Reference: Technical Assistance

Specialty: Electric and Automation

Subject: MOLD LEVEL CONTROL
Revision: 0 Dec/03 Page: 1 of 29

CONTENTS

1 TECHNICAL DATA.............................................................................................................3
2 DESCRIPTION OF COMPONENTS..................................................................................3
2.1 BRIEF DESCRIPTION....................................................................................................3
2.2 CONTROL SYSTEM.......................................................................................................4
3 OPERATION.......................................................................................................................4
3.1 OPERATION PHILOSOPHY...........................................................................................4
3.2 OPERATOR STATIONS.................................................................................................4
3.2.1 MOLD OPERATOR STATION OS 1.4 (OS1.5)........................................................4
3.2.2 OS 2.1 EMERGENCY OPERATION........................................................................5
3.2.3 LC 141.4 (141.5) TUNDISH STOPPER TUNDISH CAR A......................................5
3.2.4 LC 151.4 (151.5) TUNDISH STOPPER TUNDISH CAR B......................................6
3.3 HUMAN MACHINE INTERFACE....................................................................................8
3.3.1 PROCESS DISPLAYS..............................................................................................8
3.3.2 OPERATION / STATUS WINDOWS........................................................................9
3.3.3 ALARM / EVENT LIST............................................................................................10
3.3.4 TREND....................................................................................................................11
4 CONTROL.........................................................................................................................11
4.1 SAFETY LOGIC.............................................................................................................12
4.1.1 HARDWIRED EMERGENCY CLOSE....................................................................12
4.2 INDICATIONS................................................................................................................12
4.3 LEVEL 2 INTERFACE...................................................................................................13
5 BLOCK DIAGRAMM.........................................................................................................14
6 SKETCH............................................................................................................................16
7 LEVCON MOLD LEVEL CONTROLLER – DETAILED EXPLANATION........................17
7.1 INTRODUCTION...........................................................................................................17
7.2 OBJECTIVE...................................................................................................................17
7.3 SYSTEM DESCRIPTION..............................................................................................18
7.3.1 PROCESS DESCRIPTION OF THE CONTINUOUS CASTER.............................18
7.3.2 PROCESS EQUIPMENT........................................................................................19
7.4 CONVENTIONAL CONTROL........................................................................................20
7.5 THE MODULAR-DESIGN LEVCON MOLD LEVEL CONTROLLER............................21
7.5.1 PID CONTROLLER................................................................................................21
7.5.2 DEVIATION CONTROLLER...................................................................................22
7.5.3 SETPOINT PREPARATION...................................................................................22
7.5.4 MOLD LEVEL PREDICTION..................................................................................24
7.5.5 COMPENSATION OF BACKLASH FOR THE STOPPER ROD............................24

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7.5.6 CLOGGING.............................................................................................................24
7.5.7 EXTREME CLOGGING..........................................................................................25
7.5.8 MOLD LEVEL CORRECTION WHEN EXCESSIVE BULGING OCCURS............26
7.5.9 PILOT CONTROL...................................................................................................26
7.6 PRACTICAL IMPLEMENTATION.................................................................................27
7.6.1 TRAINING...............................................................................................................27
7.6.2 SIMULATION..........................................................................................................27
7.6.3 REMOTE MONITORING AND DIAGNOSIS..........................................................27
8 STEP 7 PROGRAM - COMMENTS..................................................................................28
9 MAINTENANCE PRACTICES AND ADJUSTMENTS - RECOMMENDATIONS..........28
10 ANNEX 1 (STOPPER ROD MECHANISM – CLEARANCE INSPECTION)...................29

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1 TECHNICAL DATA

Mold
Mold length 900 mm
Mold width minimum 760 mm
Mold width maximum 1940 mm
Mold thickness 219,5 / 270,5 mm
Hydraulic cylinder
Cylinder stroke 140 mm
Cylinder speed 100 mm/sec.
Stopper rod
Stopper diameter xxxxx mm
Stopper characteristics 7253 kg/m sec
Mold level control values
Actual mold level top range (100%) 20(*) mm
Actual mold level bottom range (0%) 160(*) mm
Actual mold level – Max Max Alarm 30(*) mm
Actual mold level – Max Alarm 34(*) mm
Actual mold level – Min Alarm 139(*) mm
Actual mold level – Min Min Alarm 146(*) mm
Actual mold level – Strand start signal 118(*) mm
(*) value from TOP of mold copper plate

2 DESCRIPTION OF COMPONENTS

2.1 Brief description

The tundish stopper is used to regulate the steel flow from the tundish to the mold.
The tundish stopper can be operated manually by means of a hand lever or in
automatic closed loop control.
The automatic closed loop control is used to maintain the steel bath level in the
mold at the set point during the casting process.

