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Technical Agreement For Syrian Profile Steel Project

Profiled Bar Production Line


Equipment Technical Agreement
Technology accessory 1

Technical

specification and parameter of


equipments
Profiled

bar

production

line

mechanical

equipment

technical plan and description


1. Name and purpose
1.1 Name: Annual 150000 tons of hot roll steel production line
1.1

Purpose:

the

continuous

casting

square

billet

of

100100,120120 and 50150 with the length of 3000 is heated by


furnace and rolled by roughing mill. Then the required products
will be made after rolled by 10 units of tandem mill units.
2. Brief introduction of production process chart
2.1 The process chart is as follows:
The

raw

material

(the

continuous

casting

billets)

will

be

transferred to the hot transporting roll table in heat condition


by the deportation chains from the continuous casting cold beds.
And then the hot billets will be transported to the feeding roll
table before the reheating furnace through the transporting roll
table and after the centering of the the centering roll table the
continuous casting billets will be sent to the reheating furnace
for heating.
1

Technical Agreement For Syrian Profile Steel Project

For the cold continuous casting billets from outside, they will be
hanged to the

feeding roll table before the reheating furnace

through the transporting roll table and after the centering of the
the centering roll table the continuous casting billets will be
sent to the reheating furnace for heating.

The

heating

furnace

heats

the

square

billet

to

the

temperature of 1150~1250C as required by the technology.

The heating furnace is pusher heating furnace. The material

feeding and discharging is one the ends.

The pusher will push the heated square billet on the

roller.

The conformity square billet goes through the former roller

and centered by guide. Then it comes into 550 rolling mill for
repeating milling.

When milling, there are different roller sequence for

different products. For 550 rolling mill, it is 5~7 sequence.


After cutting, it goes into roller for conveying and then comes
into 10 sets of rolling mill. The production of angle steel is
made by 11 sets of rolling mill. Among the 11 sets of rolling
mill, there is 1 roughing mill, 4 sets of intermediate mill and 6
sets of fine mill. The production of channel is made by 5~7 sets
of machine, in which 1 is roughing mill, 4 intermediate mill and 2
fine mill.

For 550 rolling mill, there is entrance guide and steel

plate in the front of machine. Also there is lifting platform on


the behind of machine, so as to ensure the free operation of
milling.
2

Technical Agreement For Syrian Profile Steel Project

Between roughing rolling and intermediate rolling, there is

a traceable head for mill.

The hot shearing is installed between roughing rolling mill

and intermediate mill. The hot shearing is used for cutting.

For fine mill, stand looper is installed in order to ensure

the micro-tension rolling.

Before entering the cold bed, the rolled profile bars need

to be sawed into two pieces first and then be sent to the cold
beds for cooling. After cooling, the straightening will be made.
And the straightened profile bars will be fixed-scale saw cut in
the cold sawing group with 11 cold saws. After this process the
profile bars will be detected and then bundled, weighed and
packed.

According

to

the

size,

determine

the

straightening

equipment for profile bar. For small size, 300 straightening


machine is used. For big size, 500 straightening machine is used.

3. Raw material and finished products parameter


3.1 Annual output
Angle steel 2.5~8#, channel steel 5~16#, flat steel 10~2010~40.
The total annual output of hot rolling is 150000T.
3.2 Raw material
Squire billet size:

100X100X3000

120X120X3000

Square billet size allowed tolerance:


Allowed tolerance of thickness

5.0mm

Allowed tolerance of width

5.0mm

Allowed tolerance of length

80mm
3

150X150X3000

Technical Agreement For Syrian Profile Steel Project

3.3 Finished products


Size and weight of finished products:
Angle steel

Angle
steel No.

2.5
3
3.5
4
4.5
5
6
7
8

Size
d

25
30
35
40
45
50
60
70
80

3
3
3.5
4
5
5
6
7
8

3.5
4.5
4.5
5
5
5.5
7
8
9

Cm2
Section
area
Cm2

Kg/m
Theoretic
quantity
Kg/m

1.432
1.749

1.124
1.373

M2/m
Outside
surface
area
M2/m
0.098
0.117

3.086
4.292
4.803

2.422
3.369
3.770

0.157
0.176
0.196

9.424
12.303

7.398
9.658

0.275
0.314

Product precision index:


Angle steel leg thickness tolerance (d): +/-0.45# angle steel
+/-0.6

5.6~9# angle steel

Angle steel leg length tolerance (b): +/-0.85# angle steel


1.2

5.6~9# angle steel


4

+/-

Technical Agreement For Syrian Profile Steel Project

Total length tolerance of angle steel: 8000

+50/0 .

>8000

+80/0
Channel steel

Model

5
6
6.5
8
10
12
14
16

Size
h

r1

50
60
65
80
100
120
140
160

37
30
42
45
50
55
60
65

5
6
6
6.5
7
7
8
8

7
7.5
7.5
8
8.5
9
9.5
10

7
7.5
7.5
8
8.5
9
9.5
10

3.5
3.75
3.75
4
4.25
4.5
4.75
5

Cm2
Section
area
Cm2

Kg/m
Theoretic
quantity
Kg/m

8.444
10.24
12.74

6.63
8.04
10

21.31
25.15

16.73
19.74

Product precision index:


Channel height tolerance (h): h<100

+/-1.5

Channel leg width tolerance (b): b<100


+/-2
150<b<200

+/-2.5
5

100<h<200
+/-1.5

+/-2

100<b<150

Technical Agreement For Syrian Profile Steel Project

Channel leg thickness tolerance (d): d<100

+/-0.4

100<d<200

+/-

0.5
Total length tolerance of channel: 8000

+50/0 .

>8000

+80/0

Flat steel

Width

Thickness

Nominal

Nominal

size
10~25
25~40

size
+0.5/-1.0
+0.5/-1.0

4000

10
12~20

+30/0 . 4000~6000

+0.2/-0.4
+0.2/-0.4

+50/0

6000

+70/0
Total length tolerance of flat steel: 4000
+50/0

+30/0 . 4000~6000

6000 above +70/0

4. Auxiliary

mechanical equipment technical parameter

4.1) The hot transporting chain-type conveyor: 1 set


Function: The hot billets from the continuous casting device will
be directly transferred by this set of chain-type conveyor to the
reheating furnace feeding roll table.
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Technical Agreement For Syrian Profile Steel Project

The maximum weight of the transferred pillets: 526.5kg


The elevation of the deportation chains: to be determined by the
metallurgical furnace.
Transporting speed: 0.10.3m/s.
Driving manner: single direction
The space of the the chains: 800mm
The quantity fo the chains: five pieces
Transmission mode: one group transmission
Transmission motor: AC 22KW
4.2) Feeding roller table

3 sets

Function: receive the billet from the hot transporting and sent
them to feeding port of furnace.
Max. weight for sending: 4526.5Kg/time
Roller size: 300X800mm
Roller face elevation: according to metallurgy furnace conditions
Roller speed: 1.5m/s
Roller distance: 850mm

n=20

Roller quantity: 7 pcs (in which material holding section is solid


roller, the others are hallow roller)
Operation mode: clockwise rotating and anti-clockwise rotating
Driven motor: YZR225M-8

3X22KW

720r/min

4.3) Fixed baffle 1 set


Function: used for positioning of billet at the end of roller.
Type: spring buffer type
Buffering billet weight: 5800kg
Billet speed: 1.5mm/s
Baffle face size: 600X300mm (200mm higher than the upper surface
of roller)
4.4) Pusher

2 sets

Function: for double-array feeding and pushing for heating furnace


Model: hydraulic pushing type
7

Technical Agreement For Syrian Profile Steel Project

Push force: 90X2T=180T


Max. stroke: 1600mm
Hydraulic station motor: AC 2X90KW
4.5) Returning roller table: 1 set
Function: if the billet from heating furnace cannot enter into
rolling mill, then the returning roller send them to heating
furnace for heating again.
Max. weight for sending billet: 526.5Kg
Roller size: 250X600mm
Roller face elevation: according to metallurgy furnace conditions
Roller speed: 1.5m/s
Operation mode: single direction
Roller distance: 850mm

n=12

Roller quantity: (6~7) pcs


Driven mode: separating 1 set of driven
Driven motor: YZR180L-6
4.6) Fix baffle:

15KW

1 group

Function: used for positioning of billet at the end of roller.


Type: spring buffer type
Buffering billet weight: 5800kg
Billet speed: 1.5mm/s
Baffle face size: 600X300mm (200mm higher than the upper surface
of roller)
4.7) Furnace delivery roller table: 1 set
Function: receive the billet from heating furnace and send them to
rolling mill.
Max. weight for sending billet: 526.5Kg
Roller size: 250X600mm
Roller face elevation: 800mm
Roller speed: 1.5m/s
Operation mode: single direction
Roller distance: 850mm

n=12
8

Technical Agreement For Syrian Profile Steel Project

Roller quantity: (6~7) pcs


Driven mode: separating 1 set of driven
Driven motor: YZR180L-6

15KW

4.8) Transporting roller table:

1 set

Function: the billet from heating furnace will be sent to rolling


mill through this roller.
Max. weight for sending billet: 526.5Kg
Roller size: 250X600mm
Roller face elevation: 800mm
Roller speed: 1.5m/s
Operation mode: single direction
Roller distance: 850mm

n=12

Roller quantity: (6~7) pcs


Driven mode: separating 1 set of driven
Driven motor: YZR180L-6

15KW

5.Roughing mill: 550X1 three-roller-type


Roughing mill: 1 stand
Rolling mill: semi-closed port type
Nominal size of roller: 550X1600mm
Max. diameter: 600mm

Min. diameter: 510mm

Roller central distance: Min. 520mm;

Max. 610mm;

Rolling material: ZG70 or ZG70Mn


Max. milling force: 2X3200KN
Linear speed: V2.5~2.7m/s
Holding-down device: manual pressing
Holding-down stroke: about120mm
Holding-up device: Holding-up device stroke: about 60mm
Roller bearing: rolling bearing
Axial direction regulation mode: lead screw
15mm
9

Regulation stroke:

Technical Agreement For Syrian Profile Steel Project

Fixing type of intermediate roller: angle table


Upper roller balance type: pressure spring balance
Universal direction axis balance bracket: adopting or refer to
currently used 650 rolling mill balance bracket.
Flywheel device: 1 set
Fly wheel distance: GD2=240KN-m2
Speed reducer: 1 set
Model: ZD140

A=1400mm Mn=20

i=6.887reference value

Low speed axis Max. output moment: 550KN.m


A=2x550mm

Mn25

i=1

Gear machine seat: 1 set


A=2x550mm

Mn25

i=1

Allowed handing-over-moment: 550KN.m


Connection device: 1 set
Nylon bar pin coupling and universal axis and bracket
Main motor: 1 set
Model: YR1250-10/1430
Power: 1250kw
Rotation speed: 585r/min
Voltage:10KV
5.1) Working roller before the roughing mill 1 set
Function: used to receive and send billet for roughing rolling
billet.
Max. weight for sending billet: 3526.5Kg
Roller size: 300X1900mm
Roller quantity: 6 pcs
Roller

face

elevation:

about

800mm

(according

to

aperture

conditions)
Roller speed: 3m/s
Operation mode: clockwise rotating and anti-clockwise rotating
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Technical Agreement For Syrian Profile Steel Project

Roller distance: 850mm

n=120

Driven mode: separating 1 set of driven


Driven motor: YZR225M-8

22KW

720r/min

5.2) Working roller table before the roughing mill and the tilting
plate: 1 set
Function: used to receive and send billet for roughing role
process
Max. weight for rolling billet: 2X1450Kg
Roller dimension: 300X1900mm (solid roller)
Roller

face

elevation:

about

800mm

(according

to

aperture

conditions)
Roller distance: 850mm

n=5

Roller quantity: 6 pcs


Roller speed: 3m/s
Operation mode: clockwise and anticlockwise rotating
Roller distance: 850mm

n=10

Driven motor: YZR250M1-8

30KW

725r/min

5.3) Lifting table behind the roughing mill

1 set

Function:The rolling mill with three rollers has the upper and the
lower rolling line. The lower rolling line is transported the
rolled pieces by the roll tables, while the upper rolling line is
transported the rolled pieces by this lifting table behind the
roughing mill. And the rise-and-fall and the rotation of the
lifting table are all carried out by the machinery.
Rolled piece weight: 2X526.5kg
Swing angle: about 415
Time for one swing: about 2 S
Roller size: 300X1900mm (4 solid roller in front)
Roller elevation: lower part about 800mm; upper part about
1420mm (according to aperture conditions)
Roller distance: 600X3/850X1/800X9
11

Technical Agreement For Syrian Profile Steel Project

Roller speed: 3m/s


Operation mode: clockwise and anticlockwise rotating
Platform motor: YZR315S-10

63KW

585r/min

Lifting motor under platform: YZR315S-10

63KW

585r/min

5.4) The working roller table behind the roughing mill

1 set

Function: used to receive and send the rolled billets in the


roughing milling process
Max. weight for sending billet: 2X526.5Kg
Roller dimension: 300X1900mm
Roller

face

elevation:

about

800mm

(according

to

aperture

conditions)
Roller speed: 3m/s
Operation mode: clockwise and anticlockwise rotating
Roller distance: 850mm

n=10

Roller quantity: 6 pcs


Driven motor: YZR225M-8

2X22KW

6. Head-cutting hot shearing

720r/min
1 set

Function:cut the pulling-domn of intermediate billet which rolled


by rough rolling mill, and ensure to not jamming when enter into
the intermediate rolling mill.
7.

Intermediate

rolling

mill:

450X4

with

layout
Rolling mill: 4 pcs
Type: two-roller semi-closed port type
Nominal size of roller: 450x800mm
Max. diameter: 480mm

Min. diameter: 420 mm

Roller central distance: Min. 4200mm;


Roller central line elevation: 800mm
Rolling material: nodular cast iron
Roller bearing: rolling bearing
Max. milling force: 2X2500KN
12

Max. 490 mm;

continuous

Technical Agreement For Syrian Profile Steel Project

Holding-down device: 2 sets for each


Type: manual regulation
Holding-down stroke: about100mm (reference value)
Joint speed reducer: 4 sets
Connection device: 4 sets
Nylon bar pin coupling and universal axis and bracket
Main motor: Z500-3A

600KW

500-1200r/min

7.1)

of

machine/The

Front

roller

K6

intermediate rolling mill

4 sets

roll

table

behind

the

1 set

Function: used to receive finishing milling parts and send them


into K6 machine
Max. weight for sending billet: 526.5Kg
Roller dimension: 250X800mm
Roller

face

elevation:

about

800mm

(according

conditions)
Roller speed: 2m/s
Roller distance: 1000 mm

n=18

Roller quantity: 6 pcs


Driven mode: separating 1 set of driven
Driven motor: YZR200L-8

15KW

720r/min

8.Fine rolling mill: 350X6 continuous layout


Rolling mill: 6 pcs
Type: two-roller semi-closed port type
Nominal size of roller: 350x600mm
Max. diameter: 380mm

Min. diameter:380 mm

Roller central distance: Min. 320mm


Roller central line elevation: 800mm
Rolling material: nodular cast iron
Roller bearing: rolling bearing
Max. milling force: 2X2200KN
Holding-down device: 2 sets for each
13

Max. 390mm;

to

aperture

Technical Agreement For Syrian Profile Steel Project

Type: manual regulation


Holding-down stroke: about 80mm (reference value)
Axial regulation: according to axial regulation device of bar
rolling mill of same specification of company
Regulation range: about 15mm
Joint speed reducer: 6 sets
Connection device: 6 sets
Nylon bar pin coupling and universal axis
Main motor: Z500-3A

600KW

500-1200r/min

6 sets

8.1) The roller table behind the fine rolling


Function: used to receive the rolling parts from K1 and send them
into cold bed.
Max. weight of sending billet: 526.5Kg
Roller dimension: 250X1000mm
Roller

face

elevation:

about

800mm

(according

to

aperture

conditions)
Roller speed: 4.2-6.4m/s
Roller distance: 1000mm

n=57

Roller quantity: 49pcs


Driven mode: separating 8 sets of driven
Driven motor: AC speed regulation 8X15KW
9. 1500 hot sawing machine: 1 piece
Function:Doing segmenting saw cutting to the hot-milled profiled
bars. Because of the temperature of the final hot mill is between
850950C, the hot saw is needed.

