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CERTIFICATE
This is to certify that the Project titled FUNCTIONING OF LADLE
TURRET IN CONTINUOUS CASTING SHOP SMS II is fulfillment as a part of training
program imparted by RINL/VSP during the year 2013 is a bonafide work carried on by
BRAHMANANDA REDDY SAGILI,
K.V. SIVAPRASAD
AGM
CCD (MECH)
SMS II
VISAKHAPATNAM
Date:
ACKNOWLEDGEMENT
I acknowledge my profound gratitude & thanks to Sri K.V.SIVAPRASAD,
AGM, CCD (MECHANICAL) for advising me to take up this project work on
FUCTIONING OF LADLE TURRET IN CONTINUOUS CASTING SHOP SMS II
under his able guidance & support extended to prepare this project report.
I express my deep sense of gratitude to Sri K.V.SIVAPRASAD, AGM
(CCD -MECHANICAL) for his valuable advice and help extended to me in
preparing this project in spite of his busy office schedule.
BRAHMANANDA REDDY SAGILI
MT (T)
Emp.No.123140
INDEX
5-8
9 - 11
12 13
4. SYSTEM EQUIPMENTS
13 - 16
17 - 18
19
20 - 21
22
9. ROTARY JOINT
23 - 24
24 - 25
26
[4]
26 - 27
28
[5]
Given below are the main characteristic of the Casting Machine in SMS II:
Machine type
3BLC1006
Number of strands
Machine radius
10
Unbending radii
19
Strand distance
1,5mm
Outfit sections
and 350
Ladle capacity
Ladle support
Load capacity
250 t
Hydraulic type
Pneumatic type
50 min average
Tundish car
Tundish capacity
35 t
Mould tube
Mould lubrication
[6]
Radioactive
Electromagnetic stirrer
Oscillating unit
Hydraulic actuated
Dummy bar
rigid
Straightening
24.4 m approx
0.25-4 m/min
Billet cutting
Oxy cutting
Discharge system
[7]
h) Weighing system located in the turret arms in order to continuously record the
weight of the ladle before or during casting.
[8]
LADLE TURRET
[9]
[10]
: H Type
Radius
: 5500 mm
: 250 Ton
: 150/160 Ton
: 1500 rpm
: 1.0 rpm
Direction of Rotation
: Bi Directional
: Pneumatic Motor
: 0.5 rpm
Weighing cells
Number 4+4
Type Compression
Total load capacity 250 Ton
General data
Type: H type
Ladle rotation radius: 5500 mm
Dimensions
Length with two ladle 15076 mm
Length without ladles 12684 mm
Width 5530 mm
Height 10142 mm
weight 188100 kg
Arm locking cylinder
Quantity 1
Type hydraulic
bore 100 mm
Rod 70 mm
stroke 160 mm
feeding from hydraulic central unit
[11]
Benefits:
Best utilization of the bridge crane, which is not engaged in supporting the ladle during
casting.
The shortening of the time necessary to the ladle change during the castings in sequence
TRAINING CENTER
Description:
1) First machine of the continuous casting machine;
2) Fixed basement with a housing for the base bearing for the arms rotation:
the basement is fixed to the foundation
3) Supporting saddle provided with appropriate guiding and reference devices to allow
an easy charging of the ladle from the front;
4) Drive unit composed of a varying speed motor, a planetary gear box and pinion and
equipped with pneumatic motor, mounted directly on the transmission, which ensures
the emergency rotation in case of electric motor failure;
5) a rotating coupling allows the feeding of the mobile parts on the turret;
6) The position of the turret is controlled by an installed encoder and limit switch.
TRAINING CENTER
4. COMPOSITION AND DESCRIPTION
The turret is a "normal twin-fork turret": it is composed of a double fork rotating
arm supported by a circular structure made of welded carpentry, properly Stiffened and
longitudinally ribbed. The basement upper part is realized so that it is possible to have a
housing for the thrust bearing for the arm rotation; the inferior part is fixed by a basement to
the foundations, by means of anchoring bolts. Each arm consist of a central unit and a
supporting saddle provided with appropriate guiding and reference devices to allow an easy
charging of the ladle from the front.