In automatic mode the actual measured mold level will be used as the actual
value feedback to the closed loop control.

The tundish stopper control for each tundish car consists of a hydraulic actuator
(cylinder) attached to the corresponding stopper mechanism and a corresponding
hydraulic valve block.

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The necessary hydraulic power is supplied from tundish stopper hydraulic power
unit.

One emergency accumulator per tundish stopper will provide hydraulic power for
closing the stopper in case of a failure of the hydraulic power unit.

2.2 Control system

 PLC TUNDISH COMMON
 PLC MOLD LEVEL CONTROL (separate for each strand and each tundish
car)
 Safety logic

3 OPERATION

3.1 Operation Philosophy

Automatic operation initiated from LC 141.4 (LC141.5, LC151.4, LC 151.5)
Manual Local operation in preheat position from LC 141.4 (LC141.5, LC151.4, LC
151.5)
Emergency operation from OS 2.1 or LC 141.4 (LC141.5, LC151.4, LC 151.5)
Status indications on HMI

3.2 Operator Stations

3.2.1 Mold Operator Station OS 1.4 (OS1.5)

Mushroom pushbutton TUNDISH STOPPER: EMERGENCY CLOSE (latching
type)
By actuating of this mushroom pushbutton both tundish stopper and slide plated
SEN changer will be closed.

Eventually selected automatic operation (automatic mold level control) will be

terminated.

Fault indication MOLD LEVEL CONTROL

Flashing light = mold level control summary fault.

Fault indication MOLD LEVEL MEASUREMENT

Flashing light = mold level measurement fault.

Fault indication MOLD LEVEL MAX

Flashing light = mold level is above max limit.

Fault indication MOLD LEVEL MIN

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Flashing light = mold level is below min limit.

LED-INDICATOR MOLD LEVEL ACTUAL

Actual value of mold level measurement.

LED-INDICATOR MOLD LEVEL SETPOINT

Setpoint of mold level.

LED-INDICATOR MOLD LEVEL STOPPER POSITION

Position of the mold level stopper.

Spring return switch MOLD LEVEL SETPOINT: LESS - 0 - MORE

Keep actuated the switch = the mold level setpoint will change in steps of xx
mm/sec

3.2.2 OS 2.1 Emergency operation

Mushroom pushbutton TUNDISH STOPPER: EMERGENCY CLOSE (latching
type)

same as OS 1.4 (OS1.5)

3.2.3 LC 141.4 (141.5) Tundish stopper tundish car A

Pushbutton EMERGENCY CLOSE
By actuating of this pushbutton the tundish stopper of the tundish car A strand 4
will be closed regardless of the position of the tundish car.

Eventually selected automatic operation (automatic mold level control) will be

finished if the tundish car A is in cast range.

Light pushbutton AUTO START / AUTO / OPEN

Depending on the position of the tundish car this button has different meanings:
 Car in cast position:
 If the cast has not started yet (Start of withdrawal drives): START OF MOLD
FILLING
 If the casting is in progress: Select AUTO OPERATION
 Car in preheat position:
 Open the tundish stopper by hydraulic valve control, to check the
functionality before casting.

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3.2.4 LC 151.4 (151.5) Tundish stopper tundish car B

Same as LC141.4 (141.5)

Function AUTO START LC141.4 (LC141.5):

On actuation of the light pushbutton automatic mold filling will be activated and the
withdrawal drives will be switched to AUTO at OS1.

Automatic mold filling will be started with an initial “Start stroke” of the stopper and
consecutive “Open / Close” strokes until the mold level is detected with the mold
level measuring system and automatic mold level control takes over.
The time for “Opening” and “Closing” of the stopper will be calculated depending
on the actual mold section size and an adequate mold filling time.
As soon as a certain steel level is reached in the mold, the withdrawal drives will
be started.

Automatic operation will be finished on actuation of the pushbutton

MANUAL/CLOSE, or if any interlock is active.

Flashing light will indicate that selection of automatic mold filling operation is
possible.
Steady light will indicate that automatic mold filling is active.
Interlocking:
 Emergency close function is active
 Tundish car A is not in cast position
 Operation mode “CAST” is not active
 Casting is in progress (Start of cast event)
 Mold level measuring system is faulty
 Tundish stopper hydraulic is not ready
 Solenoid control voltage fault
 Hydraulic pressure fault

Function AUTO LC141.4 (LC141.5):

On actuation of the light pushbutton automatic mold level control be activated.
The mold level will be regulated according to the preset set point.

Automatic operation will be finished on actuation of the pushbutton

MANUAL/CLOSE, or if any interlock is active.

Flashing light will indicate that selection of automatic operation is possible.

