TRAINING FOR VACUUM DEGASSING AND SECONDARY METALLURGY BY CVS MAKINA

1. 05.01.2010
CVS MAKINA is happy to welcome all of you to our training in your
offices
CVS MAKINA - VD CLASSROOM TRAINING 1
Training Objects
Theoretical Training
General description on VD plant layout
- safe operation
- technology
- metallurgy in brief
Explanation of individual VD equipment
- explanation of equipment components
- maintenance (including preventive maintenance, regular checks and lubrication)
- safety
Actions and repairs in cases of emergency (including power, cooling water and media failure,
operational emergency cases)
VD cooling water and gas media systems (incl. Standards, special valves, etc.)
Review of previous days, concluding discussion on VD matters
CVS MAKINA - VD CLASSROOM TRAINING 2
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2. 05.01.2010
Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 3
Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 4
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3. 05.01.2010
From Ore/Scrap To VD-Plant
Process Of Steel Production
• process sequence:
blast furnace - converter
• process sequence:
electric arc furnace
CVS MAKINA - VD CLASSROOM TRAINING 5
From Ore/Scrap To VD-Plant
Nowadays pig iron produced in the so-
called COREX REDUCTION MELTING
PLANTS is refined to crude steel in
converters or electric arc furnaces.
Advantages Of Utilizing The Electric Arc Furnace
Process Sequence
• production of each kind of steel grade possible
• independent on the charging (scrap, metallized iron
ore, become hardened pig iron, liquid pig iron)
• low investment requirements
• process sequence can be automized
• high efficiency
CVS MAKINA - VD CLASSROOM TRAINING 6
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4. 05.01.2010
From Ore/Scrap To VD-Plant
Secondary Metallurgy
Today converters and electric arc furnaces mostly serve as smelting plants and plants for carbon and
phosphorus reduction.
Nowadays secondary metallurgy is the most important process route for adjusting the required material
properties.
Vacuum Metallurgy
• metallurgical treatment
under reduced pressure
(< 0,1MPa)
CVS MAKINA - VD CLASSROOM TRAINING 7
From Ore/Scrap To VD-Plant
Results Of Vacuum Treatment:
Steel Grades Of:
• excellent purity
• low contents of gas
• small tolerances of alloying elements
CVS MAKINA - VD CLASSROOM TRAINING 8
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5. 05.01.2010
Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 9
Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 10
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6. 05.01.2010
Metallurgy
VD - Treatment
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Metallurgy
VD - Treatment
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7. 05.01.2010
Metallurgy
VD - Treatment
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Metallurgy
VD - Treatment
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8. 05.01.2010
Metallurgy
VD - Treatment
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Metallurgy
VOD - Treatment
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9. 05.01.2010
Metallurgy
VOD - Treatment
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Metallurgy
VOD - Treatment
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10. 05.01.2010
Metallurgy
VOD - Treatment
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Metallurgy
VOD - Treatment
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11. 05.01.2010
Metallurgy
VOD - Treatment
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Metallurgy
VOD - Treatment
Temperatures changes due to
addition of alloys
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12. 05.01.2010
Metallurgy
VOD - Treatment
Temperature changes
due to addition of 1%
alloying material Al, Si
and Mn
CVS MAKINA - VD CLASSROOM TRAINING 23
Metallurgy
VOD - Treatment
CVS MAKINA - VD CLASSROOM TRAINING 24
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13. 05.01.2010
Metallurgy
VOD - Treatment
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Metallurgy
VOD - Treatment
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14. 05.01.2010
Metallurgy
VOD - Treatment
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Metallurgy
VOD - Treatment
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15. 05.01.2010
Metallurgy
VOD - Treatment
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Metallurgy
VOD - Treatment
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16. 05.01.2010