The arms are hinged to a central structure of welded steel supported by the thrust
bearing for the simultaneous rotation of the arms. Each arm is lifted by an independent
hydraulic cylinder to allow submerged casting (insertion of the nozzle under the ladle) and
facilitate all the operations for opening the ladle side gate in case of problems or clogging
The inside of the circular structure encloses all the pipings of the service plants to the turret
and it is accessible for inspections and maintenance.
TRAI
[12]
The arm rotation takes place by means of a driving unit composed of a varying
speed motor, a planetary gear box and a pinion, a pneumatic disc brake with a cylinder and an
emergency pneumatic motor (main motor broken or missing of feeding tension).The arm
rotation speed and its stopping in perfect position are guaranteed by encoders and limit
switches.
The turret is dimensioned for supporting ladles with the following:
1 full ladle and an empty ladle;
2 full ladles;
1 full ladle and an empty arm (shock factor = 2).
In every condition, apart from the charge, the turret ensures the correct arrest during the
ladle/s rotation, respectively in the positions of casting, ladle drawing or emergency. By a
bridge crane the ladle with the liquid steel is drawn from the furnace zone and deposited on a
fork of the turret arm .he arm rotates of 180, it carries the ladle in a proper position for
casting the steel into the tundish (distribution equipment), already positioned in
correspondence with the lines.
The interlocks to enable the rotation of turret are:
General emergency stop not active
Emergency rotation cycle reset
Brake is open (brake release valve is energized and signal from limit switch)
The rotation acceleration and deceleration avoids ladle spills, the rotation cycle is:
Speed[%]
100
0
45
120
[13]
On each fork of the turret there is installed a system for the weighing of the ladle,
composed of:
4 (two + two) load cells;
Weight transmitters;
One large display installed on the casting floor in the operative area.
A rotating coupling (connected on the turret shaft) allows the feeding of the mobile parts on
the turret such as bearing, gears, pin-joints with the following fluids:
Grease.
Compressed air.
Inert gas
TRAINING CENTER
1. Compressed air (IA) system
The system feeds the pneumatic devices for the emergency rotation and the turret braking.
If necessary, the air is filtered and lubricated for every group of appliances.
The system consists of the following appliances:
Loading boxes and cells cooling;
Ladle turret brake (disk brake);
Emergency rotation (pneumatic motor);
Emergency device for slide gates.
The system is provided with solenoid valves actuating the devices listed above, flexible and
rigid pipes according to supply and gate valves on the machine. The compressed air is
supplied by the steel plant and must be of standard industrial quality.
2. Inert gas system (argon)
The plant is designed to feed the liquid steel bath of both ladles for the stirring.
The plant includes all the pipes in the turret, including hoses, pipe fittings, gas rotating joint
and quick clutches between arm and ladle.
3. Ladle rotating turret arms maneuvering hydraulic system
The central unit of this plant enables to control and actuate all the devices of the system.
In particular it services the following appliances:
Ladle lifting/lowering on the arm 1;
Ladle lifting/lowering on the arm 2;
TRAINING CENTE
[14]
[15]
Electric motor
Quantity 1
power 37 kW; 1500 Rpm; 550 Hz
Direction of rotation bi - directional
Type of brake disc brake with thruster
The drive system is equipped with an electric motor coupled to a pneumatic motor
through a common shaft. Pneumatic piston motor is used for emergency rotation in low
rotation speed. The electric drive system is hold by using a pneumatic brake. This pneumatic
brake system is operated by instrument air which is supplied at a pressure of 6bar for holding
the brake.
The connection with the bevel gear is guaranteed by means of a key connection.
The device requires oil for seal lubrication and seal check for oil leakage. The connection
with the bevel gear is guaranteed by means of a key connection. The purpose of the bevel
gear is to drive the motion from one axis to the orthogonal by means of an input shaft from
[16]
the electric motor which thanks to a spiral bevel gear 1:1, works on the output shaft double
projection (one towards the pneumatic motor and the other one towards the planetary gear
box).
Gearbox
Quantity 1
Type planetary with angular gear
Ratio 1:117
Pneumatic motor
Quantity 1 (horizontal position)
Direction of rotation bi directional
Planetary gear box: In the fixed ring gear planetary reduction gear unit, motion is
transmitted by the sun gear to the planetary gears which is enveloping the ring gear. It rotates
in the same direction as the input motion of the sun gear - entrain the planet carrier connected
to the output.