Steady light will indicate that automatic operation is active.
Interlocking:
 Emergency close function is active
 Tundish car A is not in cast position

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 Operation mode “CAST” is not active

 Casting is not in progress (Start of cast event)
 Mold level measuring system is faulty
 Tundish stopper hydraulic is not ready
 Solenoid control voltage fault
 Hydraulic pressure fault

Function OPEN LC141.4 (LC141.5):

As long as the pushbuttons is pressed the tundish stopper will be moved in the
appropriate (open) direction.

Interlocking:
 One of the emergency close / stop pushbuttons is pressed
 Tundish car A is not in preheat position
 Tundish stopper hydraulic is not ready
 Solenoid control voltage fault
 Hydraulic pressure fault

Pushbutton MANUAL / CLOSE LC141.4 (LC141.5):

Depending on the position of the tundish car A this button has different meanings:
 Car in cast position:
 Finish AUTO OPERATION to enable the tundish stopper operation by hand
lever.
 Car in preheat position:
 Close the tundish stopper by hydraulic valve control, to check the
functionality before casting.

Function MANUAL:
On actuation of the pushbutton, automatic operation will be finished and manual
operation will be enabled.
The mold level can be regulated manually by means of a hand lever.

If at begin of a cast the withdrawal drives are switched to AUTO, they will be
started automatically as soon as a certain steel level is reached in the mold,
regardless of the mold level control mode.

Interlocking:
 Emergency close function is active
 Tundish car A is not in cast position

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Function CLOSE:
As long as the pushbuttons is pressed the tundish stopper will be moved in the
appropriate (close) direction.
Interlocking:
 One of the emergency close / stop pushbuttons is pressed
 Tundish car A is not in preheat position
 Tundish stopper hydraulic is not ready
 Solenoid control voltage fault
 Hydraulic pressure fault
3.3 Human Machine Interface
3.3.1 Process displays
Casting Platform Overview 2

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3.3.2 Operation / Status Windows

Pop-Up display mold level control status

Casting Platform Overview 2

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3.3.3 Alarm / Event List

Kind Name
Critical alarm Tundish stopper car A system 1 = FAULT / 0 = OK
pressure fault
Critical alarm Tundish stopper car A control 1 = FAULT / 0 = OK
voltage fault
Critical alarm Tundish stopper car A emergency 1 = ACTIVE / 0 = OK
close
Critical alarm Tundish stopper car B system 1 = FAULT / 0 = OK
pressure fault
Critical alarm Tundish stopper car B control 1 = FAULT / 0 = OK
voltage fault
Critical alarm Tundish stopper car B emergency 1 = ACTIVE / 0 = OK
close
Critical alarm Detector fault 1 = FAULT / 0 = OK
Alarm Mold Level MAX 1 = FAULT / 0 = OK
Alarm Mold Level MIN 1 = FAULT / 0 = OK
Alarm Measuring system fault 1 = FAULT / 0 = OK
Alarm Level sensor cooling fault 1 = FAULT / 0 = OK

Event Tundish stopper car A automatic 1 = EVENT

Event Tundish stopper car A automatic 1 = EVENT
start
Event Tundish stopper car A manual 1 = EVENT
Event Tundish stopper car B automatic 1 = EVENT
Event Tundish stopper car B automatic 1 = EVENT
start
Event Tundish stopper car B manual 1 = EVENT

Critical alarm:
An electrical, equipment or process malfunction, which requires immediate
operator intervention.

Alarm:
An electrical, equipment or process malfunction, which has to be investigated but
does not require immediate operator intervention.

Event:
To track changes in equipment and machine operating conditions, as well as
operator interventions.

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3.3.4 Trend
Indication Description Range
Trend Actual mold level [mm]
Trend Actual mold level set point [mm]
Trend Actual stopper position [mm]
(cast position)
Trend Mold Level control automatic YES = 1 / NO = 0
Trend Mold Level control automatic YES = 1 / NO = 0
start
Trend Mold Level Standard [mm]
deviation

4 CONTROL
The PLC STRAND will perform the interface functions to commonly used operator
stations and to the HMI.

The PLC MOLD LEVEL CONTROL (technological package) will perform the
control functions.
The mold level control package consists of 5 PLC’s.
 PLC TUNDISH CAR COMMON: Handles the data transfer to the PLC
STRAND, to the subordinated PLC’s for TUNDISH CAR A and TUNDISH CAR
B and to the MOLD LEVEL MEASURING instrument.
 PLC MOLD LEVEL CONTROL TUNDISH CAR A/4 : Controls the tundish
stopper of the tundish car A / strand 4
 PLC MOLD LEVEL CONTROL TUNDISH CAR A/5 : Controls the tundish
stopper of the tundish car A / strand 4
 PLC MOLD LEVEL CONTROL TUNDISH CAR B/4: Controls the tundish
stopper of the tundish car B / strand 4
 PLC MOLD LEVEL CONTROL TUNDISH CAR B/5: Controls the tundish
stopper of the tundish car B / strand 5

The SAFETY LOGIC will perform the hardwired emergency close function.
There will be a signal transfer to:
 PLC STRAND for indication purpose
 PLC MOLD LEVEL CONTROL: TUNDISH CAR A and TUNDISH CAR B to
reset the control functions.
General Comment
Actuating the lamp test button on an operator station illuminates all fault
indication, indicator and push button lights on that station.

