

: 250 Ton

• Liquid Steel weight.

: 150/160 Ton

• Rotation Motor (AC type)

: 1500 rpm

• Turret Rotation Speed

: 1.0 rpm

• Direction of Rotation

: Bi – Bi – Directional Directional

• Rotation Motor (emergency)

: Pneumatic Motor

• Turret Rotation Emergency Speed

: 0.5 rpm

Weighing cells

• Number 4+4 • Type Compression • Total load capacity 250 Ton General data

• Type: “H” type • Ladle Ladle rotation radius: 5500 mm Dimensions

• Length with two ladle 15076 mm • Length without ladles 12684 mm • Width 5530 mm















Benefits:

Best utilization of the bridge crane, which is not engaged in supporting the ladle during casting. The shortening of the time necessary to the ladle change during the castings in sequence TRAINING CENTER Description:

1)

First machine of the continuous casting machine;

2)

Fixed basement with a housing for the base bearing for the arms rotation: the basement is fixed to the t he foundation

3) Supporting saddle provided with appropriate guiding guiding and reference devices to allow an easy charging of the ladle from the front; 4) Drive unit composed composed of a varying varying speed motor, a planetary gear box and pinion and equipped with pneumatic motor, mounted directly on the transmission, which ensures the emergency rotation in case of electric motor failure; 5) a rotating coupling allows the feeding of the mobile parts on the turr et; 6) The position of the turret is controlled by an installed encoder and limit switch. TRAINING CENTER 4. COMPOSITION AND DESCRIPTION













The arm rotation takes place by means of a driving unit composed of a varying speed motor, a planetary gear box and a pinion, a pneumatic disc brake with a cylinder and an emergency pneumatic motor (main motor broken or missing of feeding tension).The arm rotation speed and its stopping in perfect position are guaranteed by encoders and limit switches. The turret is dimensioned for supporting ladles with the following: 1 full ladle and an empty ladle; 2 full ladles; 1 full ladle and an empty arm (shock factor = 2). In every condition, apart from the charge, the turret ensures the correct arrest during the ladle/s rotation, respectively in the positions of casting, ladle drawing or emergency. By a bridge crane the ladle with the liquid steel ste el is drawn from the t he furnace zone and deposited on a fork of the turret arm .he arm rotates of 180°, it carries the ladle in a proper position for casting the steel into the tundish (distribution equipment), already positioned in correspondence with the lines. The interlocks to enable the rotation of turret are: General emergency stop not active Emergency rotation cycle reset













On each fork of the turret there is installed a system for the weighing of the ladle, composed of: 4 (two + two) load cells; Weight transmitters; One large display installed on the casting floor in the operative area. A rotating coupling (connected on the turret shaft) allows the feeding of the mobile parts on the turret such as bearing, gears, pin-joints with the following fluids: 

Grease.



Compressed air.



Inert gas

TRAINING CENTER 1. Compressed air (IA) system

The system feeds the pneumatic devices for the emergency rotation and the turret braking. If necessary, the air is filtered and lubricated for every group of appliances. The system consists of the following appliances: Loading boxes and cells cooling; Ladle turret brake (disk brake); Emergency rotation (pneumatic motor);













4. Grease centralized lubrication system

In the lift able ladle turning turret there are one centralized systems of grease it Supplies to the following points. Thrust bearing and pinion: 42 Arm pins: 12 Jib crane: 4 5. Ladle turret weighing system

On every turret arm, a weighing system is applied for the ladle weight measurement. 6. Electric systems

The turret's electric system includes the necessary equipment for the correct functioning of an electric component: in this particular case the electric motor for rotating the turret, electric collector for the weighing system, the solenoid valve for the pneumatic system and all the electric devices on the control panel.













5. LADLE TURRET DRIVE UNIT :















the electric motor which thanks to a spiral bevel gear 1:1, works on the output shaft double projection (one towards the pneumatic motor and the other one towards the planetary gear box).

Gearbox

• Quantity 1 • Type planetary with angular gear • Ratio 1:117 Pneumatic motor

• Quantity 1 (horizontal position) • Direction of rotation bi rotation bi – – directional directional













3) PLANETARY GEARS: the planetary gear axis is an integral part of the planetary carrier (output motion) and has the function to bring and connect the planetary gears by means of their axis. 6. BEARING FOR ROTATION













and tear of vertical rollers is measured by measuring the readings of dial gauge at different positions when the turret is moving.

7. ARM LIFTING CYLINDER • Quantity 1on each arm

• Type hydraulic • bore 600 mm • R od od 350 mm • stroke 670 mm • feeding from hydraulic central unit CH2. unit CH2. When the arm is lifting the hydraulic oil at high pressure will enter into the cylinder through P line. When the hydraulic oil enters into the cylinder it will exert pressure on the













Arm lifting cylinder has a four bar chain mechanism to lift and lower the arm. It consists c onsists of a cylinder and 3 links. The top end of the cylinder is fixed and the end of the r od is fixed to the arm link1. Link 2 is for supporting it is connected to arm from the fr ame of turret. Link 3 will joins the link 1 and 2. When the cylinder opens due to the relative motion transfer from cylinder rod to the link 1 arm will be lifted. The mechanism and arrangement of links is as shown in figure.

The load distribution of the turret will be in the following way. When a full ladle is kept on turret the t he load is acting vertically verticall y down words at the end of the link 1 and it is transferred to end of the rod. The load is balanced by the high pressure hydraulic oil which is applying pressure on the top of the rod. Some of the load is carried by the frame. From the frame the load is transmitted to the foundation. Some amount of load is acting on the gear and bearing system.













8. ARM LOCKING CYLINDER:

• Quantity 1 • Type hydraulic • bore 100 mm • Rod 70 mm • stroke 160 mm • feeding from hydraulic hydraulic central unit















9. THE ROTARY JOINT















LOCKING ELEMENT: It is constituted of a tempered bottom plate or simply by an

anchor pin clip.

The rotary joint contains 18 numbers of swivels for different purposes. 

4 swivels for ladle slide gate opening and closing of both the arms.



2 swivels for grease system. 4 swivels for lowering and lifting of arm 1 and arm 2.













The interlocks to enable the emergency rotation are: 

Brake is open (brake release valve is energized and signal from limit switch)

OTATION WITH THE PNEUMATIC DRIVE R OTATION

It is provided with an emergency rotation backup, which can be used in case of failure













11. LADLE COVER MANIPULATOR













12. LADLE TURRET MAJOR MAJOR ALARM SIGNALS TO START CASTING: CASTING:

1) Ladle turret emergency stop from LCS 1. 2) Drive not ready signal 3) Drive ready consent lost due to encoder faulty signal 4) Brake open time out 5) Compressed air pressure low-low indication















33) Recirculation pump3 tripped

Ladle Turret

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