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ISO installation manual

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ISO installation manual

  1. 1. RHI ISO Guidance&Handling and Installation Procedures RHI 等静压制品指导书和安装和操作程序 Heinz Wieduwilt / Project Manager
  2. 2. 142 RHI ISO Guidance Contents  Ladle shroud installation > Lalde shroud failures 钢包长水口安装  > 钢包长水口事故  Stopper installation > Stopper failures 塞棒安装  > 塞棒事故  Sub Entry Nozzle installation > SEN failures 浸入式水口安装  > 浸入式水口事故  Heat up instructions 预热操作指导 内容
  3. 3. 143 RHI ISO Guidance  Ladle shrouds are susceptible to fracture. Therefore, they have to be handled with great care and stored in a dry place.  钢包长水口易折断,因此操作时必须格外小心,干燥储存。  The shroud should be kept in the polythene bag prior to use. This will keep the shroud dry and reduce the risk of moisture pick up.  使用前钢包长水口存放在聚乙烯包装袋中,防止吸潮,保证 干燥。  The shroud should be carefully handled at all times. Particular care should be taken when fitting the shroud into the manipulator. Care should be taken to ensure the shroud is not scarped along the holding ring, as this will damage the glaze protection. Also ensure that the shroud is not dropped into the holding ring as this may also cause damage.  任何时候操作钢包长水口时都必须小心,往夹持器安装长水 口时更应格外小心,确保长水口和支撑环不产生剐蹭,避免 损伤保护釉层,并要确保长水口装入支撑环时不产生较大冲 击,以免损害长水口。 Ladle Shroud Installation 钢包长水口安装
  4. 4. 144 RHI ISO Guidance  Prior to fitting the shroud into the manipulator, the following should be checked:  长水口安装在夹持器前,应作如下检查: > The shroud should have adequate clearance within the holding ring, approximate 5mm per side. > 长水口和支撑环之间应有足够的间隙,每侧大约 5mm 。 > The holding ring should be free of any steel splashes as this would cause point loading stresses on the shroud and may restrict the movement of the holding ring. > 支撑环表面不能存留凸点,避免在该点给长水口施加集 中应力,限制支撑环的运动。 > The pivot points of the shroud ring must be free moving and well lubricated. > 支撑环旋转轴部位应滑快,转动自如。 > The holding ring should not be misshapen and provide adequate clearance for the shroud. > 支撑环不能变形,确保和长水口间有足够空隙。 Ladle Shroud Installation 钢包长水口安装
  5. 5. 145 RHI ISO Guidance Ladle Shroud Installation 钢包长水口安装  When the shroud is fitted onto the exchangeable nozzle, it is important to ensure that the shroud remains in a vertical position. This will ensure a good seal between the shroud and exchangeable nozzle. This will prevent premature erosion of the shroud due to air ingress. Preferential erosion of the shroud may also occur if the shroud is not vertical, i.e. steel flow impacting on the same area of the bore of the shroud. Keeping the shroud vertical will also reduce the risk of the shroud breaking due to point loading stresses.  长水口与钢包下水口配套使用时,长水口保持垂直,以确保 其与钢包下水口之间良好密封,防治空气吸入造成的过早侵 蚀。长水口不垂直,钢流冲刷长水口内壁同一部位造成其过 度侵蚀。保持长水口垂直,也能有助于减小应力集中造成的 颈部断裂。  If the ladle is not a free opener then the shroud should be removed while the ladle is lanced. When the steel stream has been established and the tundish is filled to the required level, the shroud should be refitted to the exchangeable nozzle. Prior to refitting the shroud, the following points should be checked:  钢包不能自开,需摘下长水口烧氧。引流成功,中间包钢水 升到要求高度后,长水口重新安装在钢包下水口上之前,特 别注意检查如下几点:
  6. 6. 146 RHI ISO Guidance > The throat area and bore of the shroud should be checked and cleaned if necessary; this will ensure a good seal between shroud and nozzle and prevent any blowback from the shroud. > 检查长水口碗部和内壁,必要时清理干净,确保其与钢 包下水口之间良好密封,防止呕钢。 > The fiber gasket should be checked for damage and replaced if necessary. > 检查长水口密封圈是否损坏,必要时更换。 > When refitting the shroud the slide gate should be fully closed to prevent any steel dribble from entering the throat area of the shroud, any steel between the shroud and the nozzle may lead to point loading stresses on the shroud and prevent a good seal between the shroud and nozzle. > 安装长水口时,钢包滑板完全关闭,防止钢水滴落在长 水口碗部。长水口与钢包下水口间有冷钢,会形成应力 集中,影响长水口和下水口之间密封。 Ladle Shroud Installation 钢包长水口安装