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Stopper -Y011 -Y101 - -

cylinder -10 –0 V 0- 10V Y012 Y013
Operation b a
CLOSE ☻ x x ☻
OPEN x ☻ x ☻
PRESS LESS x x ☻ ☻
EMERGENCY x x x x
CLOSE

4.1 Safety logic

4.1.1 Hardwired emergency close

This interlocking is carried out by the safety logic (hardwired - relay logic) to close
the tundish stopper in case of a PLC-failure.

Emergency close for tundish stopper and slide plated SEN changer (only for
tundish car which is in cast position ) will be activated (de-energize of all solenoid
valves) if
 one of the emergency close pushbuttons on OS 1.4 (OS1.5), OS 2.1, for the
tundish stopper is actuated
 one of the emergency stop pushbutton for the withdrawal drives is actuated

Emergency close for the tundish stopper of the tundish car A will be activated (de-
energize of all solenoid valves) if
 the emergency close pushbutton on LC 141.4 (LC141.5) is actuated

Emergency close for the tundish stopper of the tundish car B will be activated (de-
energize of all solenoid valves) if
 the emergency close pushbutton on LC 151.4 ( LC 151.5) is actuated

4.2 Indications
HMI indication MOLD LEVEL CONTROL READY (of both tundish cars per
Strand)
 signal from PLC Mold Level Control tundish car A : SYSTEM OK is set
and
 signal from PLC Mold Level Control tundish car B: SYSTEM OK is set
and
 TUNDISH CAR A SOLENOID VALVE SUPPLY is ok
and
 TUNDISH CAR B SOLENOID VALVE SUPPLY is ok

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Fault indication MOLD LEVEL CONTROL

Flashing light =
 signal from PLC Mold Level Control tundish car A : FAILURE - MOLD LEVEL
CONTROL is set
or
 signal from PLC Mold Level Control tundish car B: FAILURE - MOLD LEVEL
CONTROL is set
or
 TUNDISH CAR A SOLENOID VALVE SUPPLY is not ok
or
 TUNDISH CAR B SOLENOID VALVE SUPPLY is not ok

Indication instrument MOLD LEVEL SETPOINT

= Setpoint of mold level.
This value will be stored in the PLC TUNDISCH COMMON, and may be altered
by the spring return switch MOLD LEVEL SETPOINT: LESS - 0 - MORE.
Keep actuated the switch = the mold level setpoint will change in steps of xx
mm/sec.

Indication instrument MOLD LEVEL ACTUAL

= Actual value of mold level measurement.
Will be connected to PLC MOLD LEVEL CONTROL TUNDISH CAR COMMON.

Fault indication MOLD LEVEL MEASUREMENT

Flashing light = signal from PLC Mold Level Control tundish car Common
FAILURE - MOLD LEVEL TRANSMISSION is set.

Fault indication MOLD LEVEL MAX

Flashing light = signal from PLC Mold Level Control tundish car Common
FAILURE - MOLD LEVEL MAX is set.

Fault indication MOLD LEVEL MIN

Flashing light = signal from PLC Mold Level Control tundish car Common
FAILURE - MOLD LEVEL MIN is set.

4.3 Level 2 Interface

See Level 2 documentation:

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5 BLOCK DIAGRAMM

R I/O OS 1.4 (OS1.5)

93.61.11-A100
PLC STRAND

936111-A404

Strand Operator

OS 1.4 (OS1.5)