10. Cold bed: 1 piece


1 Processing condition and parameter
Conveying and cooling of rolling parts: channel 5#-16#
steel

2.5#-8#

flat steel
14

angle

Technical Agreement For Syrian Profile Steel Project

Max. weight of rolling part: 526.5kg/pcs


Rolling part step speed in cooling bed: 1.37m/min
2 Equipment composition
It consists of cold bed input roller, positioning baffle, cold bed
organ on steel, cold bed body, rear output roller of cold bed,
etc.
10.1) Cold bed body: 1 set
Function: for traverse movement, cooling of rolling part
Type: hydraulic stepping type cold bed
Cold bed area: 58X23mP2
Cold bed load: 60T
Fixed bed elevation: 700mm
Distance of dynamic bar: 1000mm
Distance of static bar: 1000mm
Distance between dynamic bar and static bar: 500mm
Stroke of dynamic bar: horizontal: 200-400mm
lifting: +50mm-30mm
Stepping cycle: 30s (adjustable)
Note: cold bed can be divided into design, manufacturing of three
cold beds at 18X23 m2; it may select single action or joint action
as required. Under joint action, the synchronizing precision of
three cold beds should meet the precision of large cold bed.
10.2) Positioning baffle: 1 set
Function: is equipped on the end of front roller of cold bed for
positioning of roller part.
Type: spring buffer type
Max. weight of rolling part: 526.5kg/pcs
Operation speed of rolling part: max. 6m/s
Baffle size: width height 600X250mm (baffle is 150mm higher than
roller)
10.3) The mechanism for the steel charging to the cold bed : 1 set
15

Technical Agreement For Syrian Profile Steel Project

Function: fixed on the side of front roller of cold bed, used for
pulling the rolling part to cold bed quickly to avoid blocking.
Type: multi-claw pusher (or adopt companys horizontal carrier
organ type)
Stroke of pusher claw: 700mm
Distance of pusher claw: 6000mm
Pusher claw higher than roller: 120mm
Max. transferring time: 30 times/min
Driven mode: motor drive
10.4) The output roller table behind the cold bed: 1 set
Function: for transferring the cold-rolled part to straightening
machine for straightening
Roller dimension: 250X600mm
Roller distance: about 1000 mm
Roller quantity: 77 pcs (in 11 groups, driven by DC motor)
Roller speed: 2-4m/s (adjustable)
Roller elevation: 700mm
11.500 straightening machine: 1 piece
11.1 The roller table behind the 500 straightening machine: 1
group
Function: used to receive the rolling parts from 500 straightening
machine and send them into 300 straightening machine.
Roller dimension: 250X400mm
Roller face elevation: about +700mm
Roller speed: 2.5-4.5m/s
Roller distance: 1000mm

n=2

Roller quantity: 15 pcs


Driven motor: AC speed regulation

5KW

12.300 straightening machine: 1 set


12.1) The roller table behind the 300 straightening machine : 1
16

Technical Agreement For Syrian Profile Steel Project

group
Function:

used

to

receive

the

rolling

parts

from

the

300

straightening machine and send them into the length-scaled roller


table
Roller dimension: 250X400mm
Roller face elevation: about +700mm
Roller speed: 2.5-4.5m/s
Roller distance: 1000mm

n=2

Roller quantity: 15 pcs


Driven motor: AC speed regulation

5KW

13.The length-scaled roller table


Function; used to receive the rolling parts from the straightening
machine and cutting them into ruler material after cooling.
Roller dimension: 250X400mm
Roller face elevation: about +700mm
Roller speed: 2.5-4.5m/s
Roller distance: 1000mm

n=43

Roller quantity: 8 pcs


Driven type: separating 1 set of driven
Driven motor: AC speed regulation

11KW

Structure requirement:
a. For structure design roller, the installation between cold
sawing units and horizontal movable machine shall be considered.
b. The upper of roller shall be equipped with pneumatic lifting
pressing positioning device to ensure the stable sawing.
c. The end of roller shall be set with positioning baffle.

14cold sawing group: 11 pieces


Doing segmenting saw cutting to the profiled bars after cooled
from the cold bed.
17

Technical Agreement For Syrian Profile Steel Project

15 Positioning baffle: 1 group


Function: is equipped on the end of front roller of cold bed for
positioning of roller part.
Type: spring buffer type
Max. weight of rolling part: 526.5kg/pcs
Operation speed of rolling part: max. 6m/s
Baffle size: width height 600X250mm (baffle is 150mm higher than
roller)
16 The chain-type checking rack

1 set

Function: used to traverse the scaled material after sawing from


the sawing roller table to the packing and transporting roller
table. And the checking process will be carried out during the
transporting process.
Traverse material size:
Ruler material specification: channel 5#16#, angle steel: 2.5#
8#
Ruler material length: 612m, Max. section number: 12 pcs
Max. theoretic weight: 19.74kg/m
Max. weight of each traverse: 526.5kg
Traverse stroke: 1280mm (central distance between two rollers)
Traverse period: 12s
16.1) Transition roller table

1 set

Function: used to receive the rolling materials from the chaintype conveyer and convey them to the packing stage.
Roller size: 250X400mm
Roller elevation: about+700mm
Roller speed: 2m/s
Roller distance: 2000mm

n=41
18

Technical Agreement For Syrian Profile Steel Project

Roller quantity: 8 pcs


Driven mode: 1set of drive
Driven motor: AC 11KW
17 Profile bar short-length packing machine

1 piece

Packing the sawed short-length profile bars by this packing


machine.9000X12000mm. And the packing process is doing by the
workers.
18 Profile bar fixed-length packing machine

2 pieces

Packing the sawed fixed-length profile bars by this packing


machine.9000X12000mm. And the packing process is doing by the
workers.
19 Fixed baffle

1 group

Function: used for positioning of billet at the end of the packing


rack
Type: spring buffer type
Buffering billet weight: 1230kg
Billet speed: 1.5 mm/s
Baffle face size: 600X300mm (200mm higher than the upper surface
of roller)

19

Technical Agreement For Syrian Profile Steel Project

Technical proposal and instructions for automation system


1. General description of equipment
The equipments for profiled bar production line mainly include:
550 roughing mill, 450 intermediate mill and 350 finishing mill;
ingot pusher, furnace delivery table, front roller table of
roughing mill, rear lifting platform of roughing mill, rear roller
table of roughing mill; rear roller table of intermediate mill;
rear roller table of finishing mill; front roller table of cooling
bed,

cooling

bed,

cooling

bed

flat

carrier;

cooing

bed

transferring steel, rear roller table of cooing bed; front, middle


and rear roller table of straightening; saw cutting length roller
table; pusher; off-size run-out roller table; bunch run-out roller
table; 1# thin oil station, 2# thin oil station, water treatment
system, etc..
Main equipments supplied by the equipment plant: hot sawing
equipment, 500 straightening machine, 300 straightening machine,
packing machine and air compressor station, etc.
2. General description of automation control system
Total installed capacity of 550 roughing mill, 450 intermediate
mill and 350 finishing mill is 7250 kW.
2.1 550 roughing mill uses high pressure motor of 1250 kW 10000V,
of which the soft start is realized by liquid soft-start cabinet.
2.2

Main drive of 450 intermediate mill and 350 finishing mill

rolling

line

is

by

DC

motor,

installed

capacity

of

450

intermediate mill is 4X600=2400 kW, by use of controlled silicon


DC power supply.
2.3 Installed capacity of 350 finishing mill is 6X600=3600 kW, by
use of controlled silicon DC power supply.
20

Technical Agreement For Syrian Profile Steel Project

2.4 Two-level automation control system is composed of PLC and


industrial computer, to complete the automatic control of full
line equipments. It is an open computer control system, having a
space for adding a three-level production management system.
3. Type and functions of automation system and electrical
drive
3.1 Overall performance and characteristics of control system:
3.1.1 Each operating board is operated by universal touch screen,
connected by PROFIBUS, Ethernet.
3.1.2 Emergency stop, regulation of frame speed and others are
switched in I/O module by PLC, with rapid response of operation.
3.1.3 Human-computer interface is applied the latest mainstream
operating system platform software and general PC hardware.
3.1.4 Network type is selected mainstream high speed network
software and hardware.
3.1.5 Give full play to the advantages of network and remote I/O,
reduce consumption of various cables, and save construction cost.
3.1.6 Strict hierarchical system management science is to ensure
safe and stable operation in the system.
3.1.7 Give full play to the functions of human-computer interface,
so that each of equipment may show the conditions of the equipment
and production in various aspects, to bring reliability and
convenience for inspection and spot inspection of equipment and
operation of equipment.
3.1.8 The structure of control system should be simple as much as
possible

based

on

full

consideration

of

the

functions, to reduce equipment as well as faults.


3.2 Control functions in rolling mill area:
3.2.1 manual control of all equipments in this area
3.2.2 segmental emergency stop function
21

realization

of

Technical Agreement For Syrian Profile Steel Project

3.2.3 automatic and manual operation function


3.2.4 cascade control of frame speed
3.2.5

minimum

tension

control

of

intermediate

and

finishing

rolling
3.2.6 logic control of rolling mill start/stop
3.2.7 human-computer interface:
a) equipment operating status parameter display
b) setting of rolling parameter
c) faults, display and alarm of events
d)

dynamic

simulation

display

of

rolling

lines

and

various

equipments
3.3 Technical functions of intermediate mill and finishing mill
drive system
3.3.1 General requirements of intermediate mill and finishing mill
drive system
For the equipment supplied, it shall ensure realization of various
control functions and satisfaction of the performances required by
production, and stable as well as stable and reliable operating in
a variety of environments, with convenient maintenance, low fault
rate and simple operation.
3.3.2 Characteristics of intermediate mill and finishing mill
drive cabinet
3.3.2.1 drive cabinet is reversible excitation system;
3.3.2.2 static property satisfies 0.1%, and dynamic property
satisfies 0.5%.
3.3.2.3

protection

requirement:

drive

fan,

power

components

temperature protection.
3.3.2.4 insulation of incoming line zone.
3.3.2.5

with

such

hardware

with

~220V

socket

for

Profibus-DP

communication

as

required
3.3.2.6

in

the

lighting.
22

cabinet

and

self-provided

Technical Agreement For Syrian Profile Steel Project

3.3.2.7 earthing for computer and instrument and cabinet is


designed separately. (details can be determined by the user.)
3.3.3 Electrical drive of DC main drive
The main drive of intermediate mill and finishing mill is DC
drive, and will take Siemens all-digital 6RA70 magnetic reversible
expansion

device

or

EUROTHERM

companys

SSD590

reversible

expansion device, UK as control system.


3.3.4 Drive device has the following functions:
--- overload protection for motor;
--- overcurrent/current limiting protection for excitation;
--- overcurrent protection for thyristor;
--- instantaneous over-current protection for motor;
--- AC overvoltage/under-voltage protection;
--- lack phase protection;
--- phase sequence protection;
--- overvoltage protection for motor;
--- function of communication with PLC;
4. Functions of basic automation, process automation control
system
start, stop and emergency stop control of rolling line;
cascade speed setting of rolling line;
automatic cascade control;
minimum tension control;
adaptive control of speed setting;
self-diagnosis of system;
fault alarm and event record;
print report (such as shift report, daily report);
network communication.
5. Motor paremeters
Motor parameters of roughing, intermediate and finishing mill
23

Technical Agreement For Syrian Profile Steel Project

No.

1
2

Equipment
name

550 Roughing
mill
450
Intermediate
mill
350
Finishing
mill

Electrical Qty.
equipment

Main technical data


Power (kw) Rotation Voltage
speed
(V)
(r/min)

Power
supply

Model

Main motor

YR1250

1250

585

10000

AC

Main motor

Z5003A

4x600=2400

532-1200

660

DC

Main motor

Z5003A

6x600=3600

532-1200

660

DC

Subtotal

11

7250

6. Technical characteristics of electrical control system,


automation system
Configuration for DC driving device of intermediate and finishing
mill system
6.1 DC drive power part
Adopt Siemens 6RA70 all-digital DC speed-regulating expansion
device or UK EUROTHERMs SSD590 all-digital DC speed-regulating
expansion unit.
6.2 Regulation part
Digital speed feedback speed-regulating system is composed of
Siemens 6RA70 or UK EUROTHERMs SSD590 all-digital DC speedregulating device.
Basic configuration for automatic part
The control and protection for speed-regulating system is entered
network system by communication device;
Set a S7-400PLC system, remote I/O and HMI in the intermediate and
finishing mill area, to realize cascade regulation and control as
well as closed-loop control of speed of DC main drive, control of
auxiliary equipment;
Set a S7-300PLC, remote I/O and HMI in rolling mill area, to
realize cascade, logic control, monitoring alarm and interlocking
24

Technical Agreement For Syrian Profile Steel Project

control of all low voltage driving equipments from the discharging


roller table behind the finish rolling mill to the bunch run-out
roller table, from hot sawing equipment to air compressor station
equipment;
6.3 Program of automation system
6.3.1 General description
Establishing an automatic control system, not only shall meet the
technology requirement in site production, but also shall provide
a flexible, convenient human-computer interface for the user. In
terms of the realization, or of the reliability, easy operation
and

continuous

service,

it

is

comprehensive

test

to

the

automation system. Summing up the projects we have made, and


taking into account the advanced control program of foreign
similar enterprises, we adopt a distributed control system program
made

up

by

computer

network,

which

fully

reflects

the

decentralized control, centralized management of modern computercontrolled concept.


The lower computer in this system is responsible for acquisition
and preliminary processing of data in the site, and the upper
computer is to complete other management tasks in the system. We
provide the program of automation control with two-level network
control as follows:
on-site drive, remote control network - PROFIBUS DP network
higher-level data acquisition, monitoring and management network
- Industrial Ethernet
6.3.2 Main control method
6.3.2.1 Speed cascade control
In the steel tandem mill, in order to ensure the quality of
finished products, an end frame of the finished-product frame is
taken as the reference frame, and kept its speed constant setting
25

Technical Agreement For Syrian Profile Steel Project

as reference speed, in front of which, the speed of frame is set


in

proportion

automatically

according

to

the

principle

that

metallic flow is equal. During rolling process, with manual


intervention of adjustment quantity, increase and reduce the speed
of all frames in front of it in reverse rolling direction in
order. When rolling different sizes of steel, obtain the specified
end frame no. and corresponding highest rolling linear speed VLMax
from rolling table, as well as total percentage of current
selected rolling VL%, so it can calculate the frame speed VLS.
6.3.2.2 Minimum tension control
Minimum tension control adopts current memory method. It indicates
the period that when the steel head is gripped by the no. n
rolling mill, after the dynamic speed drop of motor is restored,
before this steel is gripped by no. n+1 rolling mill. For no. n
rolling mill, in relation to free rolling without back tension,
after filtering, the rolling current sampled at this time is that
of no. n rolling mill, and is memorized. When this steel is
gripped by no. n+ 1 rolling mill and the dynamic speed drop of
motor is restored, after filtering, the current of no. n mill is
sampled again, and is compared with the memorized one, from which
the deviation can be used for adjusting the rolling speed of no.
n+1 mill so that the deviation is zero.
6.3.2.3 Compensation control of dynamic speed drop
When the head of rolled piece is entered the rolling mill, the
speed will reduce suddenly. To ensure to maintain the second flow
balancing

between

frames

for

an

instant

of

biting,

and

to

successfully complete looping among frames with loopers, set a


dynamic

compensation

value

(0.98~1.02),

multiplied

by

speed

setting value of this frame, as the speed value when biting, after
completion

of

dynamic

speed

drop

compensation value.
26

of

biting,

withdraw

the

Technical Agreement For Syrian Profile Steel Project

6.3.2.4 Crop end control of hot shearing


For flying shear control, there are two detection circuits: one is
cutting edge position detection circuit, composed of coded disc on
cutting edge shaft and high-speed counter of PLC. Another one is
the detection circuit of rolled piece head, end from HMD to hot
shear, composed of coded disc mounted on the upstream frame, HMD
and high-speed counter of PLC.
The speed setting of hot shear is given by following formula:
Vr=VcKs
In which: Vr: set value of hot shear position
Vc: speed of upstream frame
Ks: advance coefficient of speed (5~15%)
Regardless of the rolling speed, the distance from HMD to hot
shear traversed by rolled piece is fixed. As the pulse number
generated by coded disc on the motor shaft of upstream frame is
proportional to the angle rotated by roller, it is also directly
proportional to the distance traversed by rolled piece. When the
head or end of rolled piece is detected, HMD will start high-speed
counter to accumulate the pulse number of coded disc of upstream
frame, when counting to the set value, it will start the hot
shear. The starting of flying shear has two situations:
The accumulated pulse count required by starting of crop end:
CHU=C1+CHL-C2-C3
In which: CHU: accumulated pulse count required by starting of
crop end
C1: pulse count from HMD to cut point
C2: pulse count corresponding to system response time
C3: pulse count corresponding to shutdown position to cut point
6.3.2.5 Speed and motion control of pinch roll
It is better that the speed of pinch roll is generally set 1~5%
ahead of the linear speed of front frame.
There are three types of motion for pinch roll:
27

Technical Agreement For Syrian Profile Steel Project

Full pinch
Head and tail pinch
Tail pinch
The selection of pinch method is completed by the operation
station.
6.3.2.6 Interlocking of rolling line and hydraulic, lubrication
station and water treatment system
As an independent system of hydraulic station and lubrication
station and water treatment system, it must have such signal as
ready, fault and so on sending to PLC. As an integral part of
ready for whole line, if the whole line is not ready, it cannot
run. If the whole line runs, but hydraulic station or lubrication
station or water treatment system fails: for light fault, stop
tapping of heating furnace immediately; send out alarm signal; if
the fault is still existed after three minutes (this period of
time is waiting for completion of rolling in current rolling
line), shut down in corresponding area. For major fault, the whole
production line should be stopped.
6.3.2.7 Operation of rolling line equipments
There are normally two operating modes of automatic and manual for
rolling line equipments. For drive system, it is fitted with
inching operation (generally, inching setting value is 510%).
When

selecting

automatic

mode,

all

equipments

automatically

complete relevant actions in order according to the function,


interlocking

condition

and

process

control

requirement.