Metallurgy
VOD - Treatment
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Metallurgy
VOD - Treatment
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17. 05.01.2010
Metallurgy
VOD - Treatment
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Metallurgy
VOD - Treatment
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18. 05.01.2010
Metallurgy
VOD - Treatment
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Metallurgy
VOD - Treatment
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19. 05.01.2010
Metallurgy
VOD - Treatment
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Metallurgy
VOD - Treatment
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20. 05.01.2010
Metallurgy
VOD - Treatment
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Metallurgy
VOD - Treatment
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21. 05.01.2010
Metallurgy
VOD - Treatment
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Metallurgy
VOD - Treatment
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22. 05.01.2010
Metallurgy
VOD - Treatment
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Metallurgy
VOD - Treatment
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23. 05.01.2010
Metallurgy
Stainless Steel Grades
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Metallurgy
Stainless Steel Grades
CVS MAKINA - VD CLASSROOM TRAINING 46
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24. 05.01.2010
Metallurgy
Stainless Steel Grades
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Metallurgy
Stainless Steel Grades
CVS MAKINA - VD CLASSROOM TRAINING 48
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25. 05.01.2010
Metallurgy
Stainless Steel Grades
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Metallurgy
Stainless Steel Grades
CVS MAKINA - VD CLASSROOM TRAINING 50
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26. 05.01.2010
Metallurgy
Stainless Steel Grades
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Metallurgy
Stainless Steel Grades
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27. 05.01.2010
Metallurgy
Stainless Steel Grades
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Metallurgy
Stainless Steel Grades
CVS MAKINA - VD CLASSROOM TRAINING 54
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28. 05.01.2010
Metallurgy
Stainless Steel Grades
CVS MAKINA - VD CLASSROOM TRAINING 55
Metallurgy
Stainless Steel Grades
CVS MAKINA - VD CLASSROOM TRAINING 56
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29. 05.01.2010
Metallurgy
Stainless Steel Grades
CVS MAKINA - VD CLASSROOM TRAINING 57
Metallurgy
Stainless Steel Grades
CVS MAKINA - VD CLASSROOM TRAINING 58
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30. 05.01.2010
Metallurgy
Stainless Steel Grades
CVS MAKINA - VD CLASSROOM TRAINING 59
Metallurgy
Stainless Steel Grades
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31. 05.01.2010
Metallurgy
Steel Production Mix Example
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Metallurgy
Steel Production Mix Example
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32. 05.01.2010
Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 63
March Of Steel Temperature
Temperature loss due to:
• heating up of the refractory of the ladle
• radiation loss during vacuum treatment, ladle transportation and tapping
Formula for heat loss by radiation: M = weight of steel inside ladle; (example:80 t)
C = spec. Heat capacity of liquid steel; (example:
0,23Wh/kgC°)
= emission factor of liquid steel; (example 0,4)
= radiation factor of black body; 5,775*10-8 [W / m2 K4]
T = steel temperature: 1617°C = 1800 K
= time [min]
F = radiating surface of liquid steel:
- casting spout (example: approx. 1 m2)
- tapping stream (example: approx. 2,5 m2)
- inside ladle (example: approx. 5 m2)
CVS MAKINA - VD CLASSROOM TRAINING 64
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33. 05.01.2010
March Of Steel Temperature
Temperature Loss Of Liquid Steel During Tapping (Example 80 t Ladle)
Formula For
Heat Loss By
Radiation
Example for 80 t steel ladle: Example for 80 t steel ladle:
( without covering powder) Loss to refractory material
T = 56 °C
T = 2,27 x T = 33 °C (cold ladle 0°C)
Tapping time: 10 min.
T = 23 °C, loss by radiation
Example for 80 t steel ladle: Example for 80 t steel ladle:
( with covering powder) Loss to refractory material
T = 0,15 x T = 33 °C (cold ladle 0°C) T = 34,5 °C
Tapping time: 10 min.