936161-A001
ALARMS
ALARM Y
EVENT Y

SETPOINT: LESS-0-MORE

Station
SETPOINT INDICATION
EMERGENCY STOP
SAFETY LOGIC /

936193-A001

936161-A002
EMERGENCY CLOSE

Emergency
Operation
OS 2.1
EMERGENCY CLOSE

Tundish Stopper

LC 141.4(141.5)
936162-A141
PROCESS DISPLAY

EMERGENCY CLOSE
PLC TUNDISH COMMON

Car A
- OPERATION
- INDICATION

SIEMENS S7-400

936111-A010

ACTUAL MOLD LEVEL

MEASUREMENT
MOLD LEVEL

2552-A001
N
Y
Y

MPI BUS

VISUALIS. CONTROL SUB- POWER OPERATOR PERIPHERIC DEVICES

LEVEL 1 SYSTEM SYSTEM STATIONS

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PLC MOLD LEVEL CONTROL

SIEMENS S7 - 300

Tundish Stopper

LC 141.4(141.5)
TUNDISH CAR A

936162-A141
936111-A441
AUTO / MANUAL

Car A
OPEN / CLOSE

-F012
STOPPER CAR A / Str.4 FILTER CLOGGED

-F011
STOPPER CAR A / Str.4 PRESSURE OK

P
AMPLIFIER

-B011
CAR A / Str.4 STOPPER POSITION

s
AMPLIFIER
STOPPER CAR A / Str.4 VALVE POSITION

- N101
EMERGENCY STOP

s
SAFETY LOGIC /

936193-A001

-Y011
STOPPER CAR A / Str.4 OPEN / CLOSE
MPI BUS

-Y012
STOPPER CAR A / Str.4 PRESSURE RELEASE

-Y013
STOPPER CAR A / Str.4 OPERATION / E-CLOSE
MEASUREMENT
MOLD LEVEL

2552-A00 1
PLC STRAND

931111-A300

VISUALIS. CONTROL SUB- POWER OPERATOR PERIPHERIC DEVICES

LEVEL 1 SYSTEM SYSTEM STATIONS

ETHERNET SERIAL
FIELDBUS HARD WIRED

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6 SKETCH

Tundish Car A / Str.4

-B011
s
Stopper
Position
lower arm

MOLD Valve block on

tundish car Valve
position

-Y012 -Y013, -Y011

-F012 -F011
Pressure Operation Open/ -N101
Filter. ok Press. ok
release Close

Level

Mold Level
Level PLC PLC PLC PLC
Measurement
Mold Level Control M. L. C. M. L. C. M. L. C.
Str. 4
Car A / Str.4 Car A / Str.5 Car B / Str.4 Car B / Str.5

PLC
Tundish Car
see chapter
COB-CB-2552

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7 LEVCON MOLD LEVEL CONTROLLER – DETAILED EXPLANATION

7.1 Introduction
Achieving higher quality in the continuously cast product while increasing
productivity requires exact control of the process in all possible operational
conditions of the continuous caster. These characteristics, among other things, to
the unsteady conditions encountered during a ladle or tundish exchange, at the
start of casting as well as during casting size changes and variation in casting
speed, etc.
The tundish-mold area is a central issue in improving the casting rate and the
quality of the steel. High standards, which are dependent on the steel grades, are
required in this respect for the stability, accuracy and availability of a constant
mold level.
Classical and conventional mold level controllers typically are not able to
recognize the above mentioned unsteady conditions or malfunctions in the
process and to eliminate them satisfactorily. Therefore, they can easily cause
dangers to the operators and the machines, not to mention the undesirable
inhomogeneity they may cause in the steel microstructure.

7.2 Objective
Accurate regulation of the mold level is the state of the art for stable plant
operation. In addition to the increased quality requirements and higher
productivity, improvements for mold level controllers of newer design can be
achieved by controlling the unsteady conditions mentioned.
In addition to this, the controller must in any case prevent hazardous operational
conditions such as overflow, emptying the mold or breakouts in order to protect
the operators in the casting area and to protect the caster itself. Disturbing
influences such as wear of plant components (i.e. backlash of the stopper rod),
wave movements of the liquid steel in the mold and other disturbances must lie
within the preset tolerances for accuracy.
For easy adaptability, the controller should furthermore supply the best possible
results for other continuous casters with various level measurement systems
(radiometric or inductive) and different servomechanisms (stopper rod or slide
gate).
An obvious requirement is the integration of the mold level controller into a
uniform operator interface with the caster including comprehensive data collection
and recording of the mold level as well as data transfer for maintenance and
evaluation procedures. A further requirement is the simple parameterization and
handling of the controller.
A well-functioning mold level controller of modern design should conform to an
economic and mechatronic way of thinking. The solution for a modern mold level
controller now lies in a software controller of modular design which combines
tested and conventional functionality with new control technology.

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7.3 System DESCRIPTION

7.3.1 Process Description of the Continuous Caster

Figure 1: Basic design of a continuous caster

The liquid steel, defined by analysis and temperature, flows from the ladle into the
tundish with the goal of minimizing non-metallic inclusions for the duration of the
dwell time. The liquid steel flows within an admissible temperature range from the
tundish through the submerged nozzle into the mold. The mold is typically made
of water-cooled copper plates. After the surface solidifies in the mold, the strand
with its still-liquid core is withdrawn across the strand guide. The bath level
(meniscus) in the mold is consistently kept at a preset value by volume regulation
of inflow from the tundish. This process is initiated by means of a dummy bar and
is called the "start of casting.“
In order to prolong the casting operation, either the ladle or the tundish is
changed, and the casting speed is slowed to enable sequence casting.
Furthermore, higher casting sequences can be attained through in-line size
changes.