When

selecting manual method, all equipments are operated randomly by


operators according to safe interlocking conditions.
The

speed-regulating

drive

equipments

are

operated

by

corresponding set values given by operation station, with speed


and manual fine-adjusting (combined adjusting, single adjusting)
28

Technical Agreement For Syrian Profile Steel Project

compensating speed operation. Inching operation for all drive


equipments is set for local operation cabinet.
Control

of

the

operation

with

low

real-time

requirement

is

completed by the operation station (such as: ON/OFF operation of


drive systems, start/stop operation, operation of equipments and
selection of control mode, local operation allowable, rising and
dropping operation of looper rising device, etc).
Control of the operation with high real-time requirement is
completed

by

appliances

on

the

operating

board

(such

as:

operations related to manual intervention of equipment speed,


emergency stop, emergency fault handling, etc). The maintenance
operation for equipments and roller changing of rolling mill are
carried out on the local operation cabinet.
7. Automation control network system
The system is totally set two-level network, of which DP network
is divided into two lines. Only the regulation cabinet of main
rolling mill is linked to this network, which is to ensure that
the regulation cabinet has rapid response, so that it may adapt to
a large number of computing upon closed-loop control of speed and
minimum

tension

transmitting
operating

control,

between

board

and

there

regulation
local

are

large

cabinets.

operation

cabinet

number
The

of

control

will

carry

data
for
out

transmission through the second DP network, with small data


transmitted between them. The data acquisition and monitoring of
upper computer is transmitted by industrial Ethernet, of which the
control level is increased successively.
7.1 Site transmission DP network
It comprise of S7-400PLC and 10 sets of DC speed-regulating
devices through communication board.
Namely, this network completes the following control for DC speed29

Technical Agreement For Syrian Profile Steel Project

regulating devices:
PLC

DC speed-regulating device:

Start/stop signal
Inching command signal
forward and reverse signal
Specified

setting

signal

(including:

general

setting,

single

setting, cascade setting)


DC speed-regulating device PLC
Drive system status
Rotation speed signal of motor
Motor current signal
Motor voltage signal
exciting current signal
This network is applied to:
1)

realization

of

start/stop

control,

logic

control

and

interlocking protection of whole line;


2) setting and cascade control of single machine of frames
3) minimum tension control of intermediate rolling;
4vertical looper control
7.2 The system is a distributed control system (DCS) made up by L2
network which has the characteristic of handling field bus. The
local signal is handled automatically by intelligent electrical
terminal (such as: DC speed-regulating device), without having to
request the intervention of the master station, but is subject to
the macro control of master station, so that the master station
may save lots of times to handle more and more critical tasks
(such as: calculation of closed-loop speed and minimum tension
setting, etc).
7.3 S7-400 of PLC is the fastest CPU in S7 series PLC with DP port
30

Technical Agreement For Syrian Profile Steel Project

series. As the field bus technology is applied, a lot of signals


are handled in the site, and using a single CPU can complete the
project with such a large computing task, so as to save costs for
the manufacturer. In addition, only the small frame structure of
PROFIBUS network may make the communication speed of network
highest.
7.4 Reliability of network transmission
* The system has strongly reliable network transmission that is
used to send a large number of information codes, so that the
electrical

connection

between

electrical

terminals

can

be

substituted respectively (such as: operating board to controlled


silicon room, etc, large number, long distance, point-to-point
connection), which not only saves lead wires, but also reduces the
terminal nodes, and reduces the fault rate as well as the
maintenance workload.
* If some station in the network fails or is maintained, it will
not affect the operating of whole network.
* A major difference between digital system and simulation system
is that it will not have null shift, which has given a strong
assurance for system reliability and reduces maintenance workload.
7.5 Convenient commissioning and maintenance
In the drive regulation cabinet is set with necessary switching
value

and

signal,

so

it

can

complete

commissioning

of

the

regulation itself without any intervention of other equipments.


The digital system is not necessary to be maintained, and the
intermediate

relays,

contactors,

indicator

lamps

and

other

equipments can be detected by state table of PLC system and forced


variable table.
7.6 Industrial Ethernet
7.6.1 General description
It is a full protocol network in accordance with German DIIN19245
31

Technical Agreement For Syrian Profile Steel Project

standard, which has been authorized by Europe, even the whole


world. Its protocol is same as L2-DP networks, but the function
is stronger than L2-DP network, and has wide compatibility, more
suitable for mass data exchange.
7.6.2 Network functions
It completes the functions as follows:
a) monitoring of operating conditions of whole line equipments,
real-time

simulation

of

such

process

as

start/stop,

steel

carrying, rising/dropping looper and so on;


b) real-time display of digital quantity of main parameters;
c) display of rod-shaped real-time diagram of analog quantity of
main parameters;
d) real-time display of system single line diagram;
7.6.3 Main screen
A. Main screen
Power

on

and

self-check

the

system,

after

network

contact

detection, enter into the first screen in the system, it will


display version number and main menu, so when the user is
operating, it is not necessary to return to the main screen, you
can switch to other screens directly;
B. Monitoring screen of host computer
In order that the personnel not in the site can watch the rolling
process, it can real-time simulation start/stop, steel carrying,
rising/dropping looper and other processes, and display of digital
quantity

of

main

parameters,

total

setting,

single

machine

setting, actual linear speed, actual rotation speed, armature


current, armature voltage, exciting current, etc.
C. Maintenance reference screen
The screen displayed is the same as the monitoring screen of host
computer, but adding digital display of linear speed setting,
rotation speed setting, for maintenance personnel to debug;
32

Technical Agreement For Syrian Profile Steel Project

D. System single line diagram


Display flat roll, main circuit situation, for operation personnel
to monitor;
E. Rod shaped diagram of host computer
Use different colors of rod shaped diagram to display the realtime situation of voltage, current, setting, rotation speed of
host computer in proportion, cross-referencing, which will help to
identify problems;
F. Start-up diagnosis
Show all conditions before starting, once it meets, it is allowed
to start, which is extremely favorable to find the conditions for
starting;
G. Fault diagnosis
Once the machine unit fails, it can find out the reason caused
faults through fault diagnosis screen, which is to provide a
powerful weapon for shortening of processing time for fault;
H. Dynamic curve screen
Display the armature current, rotation speed of motor of machine
unit, to monitor the dynamic performance of drive system, and the
dynamic

quality

centralized

of

the

monitoring

system,

management

which
for

greatly

facilitates

operating

maintenance

personnel;
I. Rolling schedule
Establish complete rolling procedure, apply scientific management
to produce and improve the precision and efficiency;
J. Operating report
Record

the

operation

situations

of

machine

unit

and

main

parameters in chronological order and print, to replace manual


operation;
K. Historic fault inquiry
Record

the

operation

situations
33

of

machine

unit

and

main

Technical Agreement For Syrian Profile Steel Project

parameters in chronological order and print, to facilitate inquiry


and to provide basis for routine maintenance;

1#/2# dilute oil technical plan and description


1. 1# dilute oil technical parameter
1.1 Motor (Brand: ABB), one open and one stand-by
Model: Y2 132M-4
Power: 7.5Kw
Rotation speed: 1450r/min
Voltage: three phase AC380V
1.2. Screw pump (Brand: SETTIMA)
Capacity: 400ml/r
Working pressure: 5bar
Max. working pressure: 8bar

2. 1# dilute oil station working principle


start motor (clockwise turn) through single valve overflow
34

Technical Agreement For Syrian Profile Steel Project

valve pressure regulating (set 5bar) filter exchanger


outlet connection to each dilute oil point of each speed
reducer
Function:
2.1 The temperature controller controls the temperature of dilute
oil. When its temperature is higher than the set oil temperature,
open the valve and cooling will be made by exchanger.
2.2 When oil temperature is lower than the set temperature, the
oil will be heated electrically.
2.3 When the oil liquid level is less than the lower limit, it
alarms.
2.4 If the oil is polluted, it alarms by differential pressure
transmitter of filter.

3. Site positioning
3.1 The dilute oil tank is better to be installed in ground
channel, thus the oil may flow smoothly and freely and the oil
liquid of speed reducer will not overflow.

4. Working media: lubricant

5. 2# dilute oil technical parameter


(1) Motor (Brand: ABB), one open and one stand-by
Model: Y2 160L-4
Power: 11 Kw
Rotation speed: 1450r/min
Voltage: three phase AC380V
(2). Screw pump (Brand: SETTIMA)
35

Technical Agreement For Syrian Profile Steel Project

Capacity: 600ml/r
Working pressure: 5bar
Max. working pressure: 8bar

6. 2# dilute oil station working principle


start motor (clockwise turn) through single valve overflow
valve pressure regulating (set 5bar) filter exchanger
outlet connection to each dilute oil point of each speed
reducer
Function:
6.1 The temperature controller controls the temperature of dilute
oil. When its temperature is higher than the set oil temperature,
open the valve and cooling will be made by exchanger.
6.2 When oil temperature is lower than the set temperature, the
oil will be heated electrically.
6.3 When the oil liquid level is less than the lower limit, it
alarms.
6.4 If the oil is polluted, it alarms by differential pressure
transmitter of filter.
7. Site positioning
The dilute oil tank is better to be installed in ground channel,
thus the oil may flow smoothly and freely and the oil liquid of
speed reducer will not overflow.
8. Working media: lubricant
Technology Provisions for the 25T/h Pusher-type Reheating
Furnace with Heavy Oil
First

Summary

Industrial Services Corporation in Syria is preparing a new plate


production line, with one 25t/h pusher-type heating furnace as a
36

Technical Agreement For Syrian Profile Steel Project

complete set.
This item is a turnkey project and we are the general contractor
for design, equipment supply, construction, installation, baker,
commissioning and production.

1.Content and scope of design


1 Reheating furnace body, steel structure, air system in
reheating furnace area, oil circuit system, fume exhaust system,
accessory equipments for furnace, hydraulic system, steel pusher,
discharge machine, etc.
2 Electric control, instrument control and combustion control
systems for the reheating furnace.
3Evaporated cooling system for the reheating furnace.
4 Oil

circuit

system,

water,

electricity,

nitrogen

and

compressed-air system, steam system.

2.Scope of supply
(1)Reheating furnace body(steel structure, masonry work,etc.)
(2) The whole combustion system(including oil circuit system,
steam system, air system, fume exhaust system, etc.)
(3)The whole instrument control and electric control systems for
the reheating furnace.
(4)Evaporated cooling system
(5)Equipments for the reheating furnace(nozzle, door for the input
and output of material, peep-hole, access door, etc.)
(6)Steel pusher, discharge machine, etc.
(7)Hydraulic and lubrication system

37

Technical Agreement For Syrian Profile Steel Project

3. Design condition
(1) Fuel and calorific value: heavy oil, 96004.18KJ/kg
(2) Billet bloom size: 1501506000mm1501503000mm
(3) Steel species: carbon structural steel, low-alloy structural
steel, etc.
(4) Charge and discharge temperatures of billet:
charge temperature of billet: 700 800 the cold charged
temperature20
discharge temperature of billet: 1150-1250
(5) Rating output: 25t/h (cold charged)
(6) Cross-section difference in temperature: 30
(7) Unit heat consumption: (rating condition)32kg oil/t billet
(8) Bottom beam cooling method: evaporation cooling, adding valve
before water level gauge
(9) Input and output method of billet: end charge, end out
(10) Billet distribution method: 3m double-row billet; 6m single
row billet
Second

Main technical characteristics of the furnace

(1) The top and bottom of the furnace supply heat, with heath
temperature uniformity in furnace area. Setting partition in
furnace to control furnace temperature and furnace press easily,
and to reduce interference in segments.
(2) The reheating furnace sets 4 vertical water pipes to satisfy
the request of

billet distribution. Across water pipe uses T

type support. To eliminate water pipe black marking absolutely


and to reduce cross-section temperature difference of billet, the
design leaves certain length of true hearth in soaking zone, and
staggeres the soaking zone slide and the furnace floor tube at the
38

Technical Agreement For Syrian Profile Steel Project

same time. Heat resistant slider uses ZGCr25Ni20.


(3) The furance takes advantage of high-pressure fuel nozzle with
steam atomization, and we decide to use saturation steam to
atomize the fuel as considering that the steam press of furnace
contact point is 0.8Mpa.
(4) Heavy oil is heated by the spiral-plate heater on the front
furnace platform, the outlet temperature of heavy oil is 140,
and the heating medium of plate

heater is superheated steam with

the temperature of 250.


(5) Air heat exchanger and steam superheater are set in the flue.
Air

preheated

temperature

is

450,

and

steam

overheated

temperature is 250. The chimney inside the furnace is structured


by the concrete and the refractory materials; the chimney outside
the furnace is 30m high and constituted by the

three parts: the

bottom part with the height of 10m and the diameter of 1.6m
(welded by the steel plate of 20mm); the middle part with the
height of 12m and the diameter of 1.2m (welded by the steel
plate of 10mm); the top part with the height of 6m and the
diameter of 0.8m (welded by the steel plate of 6mm). The
connections of the three parts are connected by the flanges and
integrally assembled to fit the condition of the 150km/h wind
speed. The outlet diameter of the outside chimney is 0.8m and
the natural discharge of the smoke is taken use of for the
furnace. The temperature of the flue inside the furnace is
600~700, and the temperature of the bottom of the outside
chimney is 200~300.
(6) Oil supply system uses main pipe for returning oil(before
heater) to stabilize oil press, and does not set oil return device
in other segments.
(7) Designing light oil system which imports from main pipe and
only is used for starting and stoping the furnace.
(8) Water girder in furnace adopt evaporative cooling.
39

Technical Agreement For Syrian Profile Steel Project

(9) Roof and wall of the reheating furnace adopt the masonry
structure with whole cast and complex layer, strengthen the
adiathermance of the furnace masonry work, reduce radiating loss
and improve the furnace life.
10 2 segments furnace temperature control are taken used
including soaking segment and heating segment. And dual cross
amplitude limit control is adopted in the furnace temperature
control, as the oil and the fogging agent using proportion
control.
11 Equipping practical, reliable, advanced thermotechnical
automatic control system to ensure heating quality; controling the
air-fuel ratio and reasonable

furnace pressure strictly to

minimize the heat loss.

Third

Main size, technical data and process flow of

the

furnace
1. Furnace model
Adopting a three-section consecutive pusher-type reheating furnace
with billet end charge and side out. The reheating furnace uses
floor water pipes with overhead structure in preheating and
heating segments, heating double sides of billet; leave certain
length of true floor in soaking zone to balance the cross-section
difference in temperature of billet and eliminate water pipe
black marking. Soaking zone uses true floor with pink fused
alumina.
The reheating furnace takes use of two-segment furance temperature
control for the soaking segment and the heating segment. The roof
of the furnace takes the screwdown structure, and all nozzles are
installed on the wall of the upper

and lower sides of the

furnace.
The combustion control system of the reheating furance has two
40

Technical Agreement For Syrian Profile Steel Project

control segments, that is soaking segemnt and heating segment,


which

can

satisfy

the

request

of

heating

temperature

and

difference in temperatureof billet.


The reheating furnace sets 4 vertical water pipes to satisfy the
request of

billet distribution. Across water pipe uses T type

support.
Taking natural draft and down draught as the flue gas exhausting
method.
2. Main size of the reheating furnace:
Total length of the reheating furnace masonry:

16300mm

Effective length of the reheating furnace

15300mm

Innerl width of the furnace

6800mm

Height of the upper hearth

1400mm
1800mm

Height of lower hearth


Technology performance of heating furnace

Technology performance list of the reheating furnace


No
1
2

3
4
5
6
7

8
9

Name
purpose of the furnace
Heating steel species

Unit

Billet specification
Furnace approach
temperature of billet
Heating temperature

mm

Furnace output
Steel pressure
intensity of furance
floor
Fuel & low calorific
value
Rated specific

C
C

Data
Billet heating before rolling
Carbon construction steel, carbon
construction quality steel, lowalloy high-tensile structural
steel
1501506000 1501503000
20 as cold installed
700-800as hot installed
1150-1250

t/h
Rated 25Cold installed
Kg/ Cold installed 230rated
2
mP P.h
KJ/mP3
GJ/t
41

Heavy oil96004.18
Cold installed

1.296GJ/t

Technical Agreement For Syrian Profile Steel Project

10
11
12
13
14
15
16
17

consumption
Rated fuel consumption
Rated air capacity
Rated fume capacity
Oxidation burnout rate
Air preheating
temperature
Cooling method for
floor water pipe
Air pressure before
furnace
Cooling water pressure

18

Cooling water
consumption

19

Pressure of the
evaporation cooling
system
Steam output

20
21

Main equipment of the


evaporation cooling
system

kg/h
mP3P/h
mP3P/h
%
C

800
9000
9300
1.0
450
Evaporation cooling
7000Pa
0.3MPa
Clean circulating water 100t/h,
turbid circulating water 30t/h,
soft water 7t/h
0.78Mpa

2.5-5.0t/hadiabatic 100%-90%

12005000 boiler drum


one piece

3.Technical process description


Locating the qualified billets from charging stage on the roll
table out of furnace, pushing the billets into the furnace by the
steel pusher, through the heating of preheating, heating and
soaking segments, arriving at the tapping platform, pushing them
out from the side of the furnace by the steel pusher

and entering

into the rolling line.


Two pushers not only can run seperately, but also can run
together.
Fourth

The masonry work of the reheating furance

The roof wall of the reheating furnace adopts the complex masonry
work structure with monolithic cast, and the furance floor takes
the complex masonry construction; the furnace body has good
performance on heat insulation and good air tightness.
42

Technical Agreement For Syrian Profile Steel Project

According to the temperature, structure and other factors of


various parts of the furnace, making a reasonable combination of
the refractory materials to ensure that the maximum temperature of
external surfaces for every masonry work can reach the national
standards.
In regular conditions, the furnace wall and the roof can work for
more than

five years.