  7. 7. 147 RHI ISO Guidance  Once the cast has been established the shroud should be immersed in the steel bath to a minimum of 200mm. This will prevent excess turbulence in the tundish and give good tundish powder cover; it will also prevent any tundish powder entrapment in the bore of the shroud.  浇铸时长水口埋入钢水液面下至少 200mm ,防止中包液面 过度波动,中包覆盖剂卷入长水口内。  The movement of the shroud due to the slide gate throttling should not be restricted by the tundish powder crusting over. Care should be taken to ensure free movement of the shroud.  长水口随钢包下水口开闭时运动自如,不受中包覆盖剂渣壳 限制。  The ladle shroud is cleaned at the ladle change over by means of an O2 lance, where possible this should be done with the shroud in a vertical position. Lancing the shroud in a vertical position reduces the risk of the molten steel blowing back at the operator. It also prevents the molten steel running back onto the sealing face of the shroud. Care should be taken to ensure the throat area is clean and that the gasket is replaced. This will minimize the possibility of air ingress while casting and maximize the shroud life. The bore of the shroud should also be cleaned thoroughly as any steel skull left in the bore will restrict the steel flow when the slide gate is opened and may cause a blowback.  换包时长水口用氧枪清理干净,清理时长水口保持垂直,减 少清理时钢花反溅到操作工身上,以及长水口密封面上。特 别注意长水口碗部清理干净,更换新密封圈,这有助于浇铸 时减少空气吸入,延长长水口寿命。长水口内壁也应清理干 净,钢包滑板打开时,任何残留在内壁上的冷钢都会妨碍钢 流,可能造成呕钢。 Ladle Shroud Installation 钢包长水口安装
  8. 8. 148 RHI ISO Guidance Ladle Shroud Failures 长水口事故 A. Cracking Through Flange A. 凸缘贯穿裂纹 B. Horizontal Break at Collar B. 颈部横断 C. Thermal Shock Crack C. 热振裂纹 D. External Corrosion D. 外部侵蚀 E. Internal Corrosion E. 内部侵蚀 F. Internal Erosion F. 内部冲蚀 Symptoms 表现形式
  9. 9. 149 RHI ISO Guidance Ladle Shroud Failures 长水口事故 Causes 原因 A1 Excessive Counter Weight Force A1 配重力过大 A2 Ladle Nozzle Mismatch A2 钢包下水口尺寸不匹配 B1 General Condition of Holding Ring B1 支撑环问题 B2 Insufficient Clearance between Nozzle & Ring B2 支撑环和长水口间没有足够空隙 C1 Insufficient Oxidized Layer C1 氧化层太薄 C2 Excessive Moisture Pickup C2 长水口吸潮 D1 Aggressive Tundish Cover Powder D1 中包覆盖剂侵蚀性太强 D2 Slag Carry over D2 钢包下渣 E1 Slag/Powder Entrapment E1 卷渣 F1 Shroud Not Vertically Positioned F1 长水口不垂直
  10. 10. 1410 RHI ISO Guidance Stopper Installation 塞棒安装  Stoppers are susceptible to fracture. Therefore, they have to be handled with great care and stored in a dry place.  塞棒易折断,操作时要格外小心,干燥储藏。  The installation of the stopper rod into the stopper should only be done with the stopper in a vertical position. The stopper should also be securely fastened to prevent any movement. Ensure that the stopper rod has been drilled through to allow any moisture to be released to atmosphere during preheat prior to cast.  塞棒螺杆安装时,塞棒要垂直固定。螺杆拧入要保证开浇前 预热时塞棒内潮气能够排出。  The stopper mechanism must be set in middle position (theoretical movement of 50 mm in both directions).  塞棒机构行程置于中间位(理论上两个方向各 50mm 活动 量)  Place the assembled stopper / stopper rod assembly into the stopper mechanism cross arm. Adjust the bottom nut to allow for downward movement / erosion. The stopper is normally set 40 to 50mm high to allow for this.  装配好的塞棒安装到塞棒机构横臂上,调整下部螺母。通常 塞棒安装要留有 40~50mm 向下关闭余量。