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7.3.2 Process Equipment

The tundish is equipped with an outlet and a submerged nozzle (see Figure 1 and
Figure 7). A precisely positioned stopper rod is located above the outlet and is
used as an actuating value. The movements of the stopper rod are controlled
through a supporting arm by means of a lifting cylinder (hydraulic or electric). In
emergency situations the stopper rod can be controlled by the operator with a
lever. The position of the stopper rod is detected by a position indicator after
calibration in the preheating station. The measurement of the mold level is
typically radiometric or electromagnetic with respective evaluation and
measurement signal processing.

 Radiometric Measurement System – Used by NISCO

The most widespread measurement system in use today is based on the principle of
radiometry. Either a Co 60 or a Ce 137 source is used as an emitter and a scintillation
counter as a receiver which converts the received radioactive impulses into electrical
ones. The randomly selected time constant , within which the impulses n are counted,
results in a statistical error of the measurement of

I/I statistical error [%]

I 1
  100
I 2  n
 selected time constant [s]
n measured impulse rate

Thus a short time constant leads to better cycle times with less accuracy, and a longer
time constant provides more accurate results. According to experience, the accuracy of
the measurements is enough for the making of high-quality products. The advantages of
this measurement system are its high availability with low investment costs and the large
active measuring range which makes the start of casting easy.

 Inductive Measurement System – Used by COSIPA

Electromagnetic or eddy-current-based systems are gaining importance because of
official regulations imposed on radiometric systems. These are arranged in the mold cover
or suspended above the mold level. More accurate measurements coupled with the
advantage of quicker response times are contrasted against the high costs and limited
lifetime. A further limitation results from the fact that the active measuring range is
dependent on the mechanical design and is typically suitable for an automatic start of
casting only in connection with additional measuring equipment.

7.4 Conventional control

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Classical mold level controllers normally consist of PI or PID controllers. These

controllers produce acceptable results in stable casting operations. However, they
do not produce satisfactory results for a variety of process situations.

100
Mold level, stopper position [%]

90
80
70
Set mold
60
level
50
Actual mold
40 level
30 Set stopper
20 pos.
10
0
00:43,3

01:32,6

01:45,1
00:00,0
00:07,0
00:13,5
00:20,1
00:26,4
00:32,8
00:38,0

00:48,7
00:54,1
01:00,5
01:06,9
01:13,3
01:19,7
01:26,2

01:39,0
Time [s]

Figure 2: Manual start of casting

100
Mold level, stopper position [%]

90
80
Set mold level
70
60
Actual mold
50
level
40
Set stopper
30
pos.
20
10
0
01:32,5
00:00,0
00:06,2
00:12,3
00:18,5
00:24,7
00:30,8
00:37,0
00:43,1
00:49,3
00:55,5
01:01,6
01:07,8
01:14,0
01:20,2
01:26,3

01:38,6
01:45,0

Time [s]

Figure 3: Automated start of casting with the LevCon software controller

Figures 2 and 3 show the comparison between a classical mold level controller
with manual start of casting performed by the operator versus the modern LevCon
software controller, which will be described in the following.

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7.5 The modular-design Levcon mold level controller

In addition to the previously mentioned unsteady conditions, the non-linearity and

the time variance of the controlled system, the classical mold level controller is
characterized by substantial difficulties. Therefore, an improved controller is
necessary for optimum quality and to regulate a variety of process events.
These are the reasons that the LevCon mold level controller was developed. The
LevCon controller has a modular design and represents a pure software solution
on the basis of a PLC. The individual function modules are respectively correlated
to the following most important process-dependent and equipment-dependent
influential factors and are explained in the following.

Figure 4: Structure of the LevCon software controller

Observation: The fuzzy logic quoted above is not used in COSIPA mold level
controller.

7.5.1 PID Controller

The main part of the LevCon controller is a PID controller with a strongly
differential portion. The differentiator has a smoothing effect on the mold level
which leads to optimally maintaining its setpoint value. The LevCon controller
calculates the optimum parameters for the PID module from the surface area of
the mold and from the amplification factor of the stopper rod. The amplification
factor depends on the geometric dimension of the stopper rod and is indicated by
the supplier. The PID controller is optimally determined by this simple
parameterization.
The advantages resulting from this are as follows:

No experts are necessary for the parameterization of the PID controller.

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High flexibility through easy adaptability to other casters.

Even the first cast is successful.