The compositions of refractory materials of the various parts


are as follows:
The composition of materials for the furnace roof:

High alumina anchoring bricks for the furance roof(Lz-55)


Low cement casting material

230mm

Perlite insulation material

100mm

Total thickness

330mm

The composition of the furnace wall:


Low cement casting material

264mm

Light-weight insulating brick(r=1.0)

116mm

Aluminum silicate fire-proof fiber felt


Total thickness

120mm
500mm

The composition of fire-proof materials for the floor at


heating segment:
High alumina brick

116mm

Clay brick

272mm

Light brickr=1.0

136mm

Diatomite brick

136mm

Total thickness

660mm

The composition of materials for floor water pipe: vertical


and cross water pipes and uprise pipes are all used.
Fire-proof fiber felt

20mm

Self-flowing castable

60mm
43

Technical Agreement For Syrian Profile Steel Project

Thickness

Fifth

80mm

Furnace body structure

1. Furnace shell steel strucrure


Furnace shell steel strucrure is welded with profile steel and
steel plate, to install and support refractory lining, fixed beam,
various pipes of combustion system, operation and maintenance
platform, installation of furnace door and nozzles, etc.
2. Platforms, ladders and railings
Operating

platforms

are

set

around

the

furnace

and

in

the

operation areas of nozzles, control valves, thermal detection


devices, etc. And all the platforms are connected with passages
and ladders, with safety railings for the platforms, passages and
ladders. The platforms and the passages are made of profile steel
and checkered steel plates according to the different parts.
3. Furnace door

Overhaul manhole door


There is a overhaul manhole door on each side wall of the charge
end, totally two overhaul manhole doors, which are used for the
workers' in and out of the furnace, material delivery and the
floor slag removal, etc..
Overhaul manhole door specification: 5801030mm
Drossing furnace door
Seting up 4 drossing furnace doors on the end wall of the charge
end for the

slag removal.

Drossing furnace door specification: 350290mm


Peephole
44

Technical Agreement For Syrian Profile Steel Project

There are many peepholes on the wall of the charge end and the
discharge end of the furnace, which are used to observe the
furnace condition in the daily producting operation.
Peephole specification: 135mm

4. Furnace floor water pipes


The vertical and cross water pipes of the furnace adopt the
evaporation

cooling,

and

the

furance

floor

water

pipes

are

optimally designed with 4 vertical water pipes supporting the


billets and four uprights supporting the cross water pipe. The
furance floor cross water pipe is 15925 seamless thick-wall
steel pipe, while the vertical water pipes 12720 and upright
water pipes 14018. The semi-hot water pipe slideway adopts
1Cr25Ni20Si2

heat

resistant

steel

slider,

and

the

adiabatic

packing of the water pipes uses the structure of double-adiabatic


self-flow castable material.As the furnace needs a great amount of
water for cooling, the two 14KW motors are taken for the water
pump to draw water( one motor is taken for using and the other for
spare). When the electricity is broken, the adopted emergency plan
is using the diesel engine with 30 horse power for the pump with
the CAL of 200mm to supply water for the furnace. All these three
plans can guarantee the safety of the furnace.
Sixth

Combustion system

1. Heat means and heat load outfit


The

combustion

system

adopts

two-segment

furance

temperature

control of soaking segment and heating segment. These two segments


are both taking use of high pressure steam atomizing heavy oil
nozzles.
The heat load is outfitted 120% of the reheating furnace 25t/h
output.
45

Technical Agreement For Syrian Profile Steel Project

Outfit quantity: heavy oil is rated at 800kg/h, and the maximum is


960kg/h;
The upper and the lower heat supply rate: 4555.
Two segments heat supply rate: 4060.
2. High-efficiency heat exchanger
Air heat exchanger has plug-in board, and the air and the flue gas
flow upstream and staggeringly, double lines and double iourneys.
The high temperature pipe unit which meets the flue gas uses heatresistant steel pipes, and low temperature pipe unit uses boiler
pipes. When the temperature of hot wind is over, the hot wind will
escape automatically.
Performance of the air heat exchanger:
Air preheating temperature: 450
Maximum quantity of the preheating air: 8750mP3P/h
Maximum quantity of the flue gas: 9350 mP3P/h
Inlet temperature of the flue gas: 750
3. Air supply system and combustion fan
The combustion air is provided by a fan, preheated by the air heat
exchanger

and delivered to the furnace, through pipes in various

segments, flow orifice plate, electric control valve to reach the


nozzles at corresponding control segments. The hot wind pipeline
is packed outside of the pipe by the 100mm rock wool and there are
some bellow expansion joints.
In low pressure, the air system is easy to form the gas with
explosion concentration in the pipeline, so the light-minded
aluminum pressure-relief explosion-proof plates are designed to
use at the end of every air pipeline, to reduce the harm caused by
the explosion.
Parameters of the combustion fan:
Quantity: one set
Fan type: 9-19No12.5D
46

Technical Agreement For Syrian Profile Steel Project

Full pressure: 92299310Pa


Flux: 12577-18447 mP3P/h
Electrical machine: Y280S-4
Revolution: 1450r/min
Voltage: 380V
Power: 75kW
A special fan room is prepared and the fan is matched with a
muffler at the entrance of the fan tomeet the requirements of the
environment protection for noise. There is a soft connecting
device fitted at the exit of the fan to reduce the wind resistance
and to prevent the fan from unbalance loading vibration.
4. Heavy oil system
Delivering the heavy oil to the heavy oil platform before the
furnace with the

temperature of 70 90. Through heating,

filtering, metering and adjusting in the platform, the heavy oil


will be delivered to the heat supply segments of the furnace.
Furnace heavy oil pipeline takes the main pipe return oil method
and the steam jacket to preserve heat. The nozzle fogging agent
uses the superheated steam, the process is that the steam from the
workshop through the superheater will be preheated to 250280
and then sent to the nozzles in the segments.
According to the requirements of the combustion control, the
pipelines of heavy oil, air and atomize are all equipped with
necessary the flow metering and aasjusting devices.

5. The fume exhaust system


The furnace adopts the downdraught method. The furnace conbustion
47

Technical Agreement For Syrian Profile Steel Project

products flow from the flue located at the bottom of the charging
end to the flue at the back of the furance, then through the steam
superheater, the air preheater and the flue adjusting valve to the
chimney with the height of 50m and the exit dia. of 2.2m, and then
will be delivered outside of the workshop. The flue has the cold
wind mixed device to pretect the heat exchanger.
To recycle the heat from the fume, the air preheater is installed
at the discharge to preheat the combustion air to 450. The
preheater is the two-cycle metal-tube shape type with twist plugin piece, with the steam superheater in the fume entrance side.
Pluging twist metal sheet in the inside of the metal pipes, on one
hand, can increase the air speed and journey in pipes. on the
other hand, because of producing continuous backset and on the
effection of centrifugal force, the air in the center of pipes
will be mixed sufficiently with the gas at the boundary layer of
the wall surface to reduce the bottom of laminar flow, strengthen
the convective heat transfer and reduce the pipe wall temperature.
To protect the heat exchanger, the hot blast automatic exhale
device is set at the main pipe.
The steam superheater is the U-type psse preheater, which can
superheat the atomizing steam heat around 250280.
The reheating furnace takes use of the furnace end downdraught.
The

fume

passes

through

the

air

heat

exchanger,

the

steam

superheater and the flue pressure adjusting valve to the chimney


with the height of 30m and the exit dia. of 0.8m
Seventh

Evaporation cooling system

The rehearting furnace floor pipes and end wall of furnace cooling
pipes are all using the evaporatiom cooling natural circulation
system.
The design pressure of the drum(steam header) for the evaporation
48

Technical Agreement For Syrian Profile Steel Project

cooling system is 0.78Mpa, and it is put in the main rolling span


side of the reheating furnace. The standard height of the steam
header center is 7.600m; the platform of the steam header is
6.500m high with steel structure, and has 3.500m platform below it
with 0.000 floor.
Softened water for evaporation cooling is provided by the soft
water station of the factory.
The main equipment for evaporation cooling: one 12005000 steam
header.
Evaporation cooling device including: water level autocontrol,
steam pressure autocontrol, water level and pressure protection
signal, etc.
The saturation steam from the evaporation cooling device is piped
to the out net of the factory.
Heat preservation for the pipeline of evaporative cooling system
adopts the
Eighth

mineral cotton shell.

Heat engeering detection of the furance

1. Design scope
Automatic control system includes the process detect and control
of the main and assistant installations for the reheating furnace.
2. Operation mode and interface
Operation mode for this system: hand keyboard, PLC autocontrol.
PLC autocontrol is used in general condition.
Switch input and output usually use voltage of AC220V or DC24V,
and

analog input and output use 420mADC. The signal of RTD hot

resistence and TC thermocouple enter the corresponding analog


module directly.
3. Main principle of design
The

main

principle

of

design
49

is

that

according

to

the

Technical Agreement For Syrian Profile Steel Project

technological conditions and requests, designing the automatic


control system managing the request of

technology and the

consumer. The signals of instrument system are all expressed on


the computer. To be convenient for the operator to directly get
the temperature conditions about different areas of the furnace
out of the operating room, a large display screen is put on the
outer wall of the furnace (connected to the control system in the
operating

room

by

the

method

of

communication),

and

the

temperatures of the different area of the furnace can be displayed


on the screen. This screen can make the operator easily get the
furnace working conditions.
According to technology condition, the reheating furnace uses PLC
system, and the system uses puried AC uninterruptible power
supply(UPS).
4. Function description
Automatization control system carry out the following function:
(1) operation station
technology process and control menu display
control and intervention production process
affair and alarm display
technology parameter current diaplay
data communication
(2) control station
various of temperature,pressure, flux measure and alarm
collection and disposal of system data
5. Automatization control system configuration
(1)system composition
According to current technology condition and request, and to
increase the system dependability, Automatic control system choose
the programmable controller products from the SIEMENS company for
the process detect and control of the reheating furnace.
50

Technical Agreement For Syrian Profile Steel Project

(2) equipments slection


Foundation Automatization is planned to use S7-400 as the main
station of the process detect and control for the reheating
furnace, and ET200 as assistant station of the process detect and
control for the reheating furnace.
6. Process detect and control
Main items of the heat engineering control and measurement are
as follows:
detect

and

record

two-segment

furnace

temperature,

autocontrol of two-segment furnace temperature


asjustion and control of two-segment heavy oil, atomizing
dose and air ratio
indication, record and autocontrol of the furnace pressure
indication and control of the main pipe pressure of heavy
oil
indication and control of the main pipe pressure of air
air temperature alarm and auto-spread
atomizing steam temperature alarm and auto-spread
emergency water input control
indication and record of the flow of two-segment heavy oil,
air and atomizing dose
indication, record and count-up of main pipe flow of heavy
oil
indication, record and count-up of main pipe flow of the
steam for atomizing and heat preservation
record and indication of the fume temperature of front and
back of the preheater
record and indicationof the air preheated temperature
record

and

indicationof

the

atomizing

temperature
cooling water main pipe pressure indication
51

air

preheated

Technical Agreement For Syrian Profile Steel Project

cooling water pumping and drainage temperature indication


the current indication for the pressure of heavy oil and
atomizing dose before the nozzle
the current indication for the temperature of heavy oil,
atomizing dose and hot blast before the nozzle
(2)Main control items
Furnace temperature autocontrol in the soaking segment and
the heating segment
Adopting the wind and heavy oil matching cross limiting
autocontrol. When the temperature is on the high side, reduce
heavy oil then reduce wind; when temperature is on the low
side, add wind first, then add heavy oil. Temperature lag time
compensation.
Automatically

cutting

down

heavy

oil

systems

of

each

segments when the the pressure of heavy oil and air is low
The fuenace pressure automatically controls the flue valve
Emergency water automatically input
(3)Evoporstion cooling system detection and autocontrol items:
Manual and automatic control of the pressure of the steam
header and the water level
Pressure detection for soft water supply
Flow

indication

and

autocontrol

of

the

steam

header

feedwater
Over high and low water level alarm for the steam header
Over high and low pressure for the steam header
Water supply valve automatically pumping water
Manual and automatic control of the steam pressure

7. Equipment selection
The main function of the automatic instrument is the logic control
about processing equipment action and
52

the detection

about

Technical Agreement For Syrian Profile Steel Project

technical process

parameters with electric, including the setting

for the part technical parameters to ensure manufacture on the


rails under the computer system operating condition.
The main instrument selecting: the gas flow detection commonly
chooses orifice board; the water flow detection chooses electrical
flowmeter; the control valve executing afency carry out national
advanced

manufacture; the transmitter choose 1151 series pressure

transmitter.
Ninth

Public assistant establishment

1. Fuel
Adopting heavy oil
heavy oil thermal value: 96004.18kJ/mP3
contact pressure: 0.8MPa
rating wastage: 800 Kg/h
contact flow: 960Kg /h
adopting large back oil, and the back oil rate is not less than 1.51.

2. Electrical source
Three phase AC: 50HZ
Voltage: AC380V, AC220V
Power: about 30kW
There will be one 0.2t oil buring steam boiler, and the drawing of
the boiler will be supplied by the seller.
3. Cooling water
For the discharge furnace door, hydraulic station, etc.
Water quality: clean circulating water
Water temperature: inleting32, yielding 45
Contact pressure:0.3MPa
Contact flow: 30t/h
Emergency water: according to two electrical sources switch
time 0.5h;Consumption: 50t/h
53

Technical Agreement For Syrian Profile Steel Project

4Compressed air
Pressure: 0.6MPa
Flow: 20m3/h
5. Light diesel oilFor the start and stop of the furnace
The quantity should satisfy the continuous 10 hours comsuption
for the reheating furnace.
Comsuption: 1000kg/h
Pressure :0.8Mpa
6. Power supply
Electric motor for the combustion fan of the reheating
furnace: 1 piece 75 kW,

380 V

Power supply meter: AC 220V50Hz, capabiity: 10KW

Tenth

Debugging, test running, detection and acceptance

1. Equipment debugging and test running


1.1 When the equipment installation project has the condition for
the stand-alone no-load test run, the seller should organize the
test run and inform the buyer about the test content, the precept,
time and place of the test in 24 hours before the test run,
meanwhile, the seller should make the test record. The buyer and
the supervising engineer make the supervision and check of the
test running.
1.2 When the equipment installation project has the condition for
the linkage

no-load test run, the seller should organize the test

run and inform the buyer about the test content, the precept, time
and place of the test, and the requirement for the buyer about the
test preparations in 48 hours before the test run The buyer should
make preparations according to the requirement of the seller and
send

representative

to

take

part
54

in

the

test

andcheck

and

Technical Agreement For Syrian Profile Steel Project

supervise it. The seller should make the test run record. Only
after the test run is passed and both sides sign on the test
recoed, the project can be put into the head load test run stage.
1.3 If it is the seller matter that causes the failure of the
test run, the seller should afresh the test run after amending the
equipment and afford the expanse of amending and afreshing. If it
is the seller matter that affects the test running process, the
project duration will be postponed.
1.4 During debug and test run period, the seller takes charge of
turnover pieces and wearing pieces; the buyer takse charge of the
expanse of medium(oil, fuel), fuel used for baker, human and tool.
2. detection
2.1

The

project

final

detection

is

the

production-qualified

detection. The seller makes the precept for the heat load test run
and the both sides confirm the

process after negotiation. The

buyer takes charge of organization, and the

seller arranges the

technical personnel to instruct, supervise and deal with the


problems about the equipments. Passing the head load test run and
the seller finished dealing with the problems during it and
through the buyer s approbation, all equipments will be handed
over to the buyer, then the detection period(try-manufacture
period) will start, which will continue 3 months. Reaching the
established production performance assessment criteria means that
the production detecting period is over, and the both sides make
preparations for handing over documents of the project.
2.2 In the examining period, if the equipments damages are the
reasons of the seller, the seller should bear corresponding
responsibility and make maintenance or replacement.
2.3 In the examining period, if the equipments damages are the
reasons of the seller, the seller should bear corresponding
55

Technical Agreement For Syrian Profile Steel Project

responsibility and economic loss. The buyer takes charge of


comsuptions which trial manufacture needs, and the seller makes
cooperation. The seller takes charge of wearing parts..