T = 1,5 °C, loss by radiation
CVS MAKINA - VD CLASSROOM TRAINING 65
March Of Temperature
Temperature Loss Of Liquid Steel Due To „Cold“ Ladle
Temperature of refractory material
Temperature Loss Of Liquid Steel Due Temperature Loss Of Liquid Steel Due
To „Cold“ Refractory Of The Ladle To „Cold“ Refractory Of The Ladle
(40t-ladle) (80t-ladle)
CVS MAKINA - VD CLASSROOM TRAINING 66
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34. 05.01.2010
March Of Temperature
Temperature Change Due To Adding Of Alloying Material
Temperature Change Due To Adding Of Alloying Material
CVS MAKINA - VD CLASSROOM TRAINING 67
March Of Temperature
Temperature Change Due To Adding Of Alloying Material
Temperature Change Due To Adding Of Alloying Material
CVS MAKINA - VD CLASSROOM TRAINING 68
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35. 05.01.2010
Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 69
Special Risks / Hazards & Countermeasures
Electrical Energy
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36. 05.01.2010
Special Risks / Hazards & Countermeasures
Electrical Energy
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Special Risks / Hazards & Countermeasures
Electrical Energy
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37. 05.01.2010
Special Risks / Hazards & Countermeasures
Gas, Dust, Steam, Smoke
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Special Risks / Hazards & Countermeasures
Gas, Dust, Steam, Smoke
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38. 05.01.2010
Special Risks / Hazards & Countermeasures
Gas, Dust, Steam, Smoke
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Special Risks / Hazards & Countermeasures
Gas, Dust, Steam, Smoke
CVS MAKINA - VD CLASSROOM TRAINING 76
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39. 05.01.2010
Special Risks / Hazards & Countermeasures
Gas, Dust, Steam, Smoke
CVS MAKINA - VD CLASSROOM TRAINING 77
Special Risks / Hazards & Countermeasures
Gas, Dust, Steam, Smoke
CVS MAKINA - VD CLASSROOM TRAINING 78
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40. 05.01.2010
Special Risks / Hazards & Countermeasures
Gas, Dust, Steam, Smoke
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Special Risks / Hazards & Countermeasures
Gas, Dust, Steam, Smoke
CVS MAKINA - VD CLASSROOM TRAINING 80
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41. 05.01.2010
Special Risks / Hazards & Countermeasures
Gas, Dust, Steam, Smoke
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Special Risks / Hazards & Countermeasures
Gas, Dust, Steam, Smoke
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42. 05.01.2010
Special Risks / Hazards & Countermeasures
Gas, Dust, Steam, Smoke
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Special Risks / Hazards & Countermeasures
Gas, Dust, Steam, Smoke
CVS MAKINA - VD CLASSROOM TRAINING 84
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43. 05.01.2010
Special Risks / Hazards & Countermeasures
Hydraulic-, Pneumatic Equipment
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Special Risks / Hazards & Countermeasures
Noise, Vibration
CVS MAKINA - VD CLASSROOM TRAINING 86
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44. 05.01.2010
Special Risks / Hazards & Countermeasures
Noise, Vibration
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Special Risks / Hazards & Countermeasures
Noise, Vibration
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45. 05.01.2010
Special Risks / Hazards & Countermeasures
Oil, Grease And Other Chemical Substances
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Special Risks / Hazards & Countermeasures
Unexpected Malfunctions / Mechanical Hazards
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46. 05.01.2010
Special Risks / Hazards & Countermeasures
Thermal Hazards
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Special Risks / Hazards & Countermeasures
Fire And Fire Fighting / Emergency Procedures
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47. 05.01.2010
Special Risks / Hazards & Countermeasures
Fire And Fire Fighting / Emergency Procedures
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Special Risks / Hazards & Countermeasures
Fire And Fire Fighting / Emergency Procedures
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48. 05.01.2010
Special Risks / Hazards & Countermeasures
Personal Protective Equipment (P.P.E.)
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Special Risks / Hazards & Countermeasures
Personal Protective Equipment (P.P.E.)
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49. 05.01.2010
Special Risks / Hazards & Countermeasures
Personal Protective Equipment (P.P.E.)
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Special Risks / Hazards & Countermeasures
Personal Protective Equipment (P.P.E.)
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50. 05.01.2010
Special Risks / Hazards & Countermeasures
Personal Protective Equipment (P.P.E.)