7.5.2 Deviation Controller

The deviation controller monitors the divergence between the setpoint value and
the actual value of the mold level during automated operation. If the differences
are too large, such as during the start of casting, the LevCon controller increases
the setpoint value. This causes an increase in the integral portion of the PID
controller and thus leads to faster rising of the mold level. Setting the new setpoint
value back to the old value in time brings the mold level closer to the old setpoint
value with substantially reduced controller deviation.
The deviation controller can also reduce the setpoint value. This is necessary, for
example, when sediments break off from the stopper rod. In this case, the cross
section of the flow and thus the inflow of steel into the mold are suddenly
increased. This situation is remedied analogously to the method described above,
however with the additional measure of decreasing the setpoint value for a short
time as well.

The following is accomplished by taking this measure:

The mold level is brought to the setpoint value with substantially reduced
overshooting and in a very short time.

A small integral portion is attained in the PID controller.

7.5.3 Setpoint Preparation

The setpoint preparation module constantly monitors the mold level over time. If
the mold level rises too quickly, the automation takes over control of it and brings
it to the setpoint value by means of a PT1 function *). This function is required
predominantly for the start of casting.
A sudden setpoint change in a PI controller is compared with that of a LevCon
controller in Figure 5 and Figure 6.

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100
Mold level, stopper position [%]

90
80
70
Set stopper
60 pos.
50 Actual mold
40 level
Set mold
30
level
20
10
0
00:02,7

00:04,5

00:06,3

00:08,1

00:14,4
00:00,0
00:00,9

00:01,8

00:03,6

00:05,4

00:07,2

00:09,0

00:09,9
00:10,8

00:12,6

00:13,5
00:11,7
Time [s]

Figure 5: Sudden setpoint change in PI controller

*)
PT1 function: The following figure shows the general differential equation and the time
curve for the response of a PT1 term to a unit step.

dx a ( t )
T1  x a ( t)  K p  x e ( t )
dt
xa(t) Kp
Thus follows the standard unit step xe0
response with the initial condition:
x a ( t  0)  0 PT1 Function

 t 


T 
1
0,63*Kp
x a ( t )  x e0  K p  1  e 
 
 

T1 t
T

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EMBED Excel.Chart.5

100
Mold level, stopper position [%]

90
80
70
Set stopper
60 pos.
50 Actual mold
40 level
Set mold
30
level
20
10
0
00:00,0
00:00,9

00:01,8
00:02,7

00:04,5
00:05,4
00:06,3

00:07,2
00:08,1

00:09,9

00:12,6

00:13,5
00:03,6

00:09,0

00:10,8

00:14,4
00:11,7
Time [s]

Figure 6: Sudden setpoint change in LevCon control

7.5.4 Mold Level Prediction

The mold level preview is an observer which calculates the parameters for the
PID controller in advance. The parameters are calculated using the setpoint value
of the mold level, the surface area of the mold and the output signal of the PID
controller. This advance calculation of the setpoint value minimizes the dead time
of the controlled system. Thus the controller can be operated with a higher closed-
loop gain which suppresses the oscillation mode.

7.5.5 Compensation of Backlash for the Stopper Rod

A stopper rod serves as the positioner which is connected to the lifting rod by
means of a supporting arm and is driven by means of a hydraulic cylinder. The
dynamic behavior of the stopper rod is essentially determined by the servo valve
and the hydraulic cylinder. Backlash can occur in this configuration and can
negatively influence the control behavior. In order to minimize this interference,
the setpoint value of the stopper rod is superimposed by a sinusoidal
compensation for backlash of  1 mm at 1 Hz.

7.5.6 Clogging
Depending on the material, slag and other sediments collect on the stopper rod
and the openings of the submerged nozzle during casting (see Figure 7). This
causes changes in the flow of the steel and in the actual amplification factor of the
stopper rod. This results in long-term changes in the stopper-rod characteristic
which further lead to changes in the controlled system.

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Figure 7: Tundish with clogging at the submerged nozzle

The setpoint value of the stopper rod is superimposed by a sinusoidal signal of 
2 mm at 2 Hz in order to prevent or counteract material sediments.
100 826
90
824
80
Stopper position [%]

822

Mold level [mm]

70 Set stopper
60
820
pos.
50 Set mold
40
818 level
30 Actual mold
816
without adding with adding level
20
sinus signal sinus signal
814
10
0 812
20:00,1
20:03,4
20:06,8
20:10,1
20:13,4
20:16,8
20:20,1
20:23,4
20:26,8
20:30,1
20:33,5
20:37,2
20:41,2
20:45,2
20:49,2
20:53,2
20:57,2

Time [s]

Figure 8: Superimposing the setpoint value of the stopper rod with sinusoidal signal at 2 Hz
Figure 8 shows that superimposing the stopper rod with a sinusoidal signal has no
immediate noteworthy effect on the mold level. Experiments have proven,
however, that sediments form less easily in the long term when the stopper rod
oscillates.

