Nozzles NEW. for Hydromechanical Descaling

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1 Nozzles NEW for Hydromechanical Descaling SCALE MASTER HP S U P E R I O R

SCALE MASTER HP S U P E R I O R LLechler has the leading experience n

builders globally n of supplying SCALE MASTER nozzles to over 00

than 00 descaling systems n of having been the pioneer in descaling

2 SCALE MASTER HP S U P E R I O R LLechler has the leading experience n of being the leading supplier for descaling nozzles to rolling mill builders globally n of supplying SCALE MASTER nozzles to over 00 rolling mills world wide n of having reengineered and optimized more than 00 descaling systems n of having been the pioneer in descaling in thin slab rolling plants The unique coreless stabilizer eliminates turbulences. Single part stabilizer filter unit completely made from stainless steel reduces pressure losses. Nozzle tip with tungsten carbide insert.

3 R O L L E D S U R FA C E Q U A L I T Y A N D E N E R G Y S AV I N G S n SCALEMASTER HPS is fully compatible with all other SCALEMASTER nozzles (check overall length). No header modifications necessary. n Optimized stabilizer design reduces the spray footprint area (A) resulting in a higher impact. n An increased spray impact can lead to an improvement of the surface quality at no additional energy input. n A nozzle family providing higher impacts allows the use of a smaller nozzle size so that the impact can be maintained at a lower water flow and reduced energy cunsumption. Flow direction Stabilizer CFD turbulence simulation of the SCALEMASTER HPS showing optimal turbulence free inner flow conditions (dark blue area) right to the tip. Impact SCALEMASTER HPS SCALEMASTER HP SCALEMASTER Nozzle Size Impact evolution of Lechler SCALEMASTER descaling nozzles against nozzle sizes. I M P R OV E S U R FA C E Q U A L I T Y Objectives: Clear focus on maximizing the spray impact at given system water pressure and flow. Analyze n Check water pressure at header (Lechler Descaling Pressure Gauge) n Check nozzle types installed n Check nozzle arrangement (spray overlaps, inclination angle etc.) Contact Lechler for bench marking with DESCALE simulation. Change to SCALEMASTER HPS n Maximize Impact n Keep water pressure n Keep nozzle size Additional option n Reduce vertical spray height and increase impact even further Contact Lechler for DESCALE simulation and reengineering of header. S AV E E N E R G Y Objectives: Clear focus on reducing the descaling water flow. Analyze n Check water pressure at header (Lechler Descaling Pressure Gauge) n Check nozzle types installed n Check nozzle arrangement (spray overlaps, inclination angle etc.) Contact Lechler for bench marking with DESCALE simulation. Change to SCALEMASTER HPS n Maintain impact values n Install smaller nozzle size and reduce water flow n Keep nozzle size and reduce water pressure Additional option n Reduce vertical spray height allowing to further reduce the water flow Contact Lechler for DESCALE simulation and reengineering of header. 3

N O ZZ LE DATA When a descaling system is being designed the following nozzle performance parameters must be known: n The water flow rate at a given pressure n The spray width at a given

distribution over the spray foot print area.

heights are being combined, spray foot print thicknesses of only 3 mm become a challenge for the impact measurement facilities.

0 mm diameter provides the resolution required for the design of an optimal nozzle arrangement.

4 N O ZZ LE DATA When a descaling system is being designed the following nozzle performance parameters must be known: n The water flow rate at a given pressure n The spray width at a given vertical spray height (this defines the spray angle) n The spray impact and its distribution across the spray width The impact (also called impact pressure) is the momentum or force distribution over the spray foot print area. Therefore the impact can be defined as I = F/A I = Impact [N/mm ] F = Force [N] A = Area [mm ] When turbulent free descaling nozzles such as the Lechler SCALEMASTER HPS and lower spray heights are being combined, spray foot print thicknesses of only 3 mm become a challenge for the impact measurement facilities. Spray overlaps below 0mm also require a much higher precision of the spray width data. Only the new Lechler 3D impact measurement technology utilizing a sensor with only.0 mm diameter provides the resolution required for the design of an optimal nozzle arrangement. The impact distribution is measured and documented 3dimensionally throughout the entire spray in one sensor scan. The principle of impact measurement A pressure sensor passes through the spray jet at a defined speed and with defined movement. As it does so, the computer records the pulses in the jet and converts them into a threedimensional impact representation (see below). A = Area [mm ] Impact distribution against spray width Spray foot print diagram New impact measurement in operation 3D measurement protocol, impact measurement