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Special Risks / Hazards & Countermeasures
Localization Of Risks And Hazards
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51. 05.01.2010
Special Risks / Hazards & Countermeasures
Localization Of Risks And Hazards
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Special Risks / Hazards & Countermeasures
Localization Of Risks And Hazards
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52. 05.01.2010
Special Risks / Hazards & Countermeasures
Localization Of Risks And Hazards
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Special Risks / Hazards & Countermeasures
Localization Of Risks And Hazards
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53. 05.01.2010
Special Risks / Hazards & Countermeasures
Localization Of Risks And Hazards
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Special Risks / Hazards & Countermeasures
Localization Of Risks And Hazards
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54. 05.01.2010
Special Risks / Hazards & Countermeasures
Localization Of Risks And Hazards
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Special Risks / Hazards & Countermeasures
Reasons For Preventive Maintenance
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55. 05.01.2010
Special Risks / Hazards & Countermeasures
Reasons For Preventive Maintenance
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Special Risks / Hazards & Countermeasures
Reasons For Preventive Maintenance
Planning Of Maintenance Works
CVS MAKINA - VD CLASSROOM TRAINING 110
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56. 05.01.2010
Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 111
Steam Ejector Vacuum Pump
Vacuum Vessel Ejectors/Condensers Water Ring Pumps Waste Gas Line
Condenser
Booster/ejector
Water ring pump
Vacuum Vessel
Vacuum pump system (typical)
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57. 05.01.2010
Steam Ejector Vacuum Pump
Function Of Vacuum Pump
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Steam Ejector Vacuum Pump
Function Of Vacuum Pump
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58. 05.01.2010
Steam Ejector Vacuum Pump
Function Of Vacuum Pump
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Steam Ejector Vacuum Pump
Function Of Vacuum Pump
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59. 05.01.2010
Steam Ejector Vacuum Pump
Function Of Vacuum Pump
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Steam Ejector Vacuum Pump
Function Of Vacuum Pump
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60. 05.01.2010
Steam Ejector Vacuum Pump
Function Of Vacuum Pump
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Steam Ejector Vacuum Pump
Function Of Vacuum Pump
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61. 05.01.2010
Steam Ejector Vacuum Pump
Function Of Vacuum Pump
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Steam Ejector Vacuum Pump
Function Of Vacuum Pump
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62. 05.01.2010
Steam Ejector Vacuum Pump
Function Of Vacuum Pump
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Steam Ejector Vacuum Pump
Function Of Vacuum Pump: Water Ring Pump
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63. 05.01.2010
Steam Ejector Vacuum Pump
Function Of Vacuum Pump: Water Ring Pump
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Steam Ejector Vacuum Pump
Function Of Vacuum Pump: Water Ring Pump
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64. 05.01.2010
Steam Ejector Vacuum Pump
Function Of Vacuum Pump: Water Ring Pump
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Steam Ejector Vacuum Pump
Function Of Vacuum Pump: Condenser C 1
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65. 05.01.2010
Steam Ejector Vacuum Pump
Function Of Vacuum Pump: Condenser C 2
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Steam Ejector Vacuum Pump
Failure / Malfunction / Maintenance
Failure / malfunction Reason Countermeasures
Steam ejectors Problems with steam, condenser Refer to “Steam Ejector Vacuum Pump”
cooling water, valves etc.
Water ring pumps Problems with the performance of the Refer to “Water Ring Pumps”
water ring pumps
Hotwell pumps Problems with the performance of the Refer to “Hotwell Pumps”
hotwell pumps
Refer to “Automatic Aspirator”
Steam Ejector Vacuum Pump
Equipment that needs Once per
Daily Weekly Monthly Yearly
maintenance half-year
Leakage test X
Performance test X
Cleaning of the ejectors X
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66. 05.01.2010
Steam Ejector Vacuum Pump
Failure / Malfunction / Maintenance
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Steam Ejector Vacuum Pump
Failure / Malfunction / Maintenance
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67. 05.01.2010
Steam Ejector Vacuum Pump
Failure / Malfunction / Maintenance
Hot well Pump And Automatic Aspirator
Automatic Aspirator
Hot well Pumps Need To Be Flooded With Water!