7.5.7 Extreme Clogging

If the control characteristics are influenced strongly by sediments, in spite of the
superimposed sinusoidal signal, a short automatic closing of the stopper rod
activated by a fuzzy controller loosens the residues from stopper rod and/or the
submerged nozzle. Slide gates designed as plates in the bottom of the tundish
represent a much smaller problem in this respect. However, slide gates are
expensive to operate and can pose metallurgical disadvantages.

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7.5.8 Mold Level Correction when Excessive Bulging Occurs

The cast product with a still-liquid core is supported by the strand guide rolls in the
secondary solidification zone. Bulging effects occur as a result of periodic
fluctuations in the strand when it is still liquid between the guide rolls and the point
at which these bulges are pressed when passing through a pair of rollers in this
zone. Bulging effects cause oscillations which are carried over to the casting
speed and further on to the mold level. These oscillations may be caused during
the start of casting in the guide system of the dummy bar or during casting
because of roller wear, roll bending and the like.
100 12
Mold level, stopper position [%]

90 10

Bulging Correction [mm]

80
8
70
60 6
Set mold
50 4
level
40 2 Actual mold
30 level
0 Actual
20
stopper pos.
-2
10 Bulging
0 -4 correction
01:49,3
02:02,4
02:15,4
02:28,4
02:41,4
02:54,4
03:07,4
03:20,4
03:33,4
03:46,4

04:12,4
04:26,1
04:40,6
04:53,6
05:06,8
01:23,3
01:36,3

03:59,4

Time [s]

Figure 9: Bulging
The stopper rod is driven with respect to the mold level at a 90° phase shift with
the aid of a fuzzy control module in the LevCon control. Further shifting the phase
of the integral portion by 90° results in a total shift of 180°. This procedure
reduces the mold level fluctuations to approximately 60%.

7.5.9 Pilot Control

A simplified model of a stopper rod is simulated in this module. The model,
however, has a substantially higher amplification factor than the stopper rod itself.
This higher amplification factor delivers a faster command signal than the actual
position control device. This fast command signal is used as a pilot control for the
position of the stopper rod.

7.6 Practical implementation

The mold level controller described above operates at a high success rate in the
thin-slab caster built by VAI at Novahut in the Czech Republic, Voest Alpine in

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Linz and Cosipa. Compared to the previously used classical control, it offers
better constancy of the mold level. In comparison, the LevCon controller has
increased the availability of the plant, the product quality, productivity and the
protection of human life as well as equipment.

7.6.1 Training

The operators and maintenance personnel can be trained without much effort
because of the integrated controlled system simulation in the LevCon controller.
The operators can learn the processes of operation, such as the manual or
automatic start of casting as well as turning on and off the automatic control,
without any risks.

7.6.2 Simulation

The integrated controller simulation allows making changes to control parameters

and sequences. The effects resulting from these changes can be evaluated at any
time during casting intervals.

7.6.3 Remote Monitoring and Diagnosis

The operational condition of the electrical and hydraulic equipment is continually

monitored by the LevCon controller. An essential advantage of this is quick
troubleshooting as a result of the more detailed error information.
The relevant values can be passed on in 200-millisecond cycle to a PC for data
recording of the controlled system by means of an interface. Analyses can be
made on the PC without interfering with the signal transfer of the controlled
system. The LevCon controller can thus be easily updated through evaluation of
the available data.
Furthermore, if requested by the customer, data can be transferred via modem to
VAI in order to trace disturbances in the system online. Measurement data,
parameters and updates can be transferred in this manner as well.

8 STEP 7 PROGRAM - COMMENTS

You can find information about the main parameters quoted above in the step 7
program, data block DB11. This data block is very important if it is necessary to
replace the stopper or carry out some adjustments to tune the controller.

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DATA BLOCK COMMENTS

DB11.DBD182.0 Stopper gain
DB11.DBD350.0 Parameter P (gain)
DB11.DBD444 Level predictor
DBD11.DBD326 Stopper stroke
DB11.DBD290 Stopper gain
DB11.DBD354 Parameter I (gain)
DB11.DBD358 Parameter D (gain)

9 MAINTENANCE PRACTICES AND ADJUSTMENTS - RECOMMENDATIONS

a) The mold operator must keep cleaned the submerged nozzle during the
casting. The nozzle must be exchanged after some hours (in our case, Cosipa
changes the nozzle after 5 hours) before a strong clogging occurs.

b) The responsible personnel that carry out the stopper maintenance must check
the stopper machine clearance and backlash. The clearance must be at
maximum 0,2mm (see annex 1).

c) We must provide support for all pendant panels, mechanical protection

against
heat for all cables, mainly for stopper position transducer.

d) The hydraulic oil must be kept clean (pay attention during the commissioning
– see servo valve manual) . Oil analysis must be carried out at least
once a year.

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10 ANNEX 1 (STOPPER ROD MECHANISM – CLEARANCE INSPECTION)

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