  11. 11. 1411 RHI ISO Guidance Stopper Installation 塞棒安装  Tighten the top nut on the stopper rod ensuring that the stopper is correctly aligned with the SEN, i.e. off seating the stopper to the back of the SEN in line and toward the stopper control mechanism by a few millimeters. This slight off setting of the stopper will allow for any distortion of the tundish during preheat.  禁锢螺杆上部螺母时确保塞棒与浸入式水口正确对中,即沿 塞棒机构方向,塞棒向浸入式水口后错位几毫米,这一小的 错位可以抵消中包预热时产生的形变  During the installation of the stopper, lifting and lowering of the stopper should be done gently to prevent any damage to the stopper nose and SEN seating area.  塞棒安装时轻提慢放,防止损坏塞棒头和水口碗。
  12. 12. 1412 RHI ISO Guidance Stopper Installation 塞棒安装  The stopper should also be in the closed position when moving the tundish.  中间包移动时塞棒应处于关闭位置。  The delay from end of preheat to the start of casting should be kept to a minimum to prevent thermal shock cracking of the stopper and also to prevent the steel stream freezing causing the stopper to stick in the throat of the SEN. Refer to RHI recommended preheat cycle.  中间包预热结束到开浇,时间应尽量缩短,防止塞棒热振裂 纹产生,也防止钢水冷凝造成塞棒和浸入式水口粘连。请参 照 RHI 推荐的预热曲线。  The steel stopper rod can be reused after casting. All steel rods to be reused must be checked to ensure that they are straight and that the hole in the bore is not blocked. The threads of the rod should also be cleaned to ensure ease of installation and tightening.  浇铸后塞棒螺杆可再次使用。所有再次使用的螺杆都要检查 是否平直,吹氩孔有无堵塞,螺筘要清理干净,保证易于安 装和拧紧。
  13. 13. 1413 RHI ISO Guidance Stopper Failures 塞棒事故 Symptoms 表现形式 Breakage 断裂 Erosion/Corrosion 冲蚀 / 侵蚀 Causes Breakage 断裂原因 Fixing End Misalignment 安装不对中 Loose Fixing 安装不紧 Fixing Method 安装方法不对 Main Body Misalignment 本体不对中 Bent Product 塞棒不直 Nose Misalignment 塞棒头不对中 Sticking 粘结 Incorrect Nose Shape 塞棒头形状不正确 Steel Quality 钢种 Powder Quality 保护渣 Misalignment 安装不对中 Steel Flow 钢水流速 Causes Erosion/Corrison 冲蚀 / 侵蚀原因
  14. 14. 1414 RHI ISO Guidance SEN Installation 浸入式水口安装  Sub Entry Nozzles are susceptible to fracture. Therefore, they have to be handled with great care and stored in a dry place.  浸入式水口易折断,操作时要格外小心,干燥储存。  Ensure the wellblock is clean and free of any tundish rubble, any hard cement etc will affect seating and alignment of SEN and split rings.  确保座砖干净,没有各种中包碎块。火泥太硬会影响浸入式 水口和分离环的安装和对中。  Apply Resitect mortar to taper face and bottom support area of wellblock.  座砖底部和锥面涂抹火泥。  Apply Resitect to inner and outer taper face of split rings. Also apply Resitect to mating face of split rings.  分离环内外锥面、接合面涂抹火泥。  Insert SEN from bottom of tundish. Push the SEN as high as it will go to enable split rings to be installed.  浸入式水口从中包底部装入,托起浸入式水口,留出分离环 的安装高度。  After installing split rings, apply Resitect to the taper section of the SEN and lower the SEN into position in the split rings.  分离环安装后,浸入式水口斜面涂抹火泥,放下浸入式水口 安装到分离环内。  Ensure that the split rings do not rise out of the wellblock. Also ensure that the split rings are flush with one another at the top and are pushed down into the wellblock as tight as possible.  分离环不能高出座砖,并且分离环两边上端平齐,将分离环 压入座砖,越紧越好。
  15. 15. 1415 RHI ISO Guidance SEN Installation 浸入式水口安装  Ensure the SEN is also pushed down as tight as possible into the split rings. Do not hit the SEN with a hammer or similar object. The easiest way to ensure the tightest fit is to stand on top of the SEN. Check again after standing on the SEN that the split rings have not been pushed up from the wellblock and that both split rings are flush with one another on the top face.  确认浸入式水口和分离环安装紧密。不能用锤子等敲击浸入 式水口,确认安装紧密的简单的方法是站在浸入式水口上, 下来后检查分离环是否被挤出座砖,分离环两边上端是否平 齐。  Throughout the installation of the SEN someone should be below the tundish to check the SEN is properly aligned in the wellblock.  浸入式水口的安装过程中,操作工要在中包底部检查浸入式 水口与座砖准确对中。  As soon as the SEN has been installed some dimensional checks should be made to check the SEN alignment.  浸入式水口一安装好,用尺子精确测量,检查浸入式水口对 中情况。  Resitect mortar will cure during preheating of SEN.  浸入式水口预热过程中火泥会硬化定型。