Hot well Tank
Equipment that needs Once per
Daily Weekly Monthly Yearly
maintenance half-year
Cleansing inside X
Valves X
Sealings of pipe work X
CVS MAKINA - VD CLASSROOM TRAINING 133
Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 134
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68. 05.01.2010
Suction Line System
Failure / Malfunction / Maintenance
Equipment that needs Once per
Daily Weekly Monthly Yearly
maintenance half-year
Vacuum sealing X
Chain hoist X
Sealing at manholes X
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Suction Line System
Failure / Malfunction / Maintenance
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69. 05.01.2010
Suction Line System
Failure / Malfunction / Maintenance
Failure / malfunction Reason Countermeasures
Lowering/lifting of elbow is not A) Problems with the hoist A) refer to “Chain Hoist For Elbow”
possible
Moving of elbow is not possible A) Problems with the hoist A) refer to “Chain Hoist For Elbow”
CVS MAKINA - VD CLASSROOM TRAINING 137
Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 138
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Condenser
Failure / Malfunction / Maintenance
CVS MAKINA - VD CLASSROOM TRAINING 139
Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 140
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Waste Gas Measurement
Failure / Malfunction / Maintenance
Cabinet of Waste Gas Analyser
CVS MAKINA - VD CLASSROOM TRAINING 141
Waste Gas Measurement
Failure / Malfunction / Maintenance
Waste gas composition – VD process
CVS MAKINA - VD CLASSROOM TRAINING 142
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72. 05.01.2010
Waste Gas Measurement
Failure / Malfunction / Maintenance
Waste gas composition – VD/VCD process
CVS MAKINA - VD CLASSROOM TRAINING 143
Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 144
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Vacuum Vessel
Failure / Malfunction / Maintenance
Clean vessel inside depending on
accumulated slag and dust inside !
Minimum once per week.
CVS MAKINA - VD CLASSROOM TRAINING 145
Vacuum Vessel
Failure / Malfunction / Maintenance
Failure / malfunction Reason Countermeasures
Vacuum cannot be established Leakage at the sealing ring Clean the sealing flange or exchange the sealing
Stirring system does not work a) Damage to the hoses a) Exchange the hoses
b) Damage to the quick couplings b) Exchange the quick coupling
c) Porous plugs are stuck c) See “Ladle stirring equipment”
d) Malfunction at the argon/nitrogen valve d) See “Valves/Argon Rack/Nitrogen Rack”
CVS MAKINA - VD CLASSROOM TRAINING 146
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Vacuum Vessel
Failure / Malfunction / Maintenance
CVS MAKINA - VD CLASSROOM TRAINING 147
Vacuum Vessel
Failure / Malfunction / Maintenance
Equipment that needs Once per
Daily Weekly Monthly Yearly
maintenance; cleansing half-year
Sealing Flange X
Sealing Ring X
Water Cooled Channel X
Ladle Support X
Thermocouples X
Bolts X
Refractory X
Argon hoses/quick coupling/ pipework X
Vessel X
CVS MAKINA - VD CLASSROOM TRAINING 148
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Vacuum Vessel
Failure / Malfunction / Maintenance
Check :
wiring, screws, for damage
CVS MAKINA - VD CLASSROOM TRAINING 149
Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 150
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76. 05.01.2010
Vacuum Cover
Failure / Malfunction / Maintenance
The cover requires refractory
lining with monolithic castable
installation.
The refractory lining can be
repaired by warm or hot spraying
also in operating state. The binders
must be composed such that the
material.