O P T I M A L N E W N O Z Z L E A R R A N G E M E N T D E S C A L I N G S Y S T E M O P T I M I Z A T I O N System Study A descaling system study with the Lechler DESCALE software is a systematic and

5 O P T I M A L N E W N O Z Z L E A R R A N G E M E N T D E S C A L I N G S Y S T E M O P T I M I Z A T I O N System Study A descaling system study with the Lechler DESCALE software is a systematic and structured procedure for defining how an existing nozzle and header arrangement performs regarding the surface quality of the rolled product. Since 99 the Lechler DESCALE software has made crucial contributions towards increasing of surface quality and plant efficiency. Example of optimization with Lechler DESCALE software. The new Lechler DESCALE 7.X software The perfect tool to bench mark the performance parameters of the existing situation and to quickly design a new or optimized nozzle arrangement, no matter if billets, blooms, slabs or strips have to be descaled. For the first time and exclusively from Lechler the DESCALE 7.X can generate a nozzle arrangement for round billets and blooms. Lechler Descaling Pressure Gauge for precise pressure data With the new Lechler DESCA LING PRESSURE GAUGE the water pressure can be measured directly at the spray header in front of a descaling nozzle by simply taking one nozzle out and putting the pressure sensor in instead. With the exact value of the water pressure available at the nozzle a much more accurate simulation of the existing situation and the proposed modification can be made with the Lechler DESCALE software. It is also possible to detect potential pressure losses in the pipe work. Precise impact data For the DESCALE 7.X all nozzle types of all SCALEMASTER nozzle families have been impact measured with the new mm diameter sensor technology providing Lechler with the most accurate process data on the market. Lechler descaling pressure gauge Orderingno. 06P.M00

S C A L E M A S T E R H P S U P E R I O R n Improved rolled material surface n Saves on pump energy n Splash water quantity reduced The window design of the new tip in combination with the new

hot strip mills when the vertical spray height is not below 0 mm.

6 S C A L E M A S T E R H P S U P E R I O R n Improved rolled material surface n Saves on pump energy n Splash water quantity reduced The window design of the new tip in combination with the new stabilizer filter unit make the SCALEMASTER HPS a nozzle for every modern hot rolling mill which offers the following benefits: The SCALEMASTER HPS is the ideal nozzle for descaling in conventional hot strip mills when the vertical spray height is not below 0 mm. The proven SCALEMASTER HP tungsten carbide insert geometry combined with the new coreless stabilizer and the optimized filter design form the next step in the evolution of the SCALEMASTER family of descaling nozzles. n Remarkable increase of impact for better descaling n Better product surface quality due to higher impact n Reduction of descaling water flow rate possible n Potential of energy savings due to reduced slab/strip cooling n More durable tip with high mechanical strength due to window design n Interchangeable with all other SCALEMASTER nozzles (check overall length) No. Component Order no. Weight Welding nipple Length: L = 0 mm 069..C kg Material: L = 00 mm C kg AISI 30 L = 73 mm C kg Other length on request. 3 Filter stabilizer unit Material: Stainless steel with filter S = 3 06P.6.Y kg with filter S = 7 06P.6.Y kg 3 Gasket Material: Copper kg Nozzle tip Nut (standard) Material: AISI 30 F.XXX.XX see order table 0.0 kg Hex kg Max. torque 0 Nm S L Max. permissible operating pressure: 0 bar 6

