NTC Pribor LLC

We offer

• introduction of highly effective monitoring systems for industrial equipment and processes
• integrated approach to improvement of quality; increase of efficiency and durability of industrial equipment
• equipping of processing lines with state-of-the art noncontract monitoring devices for control of geometry, temperatures and levels of working medium
• complete set of services for integration of analytical systems and devices:
  • manufacturing and supply
  • installation
  • setting-up
  • commissioning
  • personnel training
  • technical support 

Our products and services allow to realize following: 

• geometry and temperature monitoring of continuous casting slabs and billets in secondary cooling zone of casters 
• cooling control of slab and billets in casters 
• scanning of internal surface and temperatures of steel ladles and basic oxygen furnaces (BOF-units) 
• level monitoring in cast iron ladles as well as control of free board dimension in steel ladles 
• steel ladle preheating control 
• wear control of crystallizer`s working surface 
• automation of databases
•  integration of our analytical systems in existing automatic process control systems 

Equipment 

• unique pyrometer blocks for temperature measurement of surface of slab and billet (including secondary cooling zone of casters) and temperature control of various linings 
• linear laser scanner for geometry determination of slabs and billets in casters 
• scanning pyrometer for determination of slabs and billets temperature field 
• scanning pyrometer/profile meter for simultaneous scanning of temperature and profile of slabs and billets  
• 3Dscanning laser blocks for monitoring of current profile and wear of hot ladle and BOF linings (synchronous scanning of internal surface and temperature of objects) 
• radar blocks for continuous level measurement of melts and burden 

Equipment can be designed and manufactured on customer demand according to local specific production and service conditions: 

• high temperatures 
• high humidity and smoke level 
• significant vibrations 
• presence of electromagnetic fields 

On customer request equipment can be developed and delivered as a part of measurement complex as well as separately. All introducedequipment can be integrated in existing automatic process control systems.

Software and mathematical models 

Equipment supplied by NTC Pribor LLC is provided with all necessary software. Systems we build in are supported with corresponding mathematical models describing the processes of: 

• slab cooling at slab and billet casters 
• steel ladle preheating at stand 

On customer request various mathematical models describing processes can be developed and supplied both as part of measurement complex as well as separately. All introduced software can be integrated in existing automatic process control systems. 

Monitoring and control systems for continuous casting 

Control of continuous casting process with purpose to increase production efficiency and quality of billets requires on-line receipt of information about technological parameters. NTC Pribor LLC offers both complex and separated variants of systems for control of continuous casting. Besides equipment the system contains mathematical models of billet cooling.

The system controlling dynamic cooling of billet by mean of mathematical model is designated to provide given quality of metal coming out from caster (reduction of such defects as cracks and heterogeneity) at fixed or the highest possible productivity.

The system allows to determine water consumption in crystallizer (in case of necessity) and in the area of secondary cooling zones considering various disturbing effects. Under disturbing effects we mean following: changes of dimensions, temperatures and chemical compositions of metal in tundish, change of casting speed. 

For calculation of cooling regimes and parameters of its management we use model of ingot solidification. This model is based on solution of nonlinear two dimensional equation of heat conductivity with boundary conditions of second and third class. Additionally we use model numerical calculation of stresses and deflection of ingot shell. Model`s adoption is carried out by pyrometer measurement of ingot surface temperature.

Control system can work in following models: 

informative mode when the system receives information from the object: geometrical parameters of slab, casting rate value, temperature and grade of steel in tundish, water consumption in crystallizer and in secondary cooling zones; on the basis of received information the system calculates temperature field and shell thickness of slab along the length of caster

control mode when, unlike the informative mode, the water consumption task is calculated and entered into control system for regulation of slab cooling

Technological capacities

• control of dimensions (cross section profile, width and thickness) of billets as well as deviations value 
• control of surfacetemperature field of billet 
• system operating both in informative and control modes  
• continuous monitoring of metal temperature in tundish 
• wear control of crystallizer`s working surface 
• calculation and visualization of current profile and dimensions of billet both in graphical and tabular forms 
• automatic formation of database 
• integration of system in existing automatic process control systems 

Equipment configuration 

• linear laser scanner for measurement of geometry  
• pyrometric block for noncontract temperature measurement 
• television system for determination of temperature field irregularity 
• industrial computer with LCD screen 
• communication wire channels 

Technical Data 

precision of measurement, dimensions of billet………………………………………….±1,5 mm
precision of measurement, surface temperature of billet………………..………………….±1,5 %
scanning step (resolution)……………………………………………………………………2 mm
scanning angle………………………………………………………………………..…up to ±180
working temperature……………………………………………………………from -30 to +60 °C
communication type………………………………………………………………………..RS-485
operating regime………………………………………………………………………..continuous
protection rate………………………………………………………………………………IP-65 

Control system for monitoring of geometry and surface temperature of slab was tested at JSC `Severstal` at slab caster ¹ 5 in 2004. 

At present time we introduce control system for monitoring of casting temperatures and cross section profile of billet as well as cooling regimes at EAF shop of JSC `Severstal`. 

Level control system 

The key element of level control system is radar range-finder (RRF) designated for continuous noncontact measurement of level in large-size spaces. RRF can be successfully applied for measurement of liquid, dry, hard and mixed materials. 