CVS MAKINA - VD CLASSROOM TRAINING 151
Vacuum Cover
Failure / Malfunction / Maintenance
CVS MAKINA - VD CLASSROOM TRAINING 152
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Vacuum Cover
Failure / Malfunction / Maintenance
Equipment that needs Once per
Daily Weekly Monthly Yearly
maintenance half-year
leaning the cover, sweep off X
Checking the cooling water
X
channels for leakage
Checking the cover sealing for
X X
leakage
CVS MAKINA - VD CLASSROOM TRAINING 153
Vacuum Cover
Failure / Malfunction / Maintenance
Failure / malfunction Reason Countermeasures
Cover cannot be raised/lowered A) Problems with hydraulic lifting A) Refer to “Hydraulic System A)”
equipment
B) Refer to “Hydraulic System C)”
B) Cover and ladle stick together
due to slag and steel splashes
C) Flood cover by air
C) Cover still under vacuum
(pressure < 950 mbar)
Cooling water not available A) Fittings do not respond A) Refer to “Piping: Valves, Fittings, Hoses, etc.“
B) Water supply interrupted B) Look for problem in water supply
Vacuum cannot be established A) Glasses of sight glass device A) Replace immediately,
damaged Refer to Annex “Glasses for Sight Glass Device”
CVS MAKINA - VD CLASSROOM TRAINING 154
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Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 155
Water Cooled Ladle Cover
Failure / Malfunction / Maintenance
Cover
Water cooled
ladle cover
CVS MAKINA - VD CLASSROOM TRAINING 156
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79. 05.01.2010
Water Cooled Ladle Cover
Failure / Malfunction / Maintenance
CVS MAKINA - VD CLASSROOM TRAINING 157
Water Cooled Ladle Cover
Failure / Malfunction / Maintenance
Equipment that needs Once per
Daily Weekly Monthly Yearly
maintenance half-year
Search leak
X
Remove deposits (slag, dust,
etc.) from top of inner shieldings X X
Check hoses for leakage and
damage X
CVS MAKINA - VD CLASSROOM TRAINING 158
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Water Cooled Ladle Cover
Failure / Malfunction / Maintenance
Behandlungsverlauf Behandlungsverlauf
[min] [min]
March Of Temperature
50,00 50,00
During Treatment
40,00 40,00
outlet temperature
30,00 30,00
Temperatur °C
Temperatur °C
Ausgangstemperatur Ausgangstemperatur
[°C] [°C]
T T (inlet temp. = 17 °C)
20,00 20,00
10,00 10,00
T
0,00 0,00
10:59:33
11:03:44
11:09:45
11:13:26
11:22:28
11:34:11
11:39:52
11:51:34
10:14:16
10:18:26
10:24:28
10:27:38
10:30:29
10:47:52
11:01:15
11:09:27
Zeit in Minuten Ze it in Minuten
CVS MAKINA - VD CLASSROOM TRAINING 159
Water Cooled Ladle Cover
Failure / Malfunction / Maintenance
Water cooled ladle cover
CVS MAKINA - VD CLASSROOM TRAINING 160
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81. 05.01.2010
Water Cooled Ladle Cover
Failure / Malfunction / Maintenance
Failure / malfunction Reason Countermeasures
Loss of pressure Leakage - Break off the process
- Replace water cooled
ladle cover and repair
No cooling water flowing A) Fittings do not respond A) Refer to “Valves/Argon-Nitrogen Rack“
B) Water supply interrupted B) Look for problem in water supply
Water temperature too high A) Flow of water too low A) Look for problem in water supply
(water too hot)
B) Water supply interrupted B) Check if fittings are opened
CVS MAKINA - VD CLASSROOM TRAINING 161
Water Cooled Ladle Cover
Alternative: Partially Refractory Lined Ladle Cover
CVS MAKINA - VD CLASSROOM TRAINING 162
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82. 05.01.2010
Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 163
Vacuum Alloying Hopper
Failure / Malfunction / Maintenance
CVS MAKINA - VD CLASSROOM TRAINING 164
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83. 05.01.2010
Vacuum Alloying Hopper
Failure / Malfunction / Maintenance
CVS MAKINA - VD CLASSROOM TRAINING 165
Vacuum Alloying Hopper