Technical Proposal of Continuous Billet Caster with Two


passes for the Two units
1 General
1.1 Working scope includes:
Design of continuous caster;
Production and supply of contractual equipment;
Guidance of installation,commissioning and trial operation;
Guidance of equipment maintenance;
Buyers staff training (including technology transfer)
Under the condition that the investment control and product
outline are relatively determined, billet continuous caster shall
be designed based on mature technology, reliable operation and
reasonable configuration.Its technical feature is to select highefficiency

devices

and

low

energy

consumption

to

obtain

extraordinary economic operating effects, which makes factories


possess higher competitiveness.
Basic technical parameters of caster:
Caster radius
Pass

6m
2 passes

Pass distance

1.30m

Ladle turret

Straight arm type

Tundish car

Four

wheel

type

with

traverse

function
Pouring mode

Metering nozzle casting, mold powder


lubrication
56

Technical Agreement For Syrian Profile Steel Project

Secondary cooling

Water

cooling,

auto

adjusting

circuits for each pass


Withdrawal straightening device

Total 5 rollers for gradual

straightening
Roller table
Dummy bar

Chain group centralized drive


Rigid, with self-adapting dummy bar
head

Billet cutting

Flame cutting

Billet conveying

Group centralized live roller

Cooling bed type

Simple cooling bed

table
The set pouring speed and correct pouring process can guarantee
high-quality products.
The automatic control system can ensure the correct and safe
equipment running.
The overall technical characteristics of the machine are
guaranteed by the design of seller, especially the experience in
production of equipment.
The type slection of equipment is closely related to the following
high target values:
Limited investment costs;
High-quality products;
High productivity;
Operation as simple as possible;
Reliability of operation;
Meet the different market demands to the maximum extent.
To ensure the normal operation and maintenance, we will provide
trainings for buyers operators and maintenance personnel on both
theory and practical operation at site or sellers school factory
during installation and commissioning.
If necessary, after handing over the equipment, we will further
supply technical assistance of equipment running and maintenance
57

Technical Agreement For Syrian Profile Steel Project

Note: The seller retains all of its right to modify while


continuously

updating

its

products

in

order

to

improve

the

performance of casters. These modifications will be completed


during the detailed design, while retaining the basic layout and
functionality.
2 Basic design parameters
2.1 Product mix
For product mix, please see the table below:
SN.

Item

Straight carbon steel

Low alloy steel

Representative
steel grade
Q235

Proportion

Remark

50%

Tentative

50%

Tentative

Billet section: 150X150mm,120120mm,100100mm


Equipment

is

equipped

with

150X150mm

Dummy

bar

head

and

crystallizer, then the 120120mm , 100100mm Dummy bar head and


crystallizer should reorder.
Fixed length: 3m, 6m.
2.2 Technical process description and production capacity
2.2.1 Technical process description
Intermediate frequency furnace:
Nominal capacity

10T

Melting cycle

90min

Intermediate frequency furnace quantity 2 sets


Average daily heats (24-hour production)
Working days per year

30 heats/day

330 days/year

In such a case that the molten steel meets the quality


requirements required for continuous caster, the billet will meet
the provisions of YB2011-83.
58

Technical Agreement For Syrian Profile Steel Project

2) Production capacity
Working days

330 days/year

Average daily heats

30heats/day

Nominal capacity

10/furnace

Production capacity

99000t/year

2.2.2 Pouring speed, productivity and passes


For casting steel of different specifications and different
steel groups, the pouring speeds of the R6m caster are as the
following table:
Pouring
section
(mm)
Casting speed
(m/min)

100X100

120X120

1.8

1.2

150X150
Pass 1
1.8

2.2.3 Continuous casting yield


The following table shows the calculated yield from molten
steel (including the residual molten steel in the ladle after
pouring) to the billets in consideration of the following factors:
Ladle capacity

10t

Passes

2 stand

Cutting length

Automatic 3m/6m

Continuous casting times


150X150
Residual
molten
steel in tundish
Residual
molten
steel in ladle
Pouring loss
Top crops
End crops
Cutting loss
Total
molten
steel
Total yield

Pass 1

15 times
Pass 1

Total (kg)
300
300

10
156
156

20
312
312

20
312
312
972
150000
99%

2.2.4 Running parameter Time of reinstalling dummy bar


The following table is the calculated time of resetting dummy
59

Technical Agreement For Syrian Profile Steel Project

bar. This time is measured from the end of last pass to the
beginning of the first pass of the next pouring cycle.
Machine radius
Angle
Bending length form the meniscus to the vertical

6.0
79.9
9.56

axis of withdrawal straightener


Distance from the vertical point to the starting

6.5

point of cutting
Distance from the starting point of cutting to the

final baffle of dummy bar


Output roller speed
Dummy bar feeding speed
Billet size
Rated pouring speed
End crop dummy bar
Cutting cycle
Dummy bar dummy bar
Molten steel level in tundish at rated pouring speed
Min. pouring speed
Molten steel level in tundish at min. pouring speed
Caster passes
Nominal tundish capacity
Delay time of emptying tundish
End billet breakout time
Billet emptying time
Time of introducing dummy bar head into mold
Preparation time of dummy bar head
Tundish car moving and centering time
Time of tuning ladle turret to the ouring station
Tundish filling up time and pass opening
Total time of resetting dummy bar

m/min
m/min
mm
m/min
m
min
m
mm
m/min
mm
t/Stand
mm
m/min
min
min
min
min
min
min
min

28.0
5.0
4
2.2
1.7
1.28
9.42
450.0
1.5
300.0
5
3.0
0.0
0.8
10
2.85
2.0
1.0
0.5
2.0
16.05

2.2.5 Pouring radius and straightening


In order to optimize the casting conditions and billet
quality, pouring speed, steel grade and cross-section shall be
considered for the selection of pouring radius.
In the present and future production process, the adaptation
of caster to users requirements will also affect the selection
60

Technical Agreement For Syrian Profile Steel Project

of pouring radius.
Therefore, the main pouring radius is determined to be 6m and
with gradual straightening function.
In the design of straightening zone, the straightening with
liquid core shall be completed to reduce the pressure on the
billets (internal and surface). Even if the pouring speed further
increases, no cracks will occur.
Gradual straightening ensures that the continuous deformation
of billets, and the elongation percentage of each straightening
point is maintained below the critical value at which crack
occurs.
The

factors

influencing

steel

cracks

are

the

initial

solidification structure (austenite or ferrite) and the tend to


form low-melting sulfides (due to Mn/S ratio).
Steel of different grades has different trends of crack
formation in straightening process. Crack tend depends on the
chemical composition of steel grade and the billet temperature
when straightening.
Following is the main situations to form internal and
external cracks:

If

the

straightening

force

on

the

solid

liquid

interphase is stronger than drawing force at critical temperature,


the

product

cracks

will

be

formed

during

liquid-core

straightening, therefore, it is required to maintain the critical


temperature within the range of high-temperature brittleness.
Surface cracks can occur when brittleness range is
700~850 . To resolve such problem, the secondary cooling shall
be

precisely

adjusted

to

ensure

the

surface

temperature

is

950/1050 when straightening.


The following factors shall be taken into account in the design of
straightening system:
61

Technical Agreement For Syrian Profile Steel Project

Billet section;
Basic radius of continuous caster;
Pouring speed;
Critical elongation percentage decided by steel grade.
The actual billet straightening deformation rates are calculated
as the table below:
Steel grade

Straight carbon
steel
Low alloy steel

(m/min)
Pouring speed
(m/min)
1.02.2
0.82.0

Efficient
deformation rate
()
Referred to the
tabular statement.
Referred to the
tabular statement.

Allowable
deformation rate
(RmaxR)
0.25
0.150.2

2.2.6 Tundish design


The design of tundish shall reach the following targets:

Max.

life

of

refractory

materials

for

long-time

continuous casting;
Low temperature drop during pouring process;
Safe pouring of multi-pass caster
No nozzle eddy flow during the replacement of ladle.
Tundish design of shape can prevent refractory materials
from peeling from tundish due to heat elongation percentage.
It is recommended to use high-quality insulating boards and
covering agents to reduce temperature drop and ensure the steel
quality.
Characteristics of refractory materials recommended:
Working lining material: insulting boards
Working lining thickness: 40mm.
It is recommended to use synthetic covering agents for tundish.
The compositions shall be able to adsorb slag inclusion and reduce
oxygen activity.
Basic features of covering agent:
Compositions

SiOR2R=2124%
62

Technical Agreement For Syrian Profile Steel Project

AlR2ROR3R=810%
(CaO+MgO)=3638%
(CaO+MgO)/SiOR2R=2
1300

Alkalinity
Melting point

Almost half of the reoxides are generated due to the poor


protection of pouring passes from ladle to tundish, therefore, in
order to prevent reoxidation, it is recommended to take effective
protection to the passes from ladle to tundish.
Special Note: In case that user use steel grade Q235, 20MnSi for
the production of 150X150 and the molten steel of the intermediate
frequency furnace can only meet the need of 24 heats of continuous
casting,

based

on

the

cost

and

organization

of

production,

insulating boards shall be selected as the tundish refractory


material. Metering nozzle casting will be a good choice.
2.2.7 Mold technology
The predominant idea of the design of mold copper tube and tube
wall thickness lies with the avoidance of permanent deformation
under the high-temperature working condition.
The deformation of mold copper tube will seriously reduce the
service life of mold, and cause deeper oscillation marks and shape
defects on billet surface. In order to avoid deformation, the
copper tube shall be able to freely expand along the longitudinal
axis under temperature action.
The taper of copper tube shall comply with the billet shrinkage
shape and maintain billet and mold surface in contact. A proper
taper can keep good contact form billet to mold outlet, reduce
possible crack and surface defects, such as off square and concave
scars.
The taper of copper tube is calculated according to the given
solidification shrinkage parameters of main steel grades. For
billets, parabolic continuous taper is widely used, which can
basically adapt to different steel grades and pouring conditions.
63

Technical Agreement For Syrian Profile Steel Project

Mold water slit design is for high water speed to keep low tube
temperature and avoid water boiling, especially near the meniscus
of molten steel in the mold.
The discontinuous changes in the temperature of copper tube wall
and unstable heat transmission will lead to cooling water boiling,
causing

permanent

tube

deformation,

furthermore,

high

wall

temperature also increase the precipitation of dissolved salts.


Inhibition of water boiling water does not only rely to water
speed, but also water pressure. In fact, the boiling temperature
and pressure has a well-known interrelationship, thus it is also
able to avoid boiling by increasing pressure.
The typical value of mode water slit design is 4mm, which is the
optimized

result

when

mold

has

high

water

speed

and

lower

pressure.
In order to ensure the water slit size, the water jacket has
stringent tolerance limits to ensure that the water slit is
constant in all cases. Main cooling parameters:
Steel grade
Water flow velocity
Max. inlet pressure
Water speed

Group
2000Lmin/pass
Bar
m/sec

12
6.0
10

Main parameters of corresponding mold:


Mold material
Wall thickness
Coating material
Coating thickness

CuAg
10mm
Cr
0.1mm

2.2.8 Mold oscillator


The design of mold oscillator achieves the following results:
To ensure the surface quality and reduce the depth of
oscillation marks
To ensure the sufficient lubrication of solidified
shells
64

Technical Agreement For Syrian Profile Steel Project

The

basic

factor

taken

into

account

for

the

selection

of

oscillation parameters is negative strip time, that is the time


interval in the case that mold speed is faster than billet speed
when the mold and billet move in the same direction. It has the
relationship with the oscillation parameters as below:
NST=60/farccos(VC1000/fs)
Where: f Oscillation frequency per minute (1/min)
VC Pouring speed (m/min)
S Stroke (mm)
The negative strip time is directly related to the depth of
oscillation marks. If the mold oscillates at higher frequency and
relatively small amplitude, the negative strip time is short and
oscillation marks are light.
Practice

has

proved

that

the

best

negative

strip

time

is

0.10~0.12s.
Depending on different pouring speed, the frequency shall be
changed to ensure constant negative strip time. The results of
changes are automatically controlled by continuous casting and
recorded by the computer.
Oscillation frequency and amplitude are determined by the negative
strip time and pouring speed.
Pouring parameters are controlled by the basic automatic system.
2.2.9 Billet support
Seller recommends the mold with foot rollers.
The purpose of foot rollers is to guide the billet after getting
out of mold and guide the introduction of dummy bar head when
resetting the dummy bar. If the billet/dummy head is without
guidance, it may scratch the bottom copper tube wall of mold,
shorten the service life of mode and result billet surface
defects.
Practice has proved that the proper use of foot rollers can reduce
65

Technical Agreement For Syrian Profile Steel Project

mold wear, and reduce the impact on the billet surface under
different pouring conditions.
Foot roller number and distance considered in design:
Section

Number of rows

Roller number of

Roller diameter

each row

mm
60

mm
150150

2.2.10 Secondary cooling


To ensure rapid solidification and eliminate the generation of
metallurgical defects through the following conditions:
Control the temperature recovery of the billet surface
which is on the spray cooling end;
A suitable form of water cooling to avoid the different
cooling rates of billet center, edges and corners;
Automatic control a suitable billet temperature to provide
good working conditions for steel rolling.
The spray cooling system is broken down into several cooling zones
according to the billet size and steel grade.
The distribution of cooling intensity effectively determines the
liquid core length and the average temperature of billet surface.
The design of spray cooling system is based on the mathematical
models of solidification and thermal conductivity. The program
estimates the best configuration of water cooling system with the
calculated theoretical thermal conductivity distribution.
In this case, there are three secondary cooling zones.
SN.
1
2

Item
Foot roller
Fixed section

Length (m)
0.20
2.4

1
Fixed section
2

2.3 Common facilities


66

Nozzle number
16
56

Cooling mode
water
cooling

Technical Agreement For Syrian Profile Steel Project

2.3.1 Power supply (excluding water treatment, air power)


Low voltage
Frequency
Continuous caster auxiliary motor, rated

380
50
200

V
Hz
Kw

power

2.3.2 Water
1) Cooling water classification
Indirect cooling water: the cooling water that does not directly
contact the cooled objects, such as the water for the primary
cooling circuit of a continuous caster.
Direct cooling water: the cooling water that directly contacts the
cooled objects, such as the water for the secondary cooling
circuit of a continuous caster.
Emergency water: the cooling water for protecting devices from the
hazards of power down.
Direct and indirect cooling water has own independent systems. The
recirculation is in two ways: closed circuit and open circuit.
When the equipment is running, it shall always guarantee the
quality characteristics of water to avoid the impact of debris and
corrosion.
Technical requirements for water are shown in the following table:
Cooling system

Device

Soft

Secondary

Emergency

Water type
PH
Ca hardness (mg/1CaCCOR3R)
Mg hardness (mg/1CaCCOR3R)
Alkalinity (mg/1CaCCOR3R)
Max. chloride (mg/1CCl)
Max. sulfide (mg/1SOR4R)
Max. iron (mg/1Fe)
Max. silicon oxide

water
a
79
30240
080
50200
200
150
0.5
50

water
aa
79
060
020
20200
50
40
0.5
10

cooling water
b
79
30360
0120
50300
250
200
0.5
75

water
c
79
30240
080
50200
200
150
0.5
50

(mg/1SiOR2R)
67

Technical Agreement For Syrian Profile Steel Project

Max. total dissolved solid

1000

500

1500

1000

(mg/1)
Total suspended solid

1020

1020

5080

1020

(mg/1)
Max. suspended solid size

100

50

200

100

(m)
Max. oil content (mg/1)

10

1) Water technical parameters of different users


In the table:

Q maximum water flow rate


Pem maximum emergency pressure
Qem emergency flow rate
Ti maximum inlet temperature
Pi 0.00m pressure
Te maximum outlet temperature
DP Pressure drop

Type

aa
a
b

Q
mP3P/h

240
100
50

Ti

Te

Pi
Mpa

DP
Mpa

35
35
35

50
50
/

0.8
0.3
0.8

0.50
0.3
/

Qem
mP3P/h

Pem
Mpa
0.3
/
/

Note: 1 Duration: 5min


2.3.3 Compressed air
Compressed air user of continuous caster
Driven by cylinder
Air for instruments
Air for cylinder and cooling, etc
The compressed air circuit shall has an air dryer to reduce
the humidity to the allowable range.
Characteristics:
Pressure: 0.4~0.6Mpa
Quality: industrial compressed air

68

Technical Agreement For Syrian Profile Steel Project

User

General
user
Pressure
head
Instrume
nt air

Q
(NmP3P/h
)
10

Pi
(Mpa)

(mg/mP3
P)

(mg/NmP3P)

(mg/mP3P)/
(mm)

0.6

20

5000

15/0.05

180

0.6

5.000

15/0.05

0.6

(dew point
-20)

5/1pm

2.3.4 Oxygen
Pressure required: 1.2Mpa
User
Oxygen lance

Peak value (mP3P/h)

Mean value (mP3P/h)


100

Peak value (mP3P/h)

Mean value (mP3P/h)


110
175

2.3.5 Fuel
Fuel type and user
Continuous caster
oxygen lance
Continuous caster

3. Main equipment and technical performance


3.1 Ladle turret
Turn the ladle full of molten steel from the receiving position to
the pouring position, at the same time, move the empty tundish back
to the receiving position to receive molten steel.
Type: Straight arm type, without capping mechanism
Structural components: ladle slewing bearing, drive unit, slewing
arm, upper slewing body, lower base, slip ring parts, anchoring
parts, slide gate nozzle operating parts and operating platform,
protective structures, etc.
Main turret technical parameters:
Carrying capacity

230t

Slewing radius

3300mm

Slewing driving mode

By

operation)
69

hydraulic

motor

(normal

Technical Agreement For Syrian Profile Steel Project

Normal slewing speed:

1r/min

Emergency slewing speed:

1r/min

Rotation angle:

270

Equipment weight:

18000Kg

Equipment Quantity:

1 set

1) Drive unit
Slewing bearing

131.50.1800
M=20

z=174

M=20

z=174

Slewing motor:

CD03477W

Speed:

50r/min

Pressure difference:

10MPa

Drive unit quantity:

1 set

3.2 Tundish
For receiving the molten steel in the ladle and pouring it to
the mold.
The cover on the tundish is mainly for the heat preservation
of molten steel.
1) Main tundish technical parameters
Tundish structure: T-type, with retaining wall and retaining
weir, overall pouring tamped Tlining
Nozzle quantity:

2Pcs

Nozzle interval:

1300mm

Nozzle opening size:

160mm

Molten steel depth/weight while pouring: 400mm/5t


Molten steel depth/weight while overflowing: 600mm/8t
Equipment weight:

1800Kg/set

Equipment quantity:

2 sets

3.3 Protective casting device (optional)


For reducing the inclusions in steel. This continuous caster has a
design of casting protection from ladle to tundish.
Main technical parameters:
70

Technical Agreement For Syrian Profile Steel Project

Structure: Lever type


Operation mode:

Manual

Equipment weight:

200Kg/set

Equipment Quantity: 1 set


3.4 Tundish car
It is on the fixed track of the pouring platform, and for
carrying tundish in and out of the pouring station. There are two
tundish cars for alternative use.
Structure: The thndish car adopts the track type, and consists
of the body, working mechanism, adjusting mechanism,
etc.
Its travel mechanism adopts the single side dual-drive mode by
electric drive. The traverse position of nozzle is fine tuned by
hand.
Main tundish car technical parameters
Carrying capacity:

20t

Track gauge size:

1600mm

Equipment Quantity:

2 sets

Equipment weight:

2500Kg/set

1) Travel mechanism parameters


Travel stroke:

mm

Travel speed:

1.210m/min

Wheel diameter:

250mm

Gear motor
Model:
Power:

2.2KW

Output speed:

12.7r/min

Frequency:

350Hz

2) Traverse mechanism parameters


71

Technical Agreement For Syrian Profile Steel Project

Working stroke:

50mm

3.5 Telescopic tube for suspended control box


It is used for the suspended electric control box of ladle
casting platform, of which one end is fixed under the beam of the
ladle casting platform and the other end is connected with the
electric control box by a check ring. This tube extends and
withdraws through a supporting roller for operators to move and
operate.
Structure: Suspended telescopic steel structural component
Main technical parameters:
Stroke:

1800mm

Equipment weight:

60Kg/set

Equipment quantity:

2 sets

3.6 Protective sleeve mechanism


For the installation between the ladle and tundish
Structure: Consist of bearing, compression member, crossbeam
and other components
Main technical parameters:
Control mode:

Manual

Quantity:

1 set

3.7 Mold
It is for the initial setting of shells. After initial setting,
billets are continuously drawn out from the lower outlet of the
mold, then come into the secondary cooling zone. It includes steel
tubes, internal water jacket, external water jacket, drainage
pipe, water ring, foot roller, bottom and top flanges, lubricating
flange and other components.
Main technical parameters:
Type:

Parabolic tubular mold

Mold type:

Parabolic curved copper tube

Copper tube material:

Chromeplated

CuAg

tube

with

approximately 0.1mm plating coat


72

Technical Agreement For Syrian Profile Steel Project

External arc radius of tube: 6000mm


Mold

length/pouring

section/fillet

radius:

850mm/150150mm/3~6mm
Copper tube cooling:

Closed

primary

cooling

system
Water seam size:

Approx 5mm

Flow rate:

Approx 8~10m / s

Water supply pressure:

0.6~0.8MPa

Water temperature (in/out):

40/48

Foot roller material:

St52-3

Foot roller bearing:

Bronze sliding bearing

Foot roller quantity:

2/set

Nozzle distribution and quantity:

One

row

above,

three

rows under; 16/sets


Quantity:

2 sets

3.8 Mold oscillator


For preventing initial solidified shell from been broken due to
its sticking to mold wall.
Structure: Semi-leaf spring type
This equipemt consists of upper and lower guide leaf springs,
eccentric oscillation mechanism, oscillating table frame, medium
pipeline, etc.
The oscillator has a converse oscillating characteristic, that is,
in

order

to

maintain

certain

negative

strip

rate,

the

oscillating frequency can be reduced to increase the oscillating


stroke, when speeding up the continuous casting speed.
Main technical parameters:
Driving mode:

VVVF

Amplitude range:

29mm

Frequency:

30~250 times/min

Oscillation mode:

Sine
73

Technical Agreement For Syrian Profile Steel Project

Amplitude adjustment:

Shutdown regulation

Frequency regulation:

Automatic

adjustment

according

to

casting speed
Oscillator quantity:

2 sets

3.9 Guide frame and spray device of secondary cooling section


For directly spraying billets for cooling, and support and guide
billets or dummy bar.
This device consists of three supporting and guide sector sections
with same radium with the basic arc, a spray water cooling device,
a fixed base, etc.
The secondary cooling is mainly for directly spraying the cooling
water to the billet surface to have billet rapidly get cool and
solidified.

The

cooling

intensity

and

the

structure

and

configuration of nozzle are all directly related to the billet


quality and yield.
Main technical parameters:
Structure:

Simplified structure

pass distnce:

1300mm

Nozzle type:

Square and hollow

Nozzle model:

3/8 PZ6065Q24

Total equipment weight:

1000Kg

3.10 withdrawal straightener


For

billet

guiding

and

straightening.

The

drawing

speed

is

adjustable to meet the different speed requirements of different


steel grades.
This equipment consists of the rack, screwdown and five rollers up
and down, drive system, water-cooling system, etc.
Before casting, the withdrawal straightener transfers the dummy
bar to the specified position in the mold; during pouring, it
forcibly draws the dummy bar and the billet solidifying with the
bar out from the mold; after passing the supporting and guide
device of the secondary cooling, it separates the billet and dummy
74

Technical Agreement For Syrian Profile Steel Project

bar and begins continuous drawing and straightening.


Main technical parameters of withdrawal straightener:
Type:

Integrated

rack

five-roller

withdrawal straightener
Driving mode/TscrewdownT mode:

Electric

drive/Thydraulic

screwdown
Straightening radius:

6000mm-12000mm-

Straightening temperature:

9501050

Drawing speed:

0.33.0m/min

Roller size:

300mm

Motor power:

11KW

Reducer velocity ratio:

340

Mode of speed control:

230mm

Variable (5-50Hz)

System working pressure:

10Mpa

Hydraulic medium:

Mineral oil

Inlet hydraulic cylinder model:

LA-200X80X60

Outlet hydraulic cylinder model:

LA-200X80X225

Equipment weight:

5000kg/set

Equipment quantity:

2 sets

3.11 Rigid dummy bar, storage rack and platform


For towing the billet out of the mold. Through the secondary
cooling section billet guidance and withdrawal straightener, the
dummy bar is stored on the storage rack for the next use.
Storage rack includes the towing gear, storage rack, guide wheels,
steel platform and other parts. Te towing speed is synchronous
with the speed of withdrawal straightener.
The rigid dummy bar is of sectional type steel plate boltfastening structure. The self-adapting function of its head can
75

Technical Agreement For Syrian Profile Steel Project

eliminate the deformation.


Main technical parameters:
External arc radius of dummy bar:

R6m

Angle of contact:

92

Dummy bar Tshank Tsection:

200140mm

Drawing speed:

0.55mmin

Power:

1.5KW

Output power:

5.1rmin

Mode of speed control:

Constant speed

Platform size:

Approx 12m3.4m2m

Weight of dummy bar and storage device:


Platform weight:

1667kg/set

10000kg

3.12 Shear entry table


3.12.1 Centralized live roll table
For conveying billets and end billets.
Structure: Water-cooling roll table that consists of the rollers,
roll table bearing beams, guide guard, roll table cover plate,
drive plat, drive unit, etc.
Main technical parameters:
Driving mode:

Centralized

(electric)

drive
Llinear velocity of roller surface:

2.5mmin

Overall dimension of roll table (per pass):

5000500450 mm

Roller (diameter/length):

240230 mm

Roller distance:

1060 mm

Roller quantity:

5/pass2 passes=10

Rated motor power:

1.5KW

Motor speed:

1500rmin

Rotation direction:

Positive and negative

Motor quantity:

1 set/pass2 passes=2 sets

3.12.2 After-shear table


76

Technical Agreement For Syrian Profile Steel Project

The first group of roll tables after cutting, consisting of


rollers, roll table bearing beams, guide guard, roll table cover
plate, water cooling system, drive unit, etc.
Main technical parameters:
Table distance:

1300mm

Roller (diameter/length):

240230mm

Roller distance:

1060mm

Roller quantity:

5/pass

3.13 Runout table


For rapidly and stably conveying the billets, which cut to fixed
dimension, out of the cutting zone to runout table . It consists
of the rollers, roll table bearing beams, guide guard, roll table
cover plate, drive unit, water cooling system, etc.
Main technical parameters:
Driving mode:

Centralized motor drive

Table speed:

15mmin

Roller size (diameter/length):

240230mm

Roller distance:

1060mm

Table distance:

1300mm

Roller quantity:

5/pass

Power:

4.0KW

Velocity ratio:

59

Motor speed:

1450rmin

Mode of speed control:

Constant speed

Gear motor quantity:

1 set/pass

3.14 Flame cutting machine


Use the flame cutting machine to cut the billet by the length
required by users.
Main technical parameters:
Cutting stroke:

1000mm
77

Technical Agreement For Syrian Profile Steel Project

Cutting seam:

7mm

Max. cutting section:

150180

3.15 The roll table for the cold bed


For conveying the billets of fixed dimension to the parallel flow
table rapidly and stably.
Structure: Water-cooling roll table that consists of the rollers,
roll table bearing beams, guide guard, roll table cover plate,
drive unit, etc.
Main technical parameters of runout table:
Driving mode:

Centralized drive

Bearing capacity of roll table:

50KN/pass2 passes=100KN

Linear velocity of roller surface:

15 mmin

Roller (diameter/length):

240230 mm

Roller distance:

1300 mm

Roller quantity:

5/pass2 passes=10

Motor type:

AC motor (AC380V, 50Hz)

Rated motor power:

4.0KW

Motor speed:

1450rmin

Motor quantity:

1 set/pass2 passes=2 sets

Roll table quantity:

1 set/pass2 passes=2 sets

3.16 Hydraulic steel shift machine


Fpr moving the billet on the roll table to the cooling bed.
Structure: Consisting of hydraulic drive mechanism, hydraulic
cylinder and other components.
Main technical parameters:
Driving mode:

Hydraulic

Hydraulic cylinder model:

TC1251800

Hydraulic cylinder stroke:

1800mm

Hydraulic cylinder working pressure:


Hydraulic cylinder working medium:

Mineral oil

Hydraulic cylinder quantity:

2 pcs
78

Technical Agreement For Syrian Profile Steel Project

Equipment quantity:

1 set

Total equipment weight:

1500kg

3.17 Cooling bed


When the heating furnace, or the steel rolling can not match the
steel making, the superfluous billets will be moved out of the
roll table and enter into the cooling bed.
Main technical parameters of cooling bed:
Mix. billet stacking quantity:

10T

Max. bed surface load:

20KN

Charring billet specification:

1501506000mm

Effective size of cooling bed (LW):

60003000mm

Equipment quantity:

1 set

Equipment weight:

2000kg

3.18 Off-line and auxiliary equipment


1) Tundish sling
For hoisting tundish and steel structural parts.
Main technical parameters:
Loading capacity:

200KN

Weight:

1490kg

Qty:

1 set

2) Tundish sling storage rack


For storing the tundish sling and steel structural parts.
Main technical parameters:
Bearing capacity ofthe storage rack:

50KN

Weight:

300kg

Quantity:

1seat

3) Mold maintenance stand (optional)


Consisting

of

the

rotating

components.
79

device,

platform

and

other

Technical Agreement For Syrian Profile Steel Project

The mold can turn to any angle though the rotating device for
maintenance.
Main technical parameters:
Motor power:

0.4KW

Reducer velocity ratio:

1003

Equipment weight:

350kg/set

Equipment quantity:

1 set

4) Mold storage rack


storing the mold and steel structural parts.
Main technical parameters:
Equipment weight:

372kg/group

Equipment quantity:

2 groups

5) Arc aligning templet


For the arc aligning inspection of the mold, secondary
cooling section and withdrawal straightener.
Main technical parameters:
External arc radius:

6000mm

Equipment weight:

14kg

Equipment quantity:

1 set

model
3.19 Hydraulic system
Mainly for the driving and control of the body of continuous
caster and off-line devices.
In order to ensure safe and reliable continuous running of the
equipment, domestic brand-name components are to be adopted as the
main components of the hydraulic system. The main pump is an axial
plug pump to adapt to the needs of high pressure and large flow
rate.
Due

to

the

transmission

requirements

and

different

control

accuracy of the equipment, as well as the difference between the


actions and functions of the main and auxiliary devices, hydraulic
80

Technical Agreement For Syrian Profile Steel Project

station is designed.
Hydraulic station.
To supply power to the withdrawal straightener, ladle turret,
roll table flap, pusher, etc.
System pressure:

8MPa

Total motor power:

44KW

Tank capacity:

2000L

Hydraulic medium:

Mineral oil

4 Electric and detecting system


4.1 System design basis
In 21st century, we are facing a distributed field bus oriented
revolutionary reformation and development trend of integration of
electric

control

technology,

electronic

instrument

control

technology, electronic computer technology (EIC) in the worldwide


automatic control field. Based on our advanced design concepts of
the world-class continuous caster automatic control system in
1990s, we selected the advanced and reliable control equipment
with full consideration to many factors, such as the advantage,
openness and stability of the equipment, the reliability of
sources, as well as cost/performance. Moreover, we also combined
our

experience

accumulated

during

the

installation

and

commissioning of control systems of shaped continuous casters and


the deep study in introduced automation equipment.
For the automation system of the production line of the two-pass
billet continuous caster, we take high reliability, durability and
cost/performance as the principle, by which we select the quality
transmitter for the measurement of the flow rate, pressure and
pressure difference for the primary instruments, select the fluid
level gauge for the measurement of liquid level, select the
electromagnetic flow meter, which owns high precision and low
81

Technical Agreement For Syrian Profile Steel Project

maintenance, as the detecting element for the measurement of the


secondary

cooling

water,

and

select

the

safe

and

reliable

pneumatic valve as the actuator to ensure stable and smooth


adjustment.
4.2 Detecting instrument
4.2.1 Control requirements
The

software

of

control

system

includes

the

system

control

software and management application software.


1) Control system software features:
Object-oriented graphical interface;
Screen display system established by the system; that is we can
get the same direct impression form object-oriented user interface
as

from

objects.

The

man-machine

interface

is

accessible,

intuitive and impressive.


Alarm and alarm management
Be able to carry out continuous monitoring of the process. Its
alarm draws your attention to the potential risks. The alarm
limits can be flexibly defined, and the information can be
displayed on the screen.
2) Management software package features
Dynamic editing function: Rich pixels and colors, which can
establish the technical process flow and create its dynamic
graphics according to requirements; Animation function, which can
simulate a variety of technical processes intuitively.
Flow chart display function: Be able to display each production
flow with intuitive pictures, and dynamically display the changes
in various process parameters, such as the update of data, state
changes of controlled devices (e.g. the on/off of valve).
Trend analysis: Be able to show the analysis of the real-time and
historical data with trend curves. Multiple trend curves can be
displayed on one screen for comparison, and every part of trend
82

Technical Agreement For Syrian Profile Steel Project

can zoom out and in. By observing the real-time and historical
trend curves, we can get full information of the control process,
and use the historical trend treatment to collect, store and
display real-time process data. The data obtained can be filed, so
that it can be made into reports for comparison.
Alarm function: Be able to continuously monitor the process, and
alarm as soon as failure occurs.
Database function: The stronger database management function can
not only establish a production database and store the raw
production data for statistics and analysis, but also establish a
fault database to record system errors and failures.
4.2.2 Inspection and control items and control mode
1) Mold
Inlet branch tube pressure and temperature detection of cooling
water, and low-pressure alarm
Inlet temperature and pressure detection of cooling water inlet
manifold and low-pressure alarm
Inlet and outlet temperature difference detection of cooling
water, and high-temperature alarm.
2) Secondary cooling zone
Inlet pressure and flow rate detection of the manifold, and
low-pressure alarm.
Flow rate and pressure detection of each pass of branch tubes.
3) Withdrawal straightener
Drawing speed inspection
Billet length inspection
5. Design scopes and work division of both parties
5.1 Party As design scope
5.1.1 Design of plant related to the continuous caster.
5.1.2 Design of off-line pipeline related to the continuous
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Technical Agreement For Syrian Profile Steel Project

caster.
5.1.3 Design of common and auxiliary facilities (including
water, electricity, wind, gas) related to the continuous caster.
5.1.4 Design of the gas supply system and gas pipeline of gas
bus.
5.1.5 Design of the power line of oxygen and compressed air.
5.1.6 Design of the tubing of gases (oxygen, gas, compressed
air) for continuous casting.
5.1.7

Design

of

the

power

cable

feeding

for

continuous

casting, and plant design lighting design;


5.1.8

Design

of

the

air

conditioning,

ventilation,

fire

control and communication systems for continuous casting.