Technological capacities 

• continuous level measurement 
• synchronous image displaying of current level (in graphical and tabular form) 
• automatic formation of database 
• integration of system in existing automatic process control systems 

Equipment configuration 

• radar range-finder 
• industrial computer with LCD screen 
• communication wire channels 

Technical Data 

precision of level measurement ……..…………………………………………………….±10 mm
working temperature……………………………………………………………from -30 to +45 °C
communication type………………………………………………………………..………RS-485
operating regime……………………………………………………...…………………continuous
protection rate……………………………………………………………………..…………IP-65 

Level control system of cast iron ladle is installed at converter shop of JSC `Severstal`. Pilot testing of cast iron weight control system is performed on measurement of metal level. 

Monitoring of ladle free board size

Size of `free board` (distance between ladle upper section and level of metal) is a substantial factor for processes of secondary treatment. Particularly, actual information about free board allows to manage regimes of steel purging during ladle degassing as well as LF-treatment. 

Technological capacities 

• measurement of free board size in ladles 
• synchronous image displaying of current level (in graphical and tabular form) 
• automatic formation of database 
• integration of system in existing automatic process control systems 

Equipment configuration 

• optical measuring module based on highly sensitive video camera with high resolution
• industrial computer with LCD screen
• communication wire channels 

Technical data 

precision of level measurement…………………………………………………………...± 50 mm
working temperature……………………………………………………………from -30 to +60 °C
operating regime………………………………………………………………………..continuous
protection rate………………………………………………………………………………..IP-65 

Control system for monitoring of ladle free board size is installed at converter shop of JSC `Severstal` (teeming of half-finished product from BOF). 

Lining conditions monitoring system

Monitoring of lining`s conditions of metallurgical units is a substantial factor for evaluation of service life. Actual information about this parameter enables to avoid breakdowns. Therefore, application of such system provides better safety for labor staff and metallurgical units. 

Technological capacities 

• monitoring of current lining conditions and its wear 
• forecast on breakdowns and urgent notification 
• high-speed scanning of local wear 
• automatic formation of database 
• integration of system in existing automatic process control systems 

Equipment configuration 

• 3D laser scanner range-finder 
• multi-axis manipulator for scanner range-finder 
• cooling block for scanning head of range-finder and manipulator 
• sensor for ladle tilting angle 
• industrial computer with LCD screen 
• communication wire channels 

Technical Data 

scanning cycle………………………………………………………………………….5-6 minutes

precision of measurement (complete/local scanning)…..…………………………..±2,5/1,25 mm

scanning speed…………………………………………….…………..to 10000 measurements/sec

scanning resolution (inner profile of lining)………………………………………………..±1 mm

minimum scanning run time…………………………………………………………………15 sec

complete scanning run time……………………………………………….………………..240 sec

distance range to scanned surface…………………………………………………….(0,5-15,0) m

resolution (temperature measurement)…………………………………..…………..up to 1700 °C

temperature of scanned surface………………………………………………………………..1 °C

precision of measurement, temperature……………………………………………………±1,5 %

working temperature………………………………………………………..…from -30 to +60 °C

communication type………………………………………………………………………..special

working regime…………………………………………………………………………..….cyclic

protection rate………………………………………………………………………………..IP-65 

Lining conditions monitoring system can be used for diagnostic of wear and temperature of linings. 

Computer control system for ceramic fibers production

This computer control system is designated for execution of ceramic fibers production. The system provides automatic stabilization of technological parameters and, respectively, guarantees stability of quality. The system outputs information about deviations in process. 

Computer control system is performed as two-level system: lower execution level; upper coordinating and recording level. Control subsystems of lower level provide controlling under separate units and parts, receive commands from upper level and return reports to it.  

Upper level control subsystem provides: 

• manual and automatic regimes of operation of control system 
• operation of controlling desk 
• displaying current situation on controlling desk 
• coordinated controlling upper level subsystems 
• registration of key technological parameters 
• information transmission to head automatic control system 

Technological capacities 

• providing given level of productivity 
• automatic charging of furnace in accordance to melting rate 
• providing given regimes of melting 
• automatic feeding of electrodes to melting zone 
• providing given working regimes for end electrodes 
• control of surface-active materials carrying 
• product thickness detection 
• detection of melting flow diameter 
• detection of melting flow temperature 
• synchronization of furnace support equipment 
• providing manual control 

Equipment configuration 

All elements of system are installed in separate control case containing: 

• industrial controller 
• power supply modules 
• symistor intermittent output modules 
• counting module 
• transistor intermittent output module 
• analog inputs modules 
• intermittent inputs modules 
• sensors of voltage and current on electrodes 

Operator`s control panel is designed on basis of programmable terminal.

Technical Data

complete information updating………………………………………………………………..>= 2 s
power consumption…………………………………………………………………….…>= 770 Wt
number of analog inputs…………………………………………………………………………24
number of intermittent input signals……………………………………………………………..32
number of module counting channels……………………………………………………………..2
number of symistor intermittent output modules……………………………………………...…32
number transistor intermittent output module…………………………………………………….8
weight, kg……………………………………………………………………………...………..150
protective rate…………………………………………………………………………………IP-64 

The system was successfully implemented at JSC `Sukhoy Log` (production of ceramic fibers).