Failure / Malfunction
Failure / malfunction Reason Countermeasures
Hoppers cannot be loaded Problems with alloying equipment Look for problem in alloying equipment
Hoppers cannot be unloaded A) Compressed air supply to pneumatic A) Make sure compressed air is provided to
cylinders interrupted pneumatic cylinders
B) Pneumatic cylinders faulty B) Replace cylinders
Hoppers cannot be evacuated A) Fittings leaky A) Refer to “Valves/Argon-Nitrogen Rack“
B) Leakage B) Search leak
Hoppers cannot be flooded A) Compressed air supply to valves A) Make sure compressed air is provided to
interrupted pneumatic cylinders
B) valves faulty B) Replace valves
CVS MAKINA - VD CLASSROOM TRAINING 166
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Vacuum Alloying Hopper
Maintenance
Equipment that needs Once per
Daily Weekly Monthly Yearly
maintenance half-year
Search leak X
Replace sealing of shut off device X
CVS MAKINA - VD CLASSROOM TRAINING 167
Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 168
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85. 05.01.2010
Cover Lifting and Travelling Device
Failure / Malfunction / Maintenance
CVS MAKINA - VD CLASSROOM TRAINING 169
Cover Lifting and Travelling Device
Failure / Malfunction / Maintenance
Failure / malfunction Reason Countermeasures
Cover travelling device A) Limit switches are not made A) Check limit switches
cannot be moved Interlock is not released => replace/repair
B) Problems with the geared brake B) Refer to Annex 11.1.4 A
motors
Car overruns the halts A) limit switch out of order A) check limit switches
=>
repair/exchange them
B) braking torque not sufficient B) Refer to Annex 11.1.4 A
Equipment that needs Once per
Daily Weekly Monthly Yearly
maintenance half-year
Check the tread of the wheels for
X
wear
Check the rails for abrasion and
X
wear
Check the rail mounting X
Lubricate bearings of the wheel X
CVS MAKINA - VD CLASSROOM TRAINING 170
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Cover Lifting and Travelling Device
Lubrication
CVS MAKINA - VD CLASSROOM TRAINING 171
Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 172
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87. 05.01.2010
Ladle Stirring Equipment / Furnace Camera
Mechanism Of Degassing Of Dissolved Gases
Mechanism Of Degassing Of Dissolved Gases
The following mechanism can be mentioned:
• heterogeneous nucleation; gas bubbles arise at solid
interfacials; for instance at the refractory material
(negligible for the steel making process)
• homogeneous nucleation; gas bubbles arise in the
liquid steel (negligible for the steel making process)
• degassing via circulation gas
CVS MAKINA - VD CLASSROOM TRAINING 173
Ladle Stirring Equipment / Furnace Camera
Mechanism Of Degassing Of Dissolved Gases
Mass transfer inside liquid steel can be influenced by the pressure above
the melting charge, ratio of surface/volume and time.
Prolongation of treatment time causes a higher temperature loss by heat
radiation and heat conduction. Thus creating higher costs resulting from
the measurements to compensate the temperature loss (for instance
aluminothermic heating).
=> Depending on the final pressure inside the vacuum vessel the major
interest is focused on a high ratio of specific surface/volume and
creating at the same time an intensive bath circulation in order to
achieve a high number of mass-transfer coefficient.
CVS MAKINA - VD CLASSROOM TRAINING 174
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Ladle Stirring Equipment / Furnace Camera
Mechanism Of Degassing Of Dissolved Gases
An enlargement of the degassing surface is created by boiling. This
boiling comes from CO origination and by flushing with argon/nitrogen
bubbling.
The degassing surface consist of the accumulation of the bath surface
and the surface of all gas bubbles.