5.1.9 Lighting design for the main electric room, each control
room and hydraulic station of the continuous caster.
5.1.10 All hydraulic, lubricating oil and grease shall be
provided by Party A.
5.1.11 Party A shall provide the convenience of work, room and
board for Party Bs felid staff.
5.1.12 Party A shall provide cranes and crane operators to
assist the construction.
5.1.13 All refractory materials and brick masonry materials
shall be provided by Party A.
5.2 Party Bs design scope
5.2.1 Layout drawing of the equipment of continuous caster
5.2.2 Basic data and drawings of the on-line equipment related
to the continuous caster (including the foundation bolt size and
load of equipment).
5.2.3 Design of on-line non-standard equipment.
5.2.4 Design of the tubing of a variety pipelines of on-line
equipment.
5.2.5

Automatic

control

system
84

design

of

the

continuous

Technical Agreement For Syrian Profile Steel Project

caster.
5.2.6 Hardware configuration of computer system
5.2.7 Programming of application software.
5.2.8 Design of the cable laying of on-line equipment.
5.2.9 Technical requirements and parameters related to the
energy medium system, water, electricity and gas of the continuous
caster, which shall be provided for Party A.
5.2.10 Design of the continuous caster and relevant civil
construction requirements.
5.2.11 Design of the water supply system requirements of the
continuous caster.
5.3 Nodes of pipeline plans of both parties:
5.3.1 The node of the compressed air pipeline: for the
compressed air, Party A is responsible to design the pipeline form
the gas source to the dedicated gas tank (including gas tank) of
the continuous caster, and Party B is responsible to design the
pipeline from the gas tank to equipment.
5.3.2 The node of the energy medium pipeline: for the gas
pipeline, Party A is responsible to design the pipeline from the
gas source to the master valve (including the master valve) of the
continuous caster, and Party B is responsible to design the
pipeline from the valve to the point of use.
5.3.3

The

design

of

lubricating

pipeline

and

hydraulic

pipeline are assumed by Party B.


5.3.4

The

node

of

the

power

supply

line:

Party

is

responsible to design the line from the power source to the power
receiving cabinet in the main electric room of the continuous
caster, and Party B is responsible to design the line from the
power receiving cabinet (including the power receiving cabinet) to
the use point of equipment..
5.4 Handing over of drawings and data
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Technical Agreement For Syrian Profile Steel Project

5.4.1 Drawings and data that Party A shall provide for Party
B.
5.4.1.1 Civil construction drawings of plant in connection
with the continuous caster; Crane outline and hook movement
location drawing, as well as hook head outline drawing, ladle
drawing, ladle slide gate nozzle assembly drawing.
5.4.1.2 Other date related to the design of the continuous
caster.
5.4.2 Date which Party B shall provide for Party A.
5.4.2.1

Provide

detailed

basic

equipment

data

of

the

continuous caster.
5.4.2.2 Provide the civil construction data of internal cable
trenches, pipe tunnels and embedded parts of the continuous
caster.
5.4.2.3 Provide the civil construction design data of the main
electric room, each control room, and hydraulic station.
5.4.2.4 Technical requirements of the three-water system and
energy medium consumption of the continuous caster; Location
coordinate drawing of the master three-water feed and return
valve, master gas tank valve, gas tank, etc.
5.4.2.5 Other data related to Party As design.
5.4.2.6 Two complete sets of installation and maintenance
drawings of equipment, electric and instruments of this project.
5.4.2.7

Technical

documents

and

data

attached

with

the

(including

the

delivery, including:
Equipment delivery list (packing list);
Outsourced

parts

and

standard

parts

list

suppliers, product certificates, etc. and other data of outsourced


parts);
Technical date of outsourced parts;
Single machine trail run, acceptance and inspection reports;
86

Technical Agreement For Syrian Profile Steel Project

Program list or floppy disks;


PLC operation manual and programming manual;
(7) Technical data of instruments and actuating apparatus.
List of equipment delivery (packing list);
6. Production of equipment & complete EIC equipment set
6.1 Supply scope of complete set of equipment
6.1.1 All designed on-line non-standard equipment, off-line
non-standard equipment, the hydraulic station and piping, and
pneumatic control cabinet.
6.1.2

Designed

complete

sets

of

electric

and

instrument

automation equipment.
7. Others
7.1 Electromagnetic stirring, automatic liquid level control
and

aerosol

cooling

system

are

not

taken

into

account

for

continuous casting at present, but in the overall design, space is


reserved for their further installation, so that, user can improve
the equipment for the production of high-quality special steel.
A part of performance of Qiaolian Heavy Industry in complete small
continuous caster equipment
In complete small continuous caster equipment, the products of
Qiaolian Heavy Industry has been serialized and have unique Haijun
features. Now, there are R8, R6, R4 and other standard series, as
well as R9, R5.25, R2.5 and other non-standard series. The billet
specification is max. 200*300 and min.80*80, with an annual single
pass production of 12t. R8, R6, R4 series continuous casters have
become the competitive products of Qiaolian Heavy Industry. 2.5
series are the products first designed to 80*80 for small and
medium-sized mill users in China, which can direct rolling without
breakdown (mills under 450 need to be slightly modified) to save
87

Technical Agreement For Syrian Profile Steel Project

tens of RMB of breakdown cost and improve the effectiveness by


several times for users. 2.5 series is the typical model of
Qiaolian Heavy Industry to obtain low cost with high technology.
At present, the technical personnel of Qiaolian Heavy Industry are
developing 70*70 continuous casters with great concentration and
aim to ultimately obtain 60*60, so that, small and medium-sized
mill users do not need to modify casters, but use it for direct
rolling. The small slab continuous casters of Haijun are in
improvement, and the engineers are working hard to meet the
requirements of majority of users as soon as possible.
The following is a part of performance of Hiajun in complete small
continuous caster equipment in recent years.
Xixing Iron & Steel Co., Ltd. Reformation of R8 three-pass
continuous caster
Guiyang Changle Steel Co., Ltd.

R6

two-pass

continuous

caster
Wuxi Qiangsheng Iron & Steel Co., Ltd.

R6

two-pass

R6

two-pass

continuous caster
Guangxi Mingang Iron & Steel Co., Ltd.
continuous caster
Ningde Rongxing Steel Industry Co., Ltd.

R6

three-pass

continuous caster
Jiangsu Changjiang Runfa (Suqian) Group R6 two-pass continuous
caster
Changzhou Xingyu Iron & Steel Co., Ltd.

R6 two-pass continuous

caster
Guangdong Xiaoheng Huidong Steel-casting Foundry
R8 two-pass continuous caster
Jiangsu Jiangyin Xinshengang Iron & Steel Co., Ltd.
R6 two-pass continuous caster
88

Technical Agreement For Syrian Profile Steel Project

Kazakstan Steel Mill

R6 two-pass continuous caster

Jiangsu Liyang Xinguang Steel Mill

R4 two-pass continuous

caster
Jiangxi Shangrao Steel Mill

R6 two-pass continuous

caster
Zhejiang Mingtai Iron & Steel Co., Ltd.

R6

two-pass

continuous caster
Chongqing Pengcheng Iron & Steel Co., Ltd.
R6 two-pass continuous caster
Guangdong Fengshun Agricultural Machinery Continuous Casting
Factory
R6 two-pass continuous caster
Guangdong Yongshun Steel-casting Foundry
R6 two-pass continuous caster
Sichuan Fufeng Iron & Steel Co., Ltd.

R6

two-pass

continuous

caste
Shandong Liaocheng Steel Mill

R6

two-pass

continuous

caste
Jiangxi Shangrao Metal Products Co., Ltd. R6

two-pass

continuous caste
Guangdong Huafa Metal Products Co., Ltd.

R6

two-pass

continuous caste
Indonesia Delong Steel Mill

R6

two-pass

continuous

caste
Zhejiang Mingtai Iron & Steel Co., Ltd.

R6

two-pass

continuous caste
Guangxi Qinzhou Hengrong Iron & Steel Co., Ltd.
R6 two-pass continuous caste
Guangdong Zhongrun Steel Industry Co., Ltd.
R6 four-pass continuous caster
Indonesia

First

Source

Steel

continuous caster
89

Co.,

Ltd.

R6

three-pass

Technical Agreement For Syrian Profile Steel Project

Vietnam Ho Chi Minh Tongjin Steel Mill

R6 two-pass continuous

caste
Thailand Taifengrong Steel Mill

R6 four-pass continuous caster

Suzhou Danuo Casting Co., Ltd.

R6

three-pass

continuous

caster
Shandong Dazong Machinery Casting Co., Ltd.
R6 three-pass continuous caster
Chongqing Yonghang Metal Products Co., Ltd.
R8 four-pass continuous caster
Technical Specification For The 10T Electrical Furnace
with Variable Frequency and Energy Conservation
1. General description
1.1 KGPS series integrated thyristor medium frequency power supply
is to rectify 50 Hz or 60 Hz alternating current into direct
current fully controlled by an ordinary thyristor, after the
ripple

is

filtered,

inverted

to

be

150HZ~10000HZ

by

fast

thyristor. It can be used for thermal processing such as melting,


forging, welding, bending, extruding, rolling, etc as well as
workpiece quenching, annealing and other heat treatment processes.
1.2 Meaning of KGPS series model is as follows:
KGPS

1250

50

Controlled

Rated output frequency (Hz)

Controlled
Rated output Power (Hz)

Frequency converter
Water cooling

1.3 The machine control system is full-integrated circuit. In the


system,

inverter

trigger

circuit

adopts

automatic

frequency-

sweeping start-up technology, to ensure the success of full-power


start-up of medium frequency power supply; rectifier control
circuit

adopts

large-scale

phase-shifting
90

rectifying

trigger

Technical Agreement For Syrian Profile Steel Project

circuit, with strong anti-interference performance, better line


shape, simple commissioning and stable operation; good performance
of current-limiting and voltage-limiting can avoid the problems on
frequent overvoltage and overcurrent caused by load variation;
comprehensive protection functions can ensure that the equipment
can carry out automatic safety shutdown in case of various faults.
The medium frequency power supply with full-integrated frequencysweeping control is a kind of new-generation medium frequency
power supply with low energy consumption, high efficiency, easy
operation and maintenance.
2. Service conditions
2.1 This devoce shall be installed in the room, and meet the
following conditions:
2.1.1 The altitude should not be more than 1000 m;
2.1.2 The ambient temperature does not exceed +40 , not less
than -10 ;
2.1.3 The relative humidity of air is not more than 85%;
2.1.4 In a place without conductive dust or various corrosive
gases;
2.1.5 In a place without explosive gas and no strong vibration;
2.1.6 Installed in a well-ventilated places.
2.2 Cooling water requirement:
Medium frequency power supply device, sensor and medium frequency
electric-heating capacitor are applied circulation water cooling,
so the conditions of cooling water provided will affect the
reliability of equipment directly.
It is recommended to carry out analysis on current cooling water
and its result should meet the following requirements. It must be
solved by the method of corresponding purification in the event of
any difference.
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Technical Agreement For Syrian Profile Steel Project

Mechanical

characteristics:

transparent,

clear,

deposit

free

(screen size of 0.38 inch), total solid content not over 250ml/L.
Chemical characteristics: at hardness of 8DH, PH value is 7.8;
Chloride

100 mg/L;

Nitrite (NOR2R)

0.04 mg/L;

Iron sulfur

0.3mg/L;

Mn

0.05 mg/L;

250 mg/L;

Resistivity: 2500.cm
Water inlet temperature: not lower than 5, not higher than 35,
the internal part of water cooling component is not scaled. When
supplying

water

on

hot

day,

it

is

important

to

avoid

condensation on the surfaces of water-cooling components.


Water inlet pressure: water pressure of controlled silicon and
capacitor1.5kg/cmP2P; water pressure of sensor 2.5~4kg/ cmP2P.
2.3 Three-phase power grid voltage should be approximate to sine
wave, and harmonic distortion should be less than 5%.
2.4 The imbalance of three-phase power grid voltage should be less
than 5%, and its fluctuation range should not exceed 5%.
2.5 In order to ensure normal and stable operation of the device,
it is required that the furnace building technology for melting
furnace as a load should be used dry furnace building method that
the lining materials can not be watered.
2.6 When the device is not in use temporarily, the ventilation and
drying measures should be strengthened, so as to avoid damaging
the internal part of the device due to damp. In the case that it
may be frozen in the room, efforts should be made to remove all
cooling water in the devices clearly.
3. Technical parameters
The technical parameters designed for KGPS series medium frequency
power supply product produced by our company are as shown in the
92

Technical Agreement For Syrian Profile Steel Project

following table:
Medium
frequenc
y
melting
furnace

Rectifor
mer

Range of the melted iron volume


Rating working temperature
Melting rate
Cooling
Flow capacity
Pressure
water
Temperature of the inlet

ton

ton/h
ton/h
MPa

1012
1600
6.5
100
0.2
40

water
Temperature rise
The inductor voltage
The inside diameter
The total height of the inductor
Power consumption for steel of per

V
mm
mm
Degree/ton

20
3200
1400
2000
660

ton(continuous casting)
Turndown mode

Hydraulic turndown

Model
Winding structure

ZS-6300
D/d/yRnR11
Secondaly

side

/Y

duplex

windingdrawing out of the center of


the star winding
KVA

Total capacity

KGPS

6300

Primary voltage
Secondary voltage

KV
A

20
1000

Power range
Inlet wire voltage
Maximum inlet wire voltage
Rectification pulse
Cooling
Flow capacity
Pressure
water
Temperature of the inlet

KW
V
A
pulse
ton/h
MPa

35005300
1000
1820
12
50
0.1
35

water
Temperature rise
Intermediate frequency voltage
IF-FRE

V
Hz

15
1600
500+50

Remarks: The parameters mentioned in the above table are the


indexes under the conditions of continuously soaking furnace,
lumping materials, feeding the full furnace and continuously
93

Technical Agreement For Syrian Profile Steel Project

working.
4. Structural description
4.1 Series structure and appearance of power supply cabinet
The series structure of the medium frequency device comprises of
four parts, as shown in Fig. 1: rectifier cabinet, inverter
cabinet, capacitor cabinet and melting furnace, of which the
rectifier cabinet and inverter cabinet are the core of the whole
system, collectively known as power supply cabinet that plays the
role of converting power frequency voltage to medium frequency
voltage.

Input

AC

Invert
er
cabin
et

Rectif
ier
cabin
et

Capa
citor
cabin
et

Meltin
g
furna
ce

Fig. 1 Medium frequency power supply system structure


The appearance schematic diagram of power supply cabinet is shown
in Fig. 2, in which, 6-pulse low power medium frequency power
supply uses only two sub-cabinets at the left side of shown
cabinet, 12-pulse medium-high power supply uses the complete
single cabinet, as shown in the figure, and 24-pulse high power
supply

uses

indicator

parallel
lamps,

dual-cabinet.

operating

Corresponding

buttons

and

instruments,

power-regulation

potentiometer are fitted on the left door of cabinet to control


and indicate the working conditions of the medium frequency power
supply, called as operation door.

94

Technical Agreement For Syrian Profile Steel Project

Overall dimension: L (3600mm) W (1200mm)H (22000mm)


Fig. 2 Appearance schematic diagram of power supply cabinet
DC voltage 1
DC current 1
Medium frequency current 1
Medium frequency voltage
DC voltage 2
DC current 2
Medium frequency current 2
Frequency
Control power supply
Main switch lamp 1
Main switch lamp 2
95

Technical Agreement For Syrian Profile Steel Project

Protection lamp
Control ON
Control OFF
Energy storage
Main power supply ON
Main power supply OFF
Power measuring knob
Reset
2 Incmoing line voltage 2
1 Incmoing line voltage 1
4.2 Description of operation door components
Totally 8 monitoring instruments,
Upper row from left to right:
DC voltmeter of rectifier 1 output;
DC ammeter of rectifier 1 output;
Medium frequency ammeter of inverter 1 output;
Medium frequency voltmeter of inverter synthetic output;
Lower row from left to right:
DC voltmeter of rectifier 2 output;
DC ammeter of rectifier 2 output;
Medium frequency ammeter of inverter 2 output;
Medium-frequency frequency meter of inverter synthetic output;
Totally 4 indicator lamps:
From left to right:
Control power lamp; main switch lamp 1; main switch lamp 2;
protection lamp
Totally 6 operating buttons:
From left to right, from up to down:
Control ON (green)
Energy storage (green)
Main power supply ON (green)

Control OFF (red)

Main power supply OFF (red)


96

Technical Agreement For Syrian Profile Steel Project

Reset (red)

Power-regulation potentiometer: in clockwise rotation, the power


increases; in counterclockwise rotation, the power reduces.
The above instruments and indicator lamps are used to observe the
working conditions of power supply. The operating buttons and
power-regulation potentiometer are used to control the working
conditions of power supply.
Note: except for the operation door, another two doors are fitted
with one AC voltmeter respectively, to show the voltage amplitude
of incoming line.
4.3 Control cabinet instructions
Open the left door of power supply cabinet, and then you can see a
trigger control cabinet on the top in the power supply cabinet, of
which the following schematic diagram is as shown in Fig. 2.