Every stage is formed by:
1) RING GEAR: (reaction element) internal tooth in contact with the planetary gears
(output motion element). There are three gears for each stage. Every planetary gear
has an associated axis and each planetary gear and axis has a group of bearings. Its
function is to support the loads acting on the planetary gears and transmit them to the
planetary gear axis.
2) SUN GEAR: the planetary gears are in contact with the sun gear (input motion
element).
[17]
3) PLANETARY GEARS: the planetary gear axis is an integral part of the planetary
carrier (output motion) and has the function to bring and connect the planetary gears
by means of their axis.
6. BEARING FOR ROTATION
The rotation of the turret is achieved by a big gear which is in contact with pinion
which is present at the end of the electric drive unit output shaft. The gear is mounted on a
three row cylindrical roller bearing. The three row roller bearing is as shown in figure. It
contains two rows of horizontal rollers and one row of vertical rollers. The two horizontal
rollers are present at top and bottom and vertical rollers are in the middle.
The horizontal rollers are provided to with stand the axial load of the system and the
radial load is with stand by vertical rollers of the bearing. Bearing is lubricated by centralized
grease system with two lines. The wear and tear of the axial rollers is measured by measuring
the distance between the two fixed points at eight different positions on the turret. The wear
[18]
and tear of vertical rollers is measured by measuring the readings of dial gauge at different
positions when the turret is moving.
[19]
Arm lifting cylinder has a four bar chain mechanism to lift and lower the arm. It consists of a
cylinder and 3 links. The top end of the cylinder is fixed and the end of the rod is fixed to the
arm link1. Link 2 is for supporting it is connected to arm from the frame of turret. Link 3 will
joins the link 1 and 2. When the cylinder opens due to the relative motion transfer from
cylinder rod to the link 1 arm will be lifted. The mechanism and arrangement of links is as
shown in figure.
[20]
The locking cylinder is used to arrest the movement of ladle turret when it is in casting
position. The locking cylinder is fixed on the stationary part of the turret. It is operated by the
central hydraulic Unit, the pressure of the system is 200 bar. When the locking command
given the hydraulic oil enters into the locking cylinder and the piston rod pushed to outside, it
will enters into the groove which is constructed on movable part of the turret, near to the
bearing. When piston rod enters into the groove it will arrest the movement of the turret.
[21]
The bottom part of the rotary joint is stationary and the top part is movable. The bottom part
contains hydraulic swivels for the supply of hydraulic oil, grease and utility lines.
Hydraulic swivels are composed of:
[22]
4 swivels for ladle slide gate opening and closing of both the arms.
[23]
Brake is open (brake release valve is energized and signal from limit switch)
It is provided with an emergency rotation backup, which can be used in case of failure
of the electrical rotating Unit. A pneumatic motor which is manually controlled achieves the
rotation. Pneumatic piston motor is used for emergency rotation in low rotation speed. The
pneumatic piston motor is connected to the common shaft of electric motor. The pneumatic
piston motor consists of 5 pistons arranged in equal angles. To run the pneumatic drive IA
(instrument air) is used. The pressure of the IA to operate the pneumatic motor is 6 Bar.
Pneumatic motor can rotate in both clockwise and anti-clockwise direction. When
there is a power failure pneumatic drive is operated manually. The pneumatic drive rotates in
both the directions. When power supply fails, the brake of the drive unit will automatically
get closed. To open the brake and to rotate the turret from casting position to home position
(non-casting position), the pneumatic drive is used. The instrument air circuit for the turret
emergency rotation is as shown in figure.
[24]
The ladle cover manipulator also called as jib crane. It is as shown in figure. The function of
the ladle cover manipulator is to reduce the heat loss from liquid metal to the atmosphere so
that the solidification of liquid steel before casting is avoided. It can rotate about 2700 from
its centre. It contains a lid type structure at its end whose diameter is equal to the diameter of
the ladle top portion. The bottom portion of the jib crane is covered by high heat resistant and
thermal insulating material so that it can with stand to high temperature and prevents heat
loss from liquid steel. It is operated by a hydraulic cylinder for lowering and lifting as shown
in below figure. The required rotation is achieved by a hydraulic motor.
[25]
[26]
[27]