CasTemp®
Continuous temperature measurement
in liquid steel
The CasTemp® system
The CasTemp® system is used to safely, reliably, and
continuously measure the temperature of liquid steel
in the tundish. It has been designed to withstand the
environment within a steel plant and is the global
standard for continuously measuring temperature.
The benefits of CasTemp® are:
improved safety by removing the possibility of the
operator being exposed to liquid steel
continuous temperature readings throughout the
whole casting sequence including preheat
a fast response because the sensor is fully
submerged in liquid steel
improved output by optimizing the speed of casting
reduced temperature-related breakouts and freezeoffs
avoids contact with corrosive slag easy to install
and set up
accurate measurements during ladle changes
ME A S G R A PH
Temperature
CasTemp®
Digitemp
Time
The graph shows the difference between spot measurements and continuous measurements
given by the CasTemp ® sensor.
CasTemp ® measuring graph
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The system
The following shows the essential parts
of the CasTemp® measurement system
1 Well block 3 Mortar
Securely holds the probe in the lining of the tundish Secures the sensor in the block
2 Embedding tool 4 Continuity checker
Correctly lines the well block up in the tundish Verifies that the sensor is working
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FIT A ND FO RGE T
The CasTemp ® system gives an accurate measurement
throughout the casting sequence and is positioned
close to the steel outlet. It is a ‘fit and forget’ system that
does not need any handling.
5 Application system 7 CasTemp® sensor
Locks the tundish equipment in place Continuous immersion temperature sensor for molten metal
6 CasTemp® instrument 8 QUBE CTW
Processes and displays the measurements Battery-powered unit transmits measurement data via
high-integrity connection
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Setup, Operation and Measuring
Preparing the system
The CasTemp sensor is inserted through the sidewall
of the tundish using a system specifically designed
mounting system.
The sensor can be used in all types of
tundish. The CasTemp® system is quick
and easy to install.
Using the CasTemp® Sensor Measuring
The sensor contains a type-B thermocouple housed in CasTemp® continuously measures the casting
a robust refractory sheath, which can withstand thermal temperature throughout a casting sequence enabling
shock and gives a fast temperature response. closed-loop caster control.
Operation of the CasTemp ® sensor The CasTemp ® retaining system
The system is not affected by the level
of liquid steel or slag, or the machine
being used.
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CasTemp®
Wireless instrument
QUBE CTW
The Qube CasTemp Wireless (CTW) is connected to the
The CasTemp® instrument is a robust sensor and transmits measurement data to the CasTemp
instrument that can be placed close Wireless Instrument. QUBE CTW is battery-powered
and is identified with a unique serial number, which
to the measurement point. ensures 1:1 pairing of the CasTemp sensor with the
instrument.
When in search mode, the measurement steps
The large display makes sure that it are typically:
can be read at a distance of up to Connect the QUBE CTW to the CasTemp sensor
Note the unique serial number of the QUBE CTW
30 metres. It sends temperature data Pair the QUBE CTW to the sensor
from the sensor to the control room Pairing is confirmed both by the instrument display
and has a number of communications and the QUBE CTW LED sequence. The measurement
continues automatically. Resetting or disconnecting
options, which are programmable. It the QUBE CTW results in “unpairing”.
eliminates the need for fixed cabling
The following shows a typical display of temperature
and results in improved safety measurement date on the CasTemp Wireless instrument:
and reliability and is designed with
a simple connection protocol to ensure
robust synchronization.
The benefits are:
the CasTemp Wireless system is simple to install,
set up, and operate
it improves safety: no maintenance on cabling
in restricted and dangerous locations
operational and cost benefits:
– Easy operator setup
– No cabling/connectors from the sensor to
instrumentation
– Long-Life battery technology
CasTemp ® Wireless instrument
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CasTemp ® Wireless instrument
Pairing protocol
This has been designed to maximise measurement
integrity in a simple-to-use and reliable way.
There may be several CasTemp Wireless systems in The optimal system uses one CasTemp instrument
operation on a steel plant; and it is vital to direct the system for each tundish car, each monitoring its own
CasTemp sensor information to the correct process QUBE CTW and enabling the measurement of
control system: preheat, casting, and post-cast liquidus temperatures
The simple 1:1 pairing process involves and assures without changing or resetting the QUBE CTW’s.
the operator
Once “paired”, the QUBE CTW cannot be paired Communication
with other CasTemp Wireless instruments: it is a The CasTemp Wireless instrument links to the
unique link plant computer and has a number of programmable
The QUBE CTW remains linked to the CasTemp communication options:
instrument until it is unpaired
Remote Viewer application to view the instrument
screen and download data files over a network
The simple-to-use 1:1 pairing protocol connection
means that it is possible to build Multiple Anybus protocols
an economical system that is easy to
operate and maintain.
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CasTemp®
Superheat
and consistently measured to ensure a viable dynamic
superheat for casting operations, and future enhance-
Dynamic superheat control is ments such as automated speed control. Liquidus is
essential for optimising the continu- measured by the direct reading CasTip liquidus probe.
ous casting process, requiring CasTemp Superheat is a development of the established
CasTemp Wireless system and combines a QUBE CTW
knowledge of the tundish temperature module and QUBE CasTip to deliver the CasTemp and
above liquidus. Good control of CasTip measurements, providing an economical and
reliable dynamic superheat value promising greater
superheat will help ensure high accuracy than existing methods.
quality production and productivity.
