Liquid Core Detection and Strand Condition Monitoring in a Continuous Caster Using Optical Fiber
Abstract
:1. Introduction
2. FBG Sensing Principle
3. Experimental Methods
3.1. Laboratory Testing
3.2. Off-Line Testing in Segment Repair Facility
3.3. On-Line Testing during Caster Operation
4. Results and Discussion
4.1. Laboratory Measurement Results
4.2. Results from Strain Measurement in an Off-Line Segment
4.3. Plant Test Results
5. Conclusions
- The highly distributed optical strain measurement technique provides a low-cost method for continuously monitoring the casting process on a large number of rolls and segments for liquid core tracking and metallurgical length monitoring.
- The optical strain signals can also provide information about the strains experienced by the caster during various events, such as at startup, at operating transients such as speed and width changes, at strand cap-off, and during steady-state operation.
- In combination with other caster data, the strain signals can also be used to calibrate and validate continuous caster model predictions. These models can then be used with a higher degree of confidence to enhance control of the continuous casting process.
- FFT analysis of the strain data provides an on-line real-time system to monitor the condition of the rolls and the solidified strand during caster operation. The signals from the optical strain gauges have been shown to be capable of detecting the presence of bent or warped rolls and shell bulging during caster operation.
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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Characteristic Frequencies for ArcelorMittal BH CC1 | |||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|
Segment | Roll | Diameter | Pitch | Roll Diameter Frequency (Hz) at Speed (ipm) | Roll Pitch Frequency (Hz) at Speed (ipm) | ||||||
30 | 35 | 40 | 45 | 30 | 35 | 40 | 45 | ||||
FR | 1 | 134.6 | 110.4 | 0.030 | 0.035 | 0.040 | 0.045 | 0.115 | 0.134 | 0.153 | 0.173 |
0 | 2 | 134.6 | 178 | 0.030 | 0.035 | 0.040 | 0.045 | 0.071 | 0.083 | 0.095 | 0.107 |
0 | 3 | 134.6 | 190 | 0.030 | 0.035 | 0.040 | 0.045 | 0.067 | 0.078 | 0.089 | 0.100 |
0 | 4 | 134.6 | 204 | 0.030 | 0.035 | 0.040 | 0.045 | 0.062 | 0.073 | 0.083 | 0.093 |
0 | 5 | 134.6 | 226 | 0.030 | 0.035 | 0.040 | 0.045 | 0.056 | 0.066 | 0.075 | 0.084 |
0 | 6 | 215.9 | 247 | 0.019 | 0.022 | 0.025 | 0.028 | 0.051 | 0.060 | 0.069 | 0.077 |
0 | 7 | 215.9 | 253 | 0.019 | 0.022 | 0.025 | 0.028 | 0.050 | 0.059 | 0.067 | 0.075 |
0 | 8 | 215.9 | 245 | 0.019 | 0.022 | 0.025 | 0.028 | 0.052 | 0.060 | 0.069 | 0.078 |
0 | 9 | 215.9 | 249 | 0.019 | 0.022 | 0.025 | 0.028 | 0.051 | 0.060 | 0.068 | 0.077 |
1 | 10–14 | 248.9 | 300 | 0.016 | 0.019 | 0.022 | 0.024 | 0.042 | 0.049 | 0.056 | 0.064 |
2 | 15–19 | 279.4 | 224 | 0.014 | 0.017 | 0.019 | 0.022 | 0.057 | 0.066 | 0.076 | 0.085 |
3 | 20–24 | 330.2 | 376 | 0.012 | 0.014 | 0.016 | 0.018 | 0.034 | 0.039 | 0.045 | 0.051 |
4 | 25–29 | 330.2 | 393 | 0.012 | 0.014 | 0.016 | 0.018 | 0.032 | 0.038 | 0.043 | 0.048 |
5 | 30–36 | 250 | 368 | 0.016 | 0.019 | 0.022 | 0.024 | 0.035 | 0.040 | 0.046 | 0.052 |
6 | 37–43 | 250 | 312 | 0.016 | 0.019 | 0.022 | 0.024 | 0.041 | 0.047 | 0.054 | 0.061 |
7 | 44–48 | 300 | 341 | 0.013 | 0.016 | 0.018 | 0.020 | 0.037 | 0.043 | 0.050 | 0.056 |
8 | 49–53 | 300 | 358 | 0.013 | 0.016 | 0.018 | 0.020 | 0.035 | 0.041 | 0.047 | 0.053 |
9 | 54–58 | 300 | 355 | 0.013 | 0.016 | 0.018 | 0.020 | 0.036 | 0.042 | 0.048 | 0.054 |
10 | 59–63 | 300 | 350 | 0.013 | 0.016 | 0.018 | 0.020 | 0.036 | 0.042 | 0.048 | 0.054 |
11 | 64–68 | 300 | 347 | 0.013 | 0.016 | 0.018 | 0.020 | 0.037 | 0.043 | 0.049 | 0.055 |
12 | 69–73 | 300 | 340 | 0.013 | 0.016 | 0.018 | 0.020 | 0.037 | 0.044 | 0.050 | 0.056 |
13 | 74–78 | 300 | 340 | 0.013 | 0.016 | 0.018 | 0.020 | 0.037 | 0.044 | 0.050 | 0.056 |
14 | 79–89 | 482.6 | 346 | 0.008 | 0.010 | 0.011 | 0.013 | 0.037 | 0.043 | 0.049 | 0.055 |
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Neelakandan, D.P.; Alla, D.R.; Huang, J.; O’Malley, R.J. Liquid Core Detection and Strand Condition Monitoring in a Continuous Caster Using Optical Fiber. Sensors 2022, 22, 9816. https://doi.org/10.3390/s22249816
Neelakandan DP, Alla DR, Huang J, O’Malley RJ. Liquid Core Detection and Strand Condition Monitoring in a Continuous Caster Using Optical Fiber. Sensors. 2022; 22(24):9816. https://doi.org/10.3390/s22249816
Chicago/Turabian StyleNeelakandan, Deva Prasaad, Dinesh Reddy Alla, Jie Huang, and Ronald J. O’Malley. 2022. "Liquid Core Detection and Strand Condition Monitoring in a Continuous Caster Using Optical Fiber" Sensors 22, no. 24: 9816. https://doi.org/10.3390/s22249816