7 N O ZZ LE DATA C O R R E CT N O ZZ LE AR RAN G E M E NT Order No. for nozzle tip Type Series 9 3 Code Spray angle Material code A ø [mm].0.7 p = 00 bar (0 psi) Water flow rate (V. ) p = 00 bar (900 psi) p = 00 bar (00 psi) Flow rate conversion for table.. V = p p. * V ) p =(V. * p [bar] V Ø " BSPP Hex Hex socket Ordering Series + Code + Mat.Code = Order no. example: =.9. A ø = equivalent bore diameter Material code : Stainless steel nozzle tip with tungsten carbide insert Special nut with hexagon socket for very narrow distances between nozzles Order no.: Nozzle spray positions. All nozzle jets turned parallel in one direction.. Nozzle jets, half of them turned outwards in opposite directions. This directs the spray water to both sides (see Fig. ). Nipple installation So that the correct alignment of the nozzle mouthpiece ( offset angle to the header's longitudinal axis see Fig. ) is guaranteed, the welding nipple on the spray header must be positioned so that its flat inner surfaces are parallel to the header's longitudinal axis. This is best achieved with the alignment aid supplied as an accessory (Fig., Order No ). To do this, it is inserted into the flat nipple opening. A rule (or similar) can now be used to easily bring the nipple into the correct parallel position where it can be welded in place. (see Fig. 3) Alignment tip The installation aid (Fig., Order No is also used as a dummy part to shut off nozzle connections or for hydrostatic pressure testing. Fig. : Alignment tip / dummy part Fig. Alignment tips Order no. Order no. Order no (for series ) (for series ) (for series ) Fig. 3: Installation example for welding nipple 7

M i n i S C A L E M A S T E R H P S U P E R I O R n Spray height reduction n Improved rolled material surface quality n Saves on pump energy n Water flow rate reduced n Less cooling of rolled product

rolling mill and which offers the following benefits: The MiniSCALEMASTER HPS is the ideal nozzle for descaling in conventional hot strip mills when the vertical spray height is typically below 0 mm

The proven SCALEMASTER HP tungsten carbide insert geometry combined with the new coreless stabilizer and the optimized filter design form the next step in the evolution of the MiniSCALEMASTER family

8 M i n i S C A L E M A S T E R H P S U P E R I O R n Spray height reduction n Improved rolled material surface quality n Saves on pump energy n Water flow rate reduced n Less cooling of rolled product The window design of the new tip in combination with the new stabilizerfilter unit make the MiniSCALEMASTER HPS an ideal nozzle for every thin slab hot rolling mill, plate mill or any other hot rolling mill and which offers the following benefits: The MiniSCALEMASTER HPS is the ideal nozzle for descaling in conventional hot strip mills when the vertical spray height is typically below 0 mm and where the nozzle pitch requires a smaller size nozzle. The proven SCALEMASTER HP tungsten carbide insert geometry combined with the new coreless stabilizer and the optimized filter design form the next step in the evolution of the MiniSCALEMASTER family of descaling nozzles. n Remarkable increase of impact for better descaling n Better product surface quality due to higher impact n Reduction of descaling water flow rate possible n Potential of energy savings due to reduced slab/strip cooling n More durable tip with high mechanical strength due to window design n Interchangeable with all other SCALEMASTER nozzles (check overall length) No. Component Order no. Weight Welding nipple Length: L = 3 mm C kg Material: L = 39 mm C kg AISI 30 L = 0 mm C kg Other length on request. 3 Filter stabilizer unit Material: Stainless steel with filter S = 3 06P.36.Y kg with filter S = 7 06P.36.Y kg 3 Gasket Material: Copper kg Nozzle tip.xxx.xx see order table 0.0 kg Nut (standard) Material: AISI 30 F Hex kg Max. torque 00 Nm S L Max. permissible operating pressure: 0 bar

9 N O ZZ LE DATA C O R R E CT N O ZZ LE AR RAN G E M E NT Series 9 3 Order no. for nozzle tip Type Code Spray angle Material code A ø [mm].0.7 p = 00 bar (0 psi) Water flow rate (V. ) p = 00 bar (900 psi) p = 00 bar (00 psi) Flow rate conversion for table.. V = p p. * V ) p =(V. * p [bar] V ,0 Ø 3 G3/ 3/" ISO BSPP Hex SW socket (Innen) Ordering Series + Code + Mat.Code = Order No. example: =.9. A ø = equivalent bore diameter Material code : Stainless steel nozzle tip with tungsten carbide insert Special nut with hexagon socket for very narrow distances between nozzles Order no.: Nozzle spray positions. All nozzle jets turned parallel in one direction.. Nozzle jets, half of them turned outwards in opposite directions. This directs the spray water to both sides (see Fig. ). Nipple installation So that the correct alignment of the nozzle mouthpiece ( offset angle to the header's longitudinal axis see Fig. ) is guaranteed, the welding nipple on the spray header must be positioned so that its flat inner surfaces are parallel to the header's longitudinal axis. This is best achieved with the alignment aid supplied as an accessory (Fig., Order No ). To do this, it is inserted into the flat nipple opening. A rule (or similar) can now be used to easily bring the nipple into the correct parallel position where it can be welded in place. (see Fig. 3) Alignment tip The installation aid (Fig., Order No is also used as a dummy part to shut off nozzle connections or for hydrostatic pressure testing. Fig. : Alignment tip / dummy part Fig. Alignment tips Order no. Order no. Order no (for series ) (for series ) (for series ) Fig. 3: Installation example for welding nipple 9