  16. 16. 1416 RHI ISO Guidance SEN Installation 浸入式水口安装 Ensure the wellblock is clean and free of any tundish rubble, any hard cement etc. will affect seating and alignment of SEN and split rings. 确保座砖干净,没有各种中包 碎块。火泥太硬会影响浸入式 水口和分离环的安装和对中。 Apply Resitect to inner and outer taper face of the split rings 分离环内外锥面涂抹火泥。 The SEN has to be positioned vertically and with its outlets parallel to the mould parallel part. Check length below tundish. No cavities or channels are allowed in the putty as air might be drawn in owing to the under pressure produced. 浸入式水口安装要垂直,吐出 孔与结晶器平行。检查探出中 包底长度。火泥要涂抹匀实, 不能有孔洞,因为在负压作用 下会吸入空气。
  17. 17. 1417 RHI ISO Guidance SEN Installation Ensure the SEN is also pushed down as tight as possible into the split rings. Do not hit the SEN with a hammer or similar object. The easiest way to ensure the tightest fit is to stand on top of the SEN. 确认浸入式水口和分离环安装 紧密。不能用锤子等敲击浸入 式水口,确认安装紧密的简单 的方法是站在浸入式水口上。 Throughout the installation of the SEN someone should be below the tundish to check the SEN is properly aligned in the wellblock. 浸入式水口的安装过程中,操 作工要在中包底部检查浸入式 水口与座砖准确对中。 As soon as the SEN has been installed some dimensional checks should be made to check the SEN alignment. 浸入式水口一安装好,用尺子 精确测量,检查浸入式水口对 中情况
  18. 18. 1418 RHI ISO Guidance SEN Failures 浸入式水口事故 A.Symptoms 表现形式 A. Cracking at Tapered Area A. 缩颈部位裂纹 B. Internal Erosion B. 内部冲蚀 C. Thermal Shock Crack C. 热振裂纹 D. Excessive External Corrosion D. 外部侵蚀 E. Internal Erosion E. 内部侵蚀 F. Cracking across Port Area F. 吐出孔部位横裂
  19. 19. 1419 RHI ISO Guidance SEN Failures 浸入式水口事故 Causes 原因 A1. Mismatch between SEN and Well Block A1. 浸入式水口与座砖尺寸不匹配 B1 Steel Quality 钢种 B2. Irregular Steel Flow 钢流不稳定 C1 Insufficient Preheat Time/Temperature C1. 预热时间短 / 温度低 C2 Long Delays between Preheat Off to Cast Start C2. 结束预热后延迟开浇 D1 Oxidation 氧化 D2 Casting Position/Ramping Procedure D2. 水口浇铸位置 / 水口斜 E1 Steel Quality 钢种 E2 Oxidation 氧化 E3 Casting Procedure/Powder Entrapment 浇铸工艺 / 保护渣卷入 F1 Internal/External Erosion 内部 / 外部冲蚀 F2 Vibration 颤动
  20. 20. 1420 RHI ISO Guidance  Heating Instructions 预热说明  Ladle shrouds have an oxidised inner layer that prevents thermal shocking on initial start up. Therefore, ladle shrouds can be used for cold start and do not need preheating.  长水口 带氧化层内衬,能防止开浇时产生热振,因此长水口 可以不用预热,冷态下开浇。  Stoppers heat up take place on the casting platform prior to casting start. During preheating the stopper is open. The stopper body is mainly heated up by the burners for heating up the tundish wear lining. The stopper nose is heated up trough the SEN body by the burners below. The delay from end of preheat to the start of casting should be kept to a minimum to prevent thermal shock cracking of the stopper and also to prevent the steel stream freezing causing the stopper to stick in the throat of the SEN  塞棒 开浇前在浇铸平台预热,预热时塞棒处于打开位。塞棒 本体和中包一起预热,塞棒头用烧嘴通过浸入式水口内孔预 热。 中间包预热结束到开浇,时间应尽量缩短,防止塞棒热振裂 纹产生,也防止钢水冷凝造成塞棒和浸入式水口粘连。  Thin Slab SEN’s should have cerawool wrapped round it prior to preheating. This prevents excess heat loss after preheater burner is closed prior to casting. Burners have to be positioned on both side of the port to maximize preheating of the SEN body and stopper nose. The delay from switching off the SEN burner to start of cast should be kept to a minimum to prevent thermal shock cracking of the SEN. The aim, “off gas to start cast” is maximum 3 minutes.  薄板坯水口 预热前包裹石棉毡,防止开浇前预热烧嘴热量过 渡损失。烧嘴布置在吐出孔两侧,最大限度加热水口本体和 塞棒头。 浸入式水口预热结束到开浇,时间应尽量缩短,防止浸入式 水口热振裂纹产生。目标:“停火到开浇时间”最长 3 分钟。
  21. 21. 1421 RHI ISO Guidance Heating Instructions 预热说明
  22. 22. 1422 RHI ISO Guidance Heating Instructions 预热说明

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