CVS MAKINA - VD CLASSROOM TRAINING 175
Ladle Stirring Equipment / Furnace Camera
Types Of Ladle Stirring Plugs
CVS MAKINA - VD CLASSROOM TRAINING 176
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Ladle Stirring Equipment / Furnace Camera
Argon / Nitrogen Valve Rack
CVS MAKINA - VD CLASSROOM TRAINING 177
Ladle Stirring Equipment / Furnace Camera
Argon / Nitrogen Valve Rack
Argon/Nitrogen Valve Racks
• Operated Via LEVEL 1 / HMI
HMI = Human Being – Machine - Interface
MMI = Man – Machine - Interface
CVS MAKINA - VD CLASSROOM TRAINING 178
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Ladle Stirring Equipment / Furnace Camera
Quick Coupling And Corrugated Hose
Alternative quick coupling
CVS MAKINA - VD CLASSROOM TRAINING 179
Ladle Stirring Equipment / Furnace Camera
Failure / Malfunction
Failure / malfunction Reason Countermeasures
Flushing does not work on all 1. Hose/coupling leaky 1. Replace hose/coupling
plugs
2. Ladle flushing plug obstructed 2. Flush plug by higher pressure (by-pass)
Plug cannot be flushed open 1. Infiltration of metal bath a) 2 flushing plugs still working:
Process can be continued
b) only 1 flushing plug is working;
abort process
Valves do not close/open 1. Control air not available 1. make control air available
2. Energy supply interrupted 2. make energy supply available
3. Others 3. we refer to “Valves/Argon/Nitrogen Rack”
Quick coupling cannot be 1. Coupling damaged 1. exchange coupling
opened/closed
2. Coupling gripes 2. we refer to “Vacuum Vessel Equipment
CVS MAKINA - VD CLASSROOM TRAINING 180
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Ladle Stirring Equipment / Furnace Camera
Maintenance
Equipment that needs Once per
Daily Weekly Monthly Yearly
maintenance half-year
Check for leakage X
Check paint for damage X
Check screwed connections for
tightness and presence of safety X
screws
Check hoses / quick couplings X
Check functionality of valves X
CVS MAKINA - VD CLASSROOM TRAINING 181
Ladle Stirring Equipment / Furnace Camera
Stirring Observation Device
CVS MAKINA - VD CLASSROOM TRAINING 182
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92. 05.01.2010
Ladle Stirring Equipment / Furnace Camera
Stirring Observation Device
Sight Glass Device
Smoke: disappears at a pressure < 80 mbar
CVS MAKINA - VD CLASSROOM TRAINING 183
Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 184
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93. 05.01.2010
Hydraulic System
Hydraulic System For Cover Lifting And Travelling Moving
CVS MAKINA - VD CLASSROOM TRAINING 185
Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 186
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94. 05.01.2010
Temperature And Sampling Lance
T & S – Lance
CVS MAKINA - VD CLASSROOM TRAINING 187
Temperature And Sampling Lance
T & S – Lance
CVS MAKINA - VD CLASSROOM TRAINING 188
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95. 05.01.2010
Temperature And Sampling Lance
T & S – Lance
CVS MAKINA - VD CLASSROOM TRAINING 189
Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 190
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96. 05.01.2010
PIPING : Valves, Fittings, Hoses, Etc.
Standards, Special Valves, etc.
CVS MAKINA - VD CLASSROOM TRAINING 191
PIPING : Valves, Fittings, Hoses, Etc.
Standards, Special Valves, etc.
CVS MAKINA - VD CLASSROOM TRAINING 192
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97. 05.01.2010
PIPING : Valves, Fittings, Hoses, Etc.
Standards, Special Valves, etc.
CVS MAKINA - VD CLASSROOM TRAINING 193
PIPING : Valves, Fittings, Hoses, Etc.
Standards, Special Valves, etc.
CVS MAKINA - VD CLASSROOM TRAINING 194
97

98. 05.01.2010
Training Contents
From Ore / Scrap To VD – Plant
Plant Overview / Plant Layout
Metallurgy
March Of Steel Temperature
Special Risks / Hazards & Countermeasures
Steam Ejector Vacuum Pump
Suction Line System
Condenser
Waste Gas Measurement
Vacuum Vessel
Vacuum Cover
Water Cooled Ladle Cover
Vacuum Alloying Hopper
Cover Lifting and Travelling Device
Ladle Stirring Equipment / Furnace Camera
Hydraulic System
Temperature And Sampling Lance
PIPING : Valves, Fittings, Hoses, Etc.
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 195
Field Instruments
CVS MAKINA - VD CLASSROOM TRAINING 196
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99. 05.01.2010
Thank You
For
Listening
CVS MAKINA - VD CLASSROOM TRAINING 197
99