Slab Quality Evaluation System - TSL QE

Enhance Slab Productivity and Accelerate Quality Decision

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A constraint in the slab casting process is the delayed quality assessment of the slabs due to conventional off line slab grading processes. This not only delays the downstream processing and increases the chances of human error, but also results in a huge amount of energy loss

 

Reducing Decision Time in a Slab Casting Process

The need of the hour for all manufacturing units is to maximize yield with minimum costs, resources and energy. Therefore, in any manufacturing process, it is crucial to detect defects as early as possible in the process. Knowing about the problems early and accurately will allow immediate response to it and therefore will prevent the defective material to be passed on to the value added processes , reduce scrap & rejections and consequently increase yield.

 

A constraint in the slab casting process is the delayed quality assessment of slabs due to conventional off line slab grading processes. This not only delays the downstream processing and increases the chances of human error, but also results in a huge amount of energy loss.

 

Tata Steel offers you a reliable and affordable automation system for faster online quality evaluation of slabs during the entire process route to cut down on the decision time and human errors.

 

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Principle of Operation of Slab Quality Evaluation System- TSL QE

  • Interfacing with other systems in the shop such  as  Caster Level-1,  Steelmaking  Level-II, Lab. Management  and level III  systems  for acquisition of steel making & casting process data, steel chemistry data, online casting parameters data and reference parameters
  • Online quality assurance functions comprising process data tracking, detection of production deviations and inspection advice

 

Online Slab Quality Abnormality Tracking Module

The TSLQE will track the various casting process parameters and associate it with the corresponding strand portion being cast at that moment. It will receive the required parameters at a fixed frequency (1/5/10 sec) and consolidate them for every 0.5 m of length that has been cast. Hence, all the abnormalities will be associated with that half meter of length cast. Further, the tracker also generates a unique Slab ID for each slab to ensure proper traceability and storage in the slab yard.

 

Online Slab Quality Evaluation Module

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The TSLQE will do online grading of the slabs according to your business rules based on the processing route, online chemistry from each processing station, casting acceptance norms based on casting parameters. Based on the grading by TSL QE, some slabs are sent directly for rolling whereas the others are marked by TSLQE for rework like crop cutting, sub-surface inspection, removal of sub-surface defects etc, before being sent for rolling.

 

 

 

 

 

Features

  • The TSL QE  will calculate the frequency of the point defects like strand stoppages, stickers, speed fluctuations, flushing etc. occurring  during casting up to the slab level.
  • The TSL QE  will show the length of the slab affected due to abnormalities like un-shrouded cast, low tundish weight, low casting speed, mould level control, transition slab up to the slab level.
  • The TSL QE  will also map online  the customer requirements while evaluating the quality of the slab.
  • User friendly screens show details of slab level abnormalities & slab details
  • Visualization of strand

 

Benefits

  • Quick assessment of slabs –  over 95 %  of slabs  graded on time
  • Improve direct hot charging of slabs
  • Helps in faster and accurate slab disposition
  • Reduces inspection load
  • Reduces human error