Frequency meter

Control Panel
Locking
hole

A trigger control panel is placed in the cabinet, and three small


voltmeters installed on the control cabinet panel are used to
indicate the power supply situation of the trigger control panel.
97

Technical Agreement For Syrian Profile Steel Project

In which, +24 V2 and +24 V1 are output voltage of control power


supply rectifier bridge without voltage stabilization, of which
+24 V1 is rectifier trigger circuit power, and +24 V2 is inverter
trigger circuit power and provided for the control panel to form
+12 V positive supply of voltage regulator. The display value of
+24 V1 and +24 V2 changes slightly with the variation of power
grid voltage, usually in the range of 18V ~ 28V; the value shown
in frequency meter is proportional to the highest frequency of the
inverter frequency sweep.
5. Start-up preparation
5.1 Start the water pump at first, and check that each water
circuit meets the following requirements:
5.1.1

Water

inlet

pressure

of

medium

frequency

cabinet

and

capacitor cabinet: 0.1Mpa~0.2Mpa; water inlet temperature: 30;


5.1.2 Water inlet pressure of melting furnace: 0.2Mpa~0.3Mpa;
0.1Mpa~0.2Mpa; water inlet temperature: 35;
5.1.3 There is no water leaking at each water connection.
5.2 Before the medium frequency power supply is turned on, measure
if each main component is normal at the resistance stage of
multimeter:
5.2.1 Each fuse resistance is 0 (it can not be measured until the
main transformer is powered off, and the stage is in the position
of 1);
5.2.2 Each controlled silicon resistance 2K (the stage is in
the position of 1K);
5.2.3

Resistance

between

primary

and

secondary

sides

of

transformer >100K (the stage is in the position of 10K);


5.2.4 Resistance of each electrical point to shell > 2K (the
stage is in the position of 1K);

98

Technical Agreement For Syrian Profile Steel Project

6. Operating sequences
* The device is strictly prohibited starting with empty furnace,
and the furnace must be charged in order to start properly.
* It is prohibited that the furnace can not be emptied when there
is output power, that is to say, when discharging molten steel,
the potentiometer must be adjusted anti-clockwise back to zero.
6.1 Turn anticlockwise the power-regulation potentiometer on
the door of medium frequency power supply cabinet to the end, then
press Control power ON button, so that the control system is
powered on. Observe that the indication of +24V voltmeter on
control cabinet panel is between 18V and 28V, and that inverter
pulse lamp should be fully lighted.
6.2 Press Reset button, then the red lamp on the control panel
shall be extinguished, but the red lamp on the door is still
bright, this is because KP inspection board locks the rectifier
pulse and lightens the protection lamp.
6.3 Press and hold the Pre-storage energy button, then the
protection lamp is extinguished, and rectifier pulse lamp is
fully bright. After releasing the button, the storage motor
actuates, with energy storage in place. If the motor fails to
actuate after releasing the Pre-storage energy button and
the protection lamp is re-lighted, it shall check if KP and its
resistance-capacitance absorption components are normal, if
there are problems on lack of phase, phase-to-phase short
circuit or short circuit to ground at the joint of main switch.
6.4 Press the Main power supply ON button, then the main
switch is turned on. Now DC voltmeter shall be reversal of
biasing.
6.5 Turn clockwise Power-regulation potentiometer slowly, to
observe that the Fmin lamp (frequency low lamp) in the control
cabinet should be flashing, which indicates startup of inverter
99

Technical Agreement For Syrian Profile Steel Project

frequency-sweeping is enabled. DC voltmeter of main circuit


rectification

output

also

will

oscillate

up

and

down,

indicating that the self-starting of rectifier also works.


After start-up several times, the medium frequency voltage will
indicate, and it can hear the sound squeaking from medium
frequency, and relevant instruments stop oscillating and point
to the appropriate position, indicating success of starting.
6.6 Continue to turn Power-regulation potentiometer slowly,
until the medium frequency voltage is up to the operating
position. During this process, observe the two DC ammeters and
two medium frequency ammeters, of which the indicated values
should be basically same. If the difference between indicated
values is too large, please ask electrician to check.
6.7 Shutdown sequence:
6.7.1 Turn back the power-regulation potentiometer anticlockwise;
6.7.2 Press the Main power supply OFF button, the main switch
is disconnected;
6.7.3 Press the Control power supply OFF button, the control
power supply is powered off.
Instructions:
For this device, after main circuit is powered on, each working
status lamp of controlled silicon (located on the resistancecapacitance absorption board) should be lighted, otherwise, it
shall ask the electrician to check.
During operating of the device, it shall carry out record and
observation on all electrical instruments, if any abnormity is
detected, it shall shut down immediately and check, after the
fault is eliminated, it can be continued to use.
When the protection lamp on the door of medium frequency power
supply cabinet is light, it shall record which red lamp is lighted
100

Technical Agreement For Syrian Profile Steel Project

on the control panel, and observe if the status indicator lamp of


controlled

silicon

is

extinguished.

If

any,

please

ask

the

electrician to check.
After protection is presented, it shall be aware of whether there
is any ignition, water leakage and other abnormal phenomenon, if
no abnormity, and the status indicator lamp of controlled silicon
and pulse lamp are normally lighted, then press the "Reset" button
so that the protection lamp is off, re-test the machine. If there
will be repeated several times to protect, it should shut down and
ask the electrician to check the problem.
During operating of the device, if such phenomenon as water
leakage or blocking in water circuit and water cooling components
are detected, it shall shut down and check and repair immediately,
after the problems are eliminated, it can be continued to use.
In order to ensure safety in production, the power operators
should put a dry wood plate at the feet, and the furnace operators
should put a rubber insulating mat at the feet to prevent electric
shock accident caused by electrical leakage.
7. Introduction to functions of control circuit board:
For following introduced component names and their distribution
positions on the control panel, please refer to hereinafter
attached control circuit board function distribution drawing.
Functions of potentiometer:
P2: over-current 2 potentiometer, set the protection value
of over-current 2, increased in clockwise rotation, in reverse
reduced.
P3: 2=0potentiometer, angle is reduced in clockwise
rotation and pulse moves forward; angle is increased in
anticlockwise rotation and pulse moves backward.
P5: current limiting potentiometer, current limiting value
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Technical Agreement For Syrian Profile Steel Project

is increased in clockwise rotation and reduced in anticlockwise


rotation.
P6: over-current 1 potentiometer, set the protection value
of over-current 1, increased in clockwise rotation, in reverse
reduced.
P7: 1=0potentiometer, is reduced in clockwise rotation
and pulse moves forward; is increased in anticlockwise
rotation and pulse moves backward.
P9: overvoltage potentiometer, set the protection value of
medium frequency voltage, increased in clockwise rotation, in
reverse reduced.
P10: voltage limiting potentiometer, voltage limiting value
is increased in clockwise rotation and reduced in anticlockwise
rotation.
P11: highest frequency-sweeping potentiometer, increased in
clockwise rotation and reduced in anticlockwise rotation.
P12: angle potentiometer: set the angle of inverting
work,

increased

in

clockwise

rotation

and

reduced

in

anticlockwise rotation.
Introduction to functions of control panel:
L1: over-current 2 protection lamp of rectifier 2;
L2: current limiting 2 lamp of rectifier 2;
L3: emergency stop lamp: when pressing the emergency stop
button, the equipment stops emergently in the condition of
protection.
L4: KP protection lamp;
L5: water circuit protection lamp: when water pressure is
too low or water temperature is too high, the equipment will
shut down automatically, and this lamp will be lightened.
L6: +12V indicator lamp;
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Technical Agreement For Syrian Profile Steel Project

L7: - 12V indicator lamp;


L8: power supply protection lamp: when incoming line voltage
is too low or lack of phase, reserve phase, the equipment will
automatically shut down and this lamp will be lighted.
L9: over-current 1 indicator lamp of rectifier 1;
L10: current limiting 1 indicator lamp of rectifier 1;
L12: voltage limiting indicator lamp;
L13: self-starting medium frequency lamp: when the medium
frequency voltage is set up (above 100V), this lamp will be
lighted.
L14: overvoltage protection lamp;
L15: low frequency lamp: when inverter frequency is lower
than an appropriate value (below 100HZ), this lamp will be
lighted. Meanwhile, DC phase-shifting voltage is drawn
back to zero point, and output frequency of frequency
sweeping

oscillator

is

drawn

back

to

the

highest

frequency.
L16: large angle lamp: when the phase-locked angle of
inverter is more than the set value, this lamp will be
lighted. Meanwhile, the current limiting value will be
reduced to an appropriate value, so that the phase-locked
tracking circuit may be returned to the stable condition.

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Technical Agreement For Syrian Profile Steel Project

Introduction to the functions of control panel micro switch:


S1:

over-current

halving

inspection

switch,

when

switching on, the protection setting value is reduced a half;


S2:

current

sharing

switch,

when power on, the current

sharing function is available;


S3:

over-current

halving

inspection

switch,

when

switching on, the protection setting value is reduced a half;


S5: overvoltage halving inspection switch, when switching
on, the protection setting value is reduced a half;
S6:

inverter

starting

switch,

when

switching

on,

the

function starting at large angle is available;


S7:

Frequency-sweeping

self-starting

switch,

the

self-

starting function is available;


8. Routine maintenance:
Water circuit:
1

During

normal

working,

it

should

regularly

check

the

conditions of water circuit, such as too low water pressure,


small flow rate or too high water temperature, or water
leakage. If any abnormity is detected, it shall check and
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Technical Agreement For Syrian Profile Steel Project

eliminate it immediately.
2. A drainage valve is normally mounted on the end of water
inlet pipe. Drain off the water regularly so as to remove the
solid sundries and sludge accumulated in the pipes.
3. For hard water or with more solid particles (i.e. more
turbid), the surface inside of water circuit and component
radiator is liable to scale, so it must flush the water circuit
and replace the radiator regularly.
Circuit:
1. During normal working, regularly check the conditions of
relevant indicator lamps (such as resistance-capacitance
absorption

board,

pulse

transformer)

in

the

electrical

cabinet and see if they are normal.


2.

During

normal

working

process,

regularly

test

the

temperature of each component and electrical connections by


infrared temperature measuring gun.
3. Regularly clean up the internal part of electrical cabinet,
mainly to remove the internal dust deposit;
4.

Check

and

electrical

see

if

cabinet

the
are

electrical
loose,

connections

heating

or

in

the

discharging

frequently.
5.

Under

the

condition

of

shutdown,

regularly

check

the

resistance at each electrical point and component of the


equipment by use of multimeter. Under the condition of
startup, regularly check the working waveform of each key
point by use of oscilloscope, to ensure that the electrical
indicator satisfies the requirements.
Furnace:
1.

Arrange

full-time

personnel

to

be

responsible

for

maintenance of the furnace. Check the furnace half an hour in


advance before starting it every day.
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Technical Agreement For Syrian Profile Steel Project

2. Use air pump to blow off the conductive dust on the surface
of sensor; use magnet to absorb the iron chips between coils of
sensor.
3. Check the fixed screws of bakelite column of sensor and see
if they are loose, and check whether the magnetic yoke post rod
is loose.
4. Check the water circuit, if the water flow of some circuit
is too small, or if water connector leaks.
5. During production process, if the sensor has discharge
ignition, resulting in carbonizing and darkening on the edge of
mica plate, on the side of bakelite column and on the surface
of coated sludge, it must use a knife to shave the blackening
layer clearly. The bare copper exposed on the surface of copper
pipe due to discharge shall be brushed a layer of insulating
paint after worn flat by sand paper.
6. When deslagging or tapping every time, providing that the
furnace panel is not set level, it shall turn off the fan on
the furnace platform, so as to prevent the iron chips being
blown into the sensor.
7. Steel tapping must be carried out after shutdown. After
tapping, it shall charge completely before starting. Starting
with empty machine is prohibited.
9. Reference waveform
9.1 Rectifying pulse:
Characteristics: dual modulation pulse, interval 60 between
two pulses, each modulating pulse is a sequence composed of 4~8
small pulses, with total width of about 1000S. As general
pulse amplitude of 3~6V, the width of small pulse should be
more than 80S.

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Technical Agreement For Syrian Profile Steel Project

9.2 Phase-shifting range:


Adopting Dual-trace oscilloscope, one trace observes some phase
(A, B or C phase) of secondary side of synchronous transformer,
and another trace observes corresponding pipes (1, 3 or 5#KP).
When

the

power-regulation

potentiometer

increases

to

the

maximum from zero, the position of pulse with respect to the


synchronous voltage is moved to B from A as shown in the
following figure.
9.3 Inverter pulse:
Pulse characteristics: single pulse, general pulse amplitude of
3~6V, the pulse width should be more than 20S.
9.4 Output voltage of rectifier:
9.5 Sampling current of incoming line:
Oscilloprobe is connected to any group of output (68, 69), (69,
70) and (70, 68) of 5 0.1 transformer: Fig. B is in the case
of higher DC voltage, angle close to 0, and getting closer
and closer to flatness on the top.
9.6 Working waveform of inverter
In the single pipe waveform, flat part is controlled silicon
conduction period, below flat part is inverse voltage borne by
the controlled silicon. The actual working waveform has spine
extended down at the lowest point of inverse voltage, in
general, not exceeding 2~3 times of inverse voltage. If the
spine is too long, it indicates that the resistance-capacitance
absorption circuit of the controlled silicon is abnormal or the
performance of it is not good.
10. Operating instructions
* The device is strictly prohibited starting with empty furnace,
and the furnace must be charged in order to start properly.
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Technical Agreement For Syrian Profile Steel Project

* Emptying furnace without shutdown is prohibited, that is to say,


when discharging molten steel, the potentiometer must be adjusted
anti-clockwise back to zero.
10.1 Turn anticlockwise the power-regulation potentiometer on
the door of medium frequency power supply cabinet to the end,
then press Control power ON button, so that the control
system is powered on. Observe that the indication of +24V
voltmeter on control cabinet panel is between 18V and 28V, and
that pulse transformer lamp should be fully lighted.
10.2 Press and hold the Pre-storage energy button, then the
red

lamp

on

KP

inspection

board

is

extinguished.

After

releasing the button, the storage motor actuates, with energy


storage in place. If the motor fails to actuate after releasing
the Pre-storage energy button, please ask the electrician
to check.
10.3 Press the Main power supply ON button, then the main
switch is turned on. Now DC voltmeter shall be reversal of
biasing.
10.4 Press the Reset button, the red lamp on the control panel
shall be extinguished as well as protection lamp.
10.5 Turn clockwise Power-regulation potentiometer slowly, DC
voltmeter may oscillate up and down. After oscillating several
times, the medium-frequency frequency meter shall indicate, and
it can hear the sound squeaking, and relevant instruments
stop

oscillating

and

point

to

the

appropriate

position,

indicating success of starting.


10.6 Continue to turn Power-regulation potentiometer slowly,
until the medium frequency voltage is reached to the operating
position. Frequently observe the two DC ammeters, of which the
indicated values should be basically same. If the difference
between indicated values is too large, please ask electrician
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Technical Agreement For Syrian Profile Steel Project

to check.
10.7 Shutdown sequence:
10.7.1

Turn

back

the

power-regulation

potentiometer

anti-

clockwise;
10.7.2 Press the Main power supply OFF button, the main switch
is disconnected;
10.7.3 Press the Control power supply OFF button, the control
power supply is powered off.
Instructions:
For this device, after main circuit is powered on, each working
status lamp of controlled silicon (located on the resistancecapacitance absorption board) should be lighted, otherwise, please
ask the electrician to check.
During working process, when the protection lamp on the door
is light, it shall record which red lamp is lighted on the control
panel, and observe if the status indicator lamp of controlled
silicon is extinguished. If any, please ask the electrician to
check.
After protection is presented, it shall be aware of whether there
is any ignition, water leakage and other abnormal phenomenon, if
no abnormity, and the status indicator lamp of controlled silicon
and pulse lamp are normally lighted, then press the "Reset" button
so that the protection lamp is off, re-test the machine. If there
will

be

repeated

several

times

to

protect,

please

ask

the

electrician to check the problem.


During working process, if such phenomenon as water leakage or
small flow of water outlet pipe or no water is detected, it shall
immediately shut down and cut off the power to check and repair,
after the problems are eliminated, it can be continued to use.

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Technical Agreement For Syrian Profile Steel Project

Circui

t schematic drawing of 15T Medium frequency electrical furnace


DC voltmeter 1
DC voltmeter 2
Integrated protection circuit
Voltage control circuit
Rectifier 2 synchronous circuit
Rectifier 2 control regulator
Rectifier 1 synchronous circuit
Rectifier 1 control regulator
Protection circuit
Frequency tracking regulator
Rectifier 2 drive circuit
Rectifier 1 drive circuit
Electrolytic control circuit
Frequency phase loop control circuit
Variable drive circuit
Secondary board
Current sharing board
Mainboard
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Technical Agreement For Syrian Profile Steel Project

Synchr

onous voltage A way


Rectifier pulse (1# pipe)
Fig.5 (A) location oscillogram of synchronous voltage of=150
and corresponding pulse

Synchronous voltage A way


Rectifier pulse (1# pipe)
Fig.5 (B) location oscillogram of synchronous voltage of=0 and
corresponding pulse

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Technical Agreement For Syrian Profile Steel Project

Fig. 6 Inverting thyristor gate pulse waveform

Rectifying
phase-shifting
angle

Rectifier
bridge
voltage waveform

output

Rectifying tube end pressure


waveform

Rectifier output voltage oscillogram

112

Spare
L3

Water
pressure L5

Overcurrent 2

Technical Agreement For Syrian Profile Steel Project

Sub-lower
limit

Abnormal
medium
frequency

Medium
frequency

Voltage
limiting

Main control panel schematic drawing

Fig.7 (A) lower waveform of DC voltage. Large fluctuation on the


top
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Technical Agreement For Syrian Profile Steel Project

Fig.7 (B) hgiher waveform of DC voltage. Nearly flat on the top

Medium frequency output voltage

Single pipe end pressure waveform

Trigger pulse

Single pipe end pressure waveform

Trigger pulse

Inverter input voltage waveform


Fig.8 Key working waveform of inverter

Pulse expansion waveform

Fig. 4 Rectifier thyristor gate pulse waveform

114