The system is wireless and it is designed with a simple
connection protocol to ensure robust synchronization
built on the existing CasTemp Wireless system protocol.
Liquid steel temperature is obtained using the CasTemp A configurable user interface (UI) can be easily adapted
“through the wall” continuous temperature measure- to provide a digital superheat display suitable for
ment, which is optimally sited near the tundish shop floor operation, or graphical trending for use in
outlets. Therefore the liquidus has to be accurately the control room.
CasTip probe
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The benefits are:
dynamic superheat through casting of the ladle
in built trending package
no cabling/connectors from the sensor to
instrumentation
long-life battery technology
advisory knowledge of superheat to the end of the
ladle using forward prediction
existing CasTemp® Wireless users can benefit through
a software upgrade
Potential benefits that can be realized include: Whilst the grade liquidus value is stable, its accuracy
automated casting speed control can be implemented on a given ladle is dependent upon the deviation of
by users the casting analysis from the grade chemistry used in
improved consistency of operator decisions offered the calculation.
through use of the trending and prediction package
faster casting Liquidus obtained from sample analysis is dynamic and
increased productivity relevant to the ladle in question, but is subject to
improved steel product quality uncertainties caused by analytical technique, delay,
lower superheat in the ladle sample quality and, indeed, sample identity. The
reduction in input energy costs accuracy of the liquidus is mainly determined by the
selection of the equation, and its precision mainly
Liquidus Determination by the variation of the alloy content values used in the
A number of liquidus equations are in regular use and calculation from the actual chemistry in the tundish.
calculate the liquidus from the steel chemistry. As all
equations start at the nominal melting point of pure iron,
then error in liquidus temperature is magnified by
incorrect coefficients as alloy content increases, in CasTip is a direct reading liquidus probe
particular carbon.
which records the liquidus arrest plateau
Equations also differ in the constant chosen to represent during solidification of a captured
the melting point of iron, so there can be inconsistency
in prediction even at lower carbon contents. Many plants
sample. It is optimized for use
choose to define a single value for liquidus for a casting in the tundish, and will deliver a stable
sequence, based upon grade chemistry, whilst others use
sample analysis.
plateau using thermocouple technology
for interpretation by the CasTemp
Wireless measurement instrument.
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CasTemp® Superheat
System Components
1 CasTemp Wireless instrument 3 CasTemp “through the wall” continuous measurement sensor
2 QUBE CTW 4 CasTip probe & holder
battery-powered unit transmits CasTemp continuous immersion probe for liquidus determination attached
temperature measurement data to the CasTemp to a standard pole and connected to the QUBE CasTip
Wireless instrument by an internal signal cable
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Continuous Temperature Measurement
Obtaining an accurate liquid steel temperature trend
is fundamental to the CasTemp Superheat system.
This measured by CasTemp via the QUBE CTW module.
Liquidus Measurement
CasTip is a direct reading liquidus probe which
records the liquidus arrest plateau during solidification
of a captured sample.
It is optimized for use in the tundish and
will deliver a stable plateau using
thermocouple technology for interpreta-
tion by the CasTemp Wireless measure-
ment instrument.
Measurement of liquidus by CasTip uses manual
measurement techniques familiar to virtually all caster
operations:
Connect the CasTip Liquidus sensor to the pole and
obtain green light on the QUBE CasTip
Immerse the probe quickly through the slag layer and
into the melt for approximately 4–6 seconds to
capture the sample
Remove the probe from the melt and allow up to
20 seconds for the liquidus arrest to complete
Once completed it will show on the CasTemp Wireless
screen
All measurement operations are indicated by the
signalization LED on the QUBE CasTip, and will be
displayed on the CasTemp Wireless screen or Remote
Viewer facility
5 CasTip Wireless Instrument
6 QUBE CasTip
battery-powered unit transmits CasTip liquidus
measurement data to the CasTemp wireless instrument
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CasTemp® Superheat
System Components
User Interface and trending advisory time when the critical limit will be reached if
In CasTemp Superheat mode, the CasTemp Wireless within the expected casting time.
instrument indicates the status of the respective QUBE
measurement modules and their latest recorded
temperature values. The screen can be configured to This provides operators with an early
display either digital values, for easy reference on the
caster floor, or a graphical interface.
warning of potential problems, and can
be used to encourage consistency of
Both displays can be duplicated on a PC based Remote
Viewer facility located in the control room. The graphical
decision making. The advisory forward
interface displays the movement of the CasTemp prediction is automatically enabled on
tundish temperature over time and displays the liquidus
recorded by CasTip.
taking a CasTip liquidus measurement.
A critical superheat limit can be user defined, and the System Requirements
system will monitor the progress of the trend towards CasTemp Superheat requires connection to level 1 or
this limit and on to end of cast, offering both an advisory level 2 systems for optimal operation, though its
prediction of superheat at end of cast and also an benefits can be demonstrated without such connection.
SUPERHE AT USER INTERFACE
CasTemp Trend
Critical Superheat
CasTip Liquidus
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Centrum Zuid 1105
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