N O ZZ LE AR RAN G E M E NT O N TH E S P RAY H EAD E R The following apply to the arrangement on the spray header: E = C D C = cos γ B β =, 0 or A = Spray length B = Spray width C = Spray width in

10 N O ZZ LE AR RAN G E M E NT O N TH E S P RAY H EAD E R The following apply to the arrangement on the spray header: E = C D C = cos γ B β =, 0 or A = Spray length B = Spray width C = Spray width in rolling direction D = Overlap E = Nozzle distance h = Vertical spray height α = Nozzle spray angle β = Angle of inclination γ = Offset angle of the nozzle against pipe roll axis Spray length (A), Spray width (B, C), Overlap (D), Nozzle distance (E) at vertical spray height (h ), Nozzle spray angle (α) and Angle of inclination (β) Vertical spraying height h [mm] Angle of inclination β = A [mm] B C D E B C D E B C D E B C D E [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] Nozzle spray angle α at p = 0 bar α = α = 6 α = 30 α = ). 3) ).7 3) ) ).3 ) 6.3 3) , ) ) ) Explanation of the table:. Spray widths: These values refer to a spray pressure of p = 0 bar. Allowance is made in the table for the spray convergence. Details of spray widths at other spray pressures are available on request.. Spray angle tolerances: + 3 at α =, 6 and 30, + at α = 0. This means that B + C are minimum values. ) only MiniSCALEMASTER HPS with hexagon socket nut ) only MiniSCALEMASTER HPS 3) only with hexagon socket nut 0

G E N E RAL I N STR U CTI O N D E S CALI N G P R E S S U R E GAU G E Tip extractor The tip extractor (Fig., Order No. 09.009.

The entire nozzle unit can be pulled out when the union nut is unscrewed.

spray header in front of a descaling nozzle by simply taking one nozzle out and putting the pressure sensor instead.

n Simple and userfriendly key operation n sensor inputs, automatic sensor recognition Sensor details n Measuring range: 0 600

bar) n Protection class: IP67 Hand held pressure reading Complete Descaling Pressure Gauge (Ordering No. 06P.M00.

11 G E N E RAL I N STR U CTI O N D E S CALI N G P R E S S U R E GAU G E Tip extractor The tip extractor (Fig., Order No for SCALEMASTER HPS and for MiniSCALEMASTER HPS) is pushed onto the recess on the mouthpiece. The entire nozzle unit can be pulled out when the union nut is unscrewed. Hand held pressure reading With the new Lechler descaling pressure gauge the water pressure can be measured directly at the spray header in front of a descaling nozzle by simply taking one nozzle out and putting the pressure sensor instead. For detailed information please ask for the special product data sheet. n Simple and userfriendly key operation n sensor inputs, automatic sensor recognition Sensor details n Measuring range: bar n Burst pressure:,000 bar n Accuracy of sensor: ± 0. % of full scale (±. bar) n Protection class: IP67 Hand held pressure reading Complete Descaling Pressure Gauge (Ordering No. 06P.M ) Sensor adaptors for (Mini SMHPS) and (SMHPS) nozzle tips included. Fig. : Tip extractor (data sheet on request) Antiseize compound (Ordering No. 9ET ; 0g) The application of the antiseize compound on the thread of the welding nipples is recommended and ensures easy removal of the nut.

12 Questionnaire for Nozzle Arrangement Lechler GmbH Precision Nozzles Nozzle Systems P.O. Box Metzingen / Germany Phone: +9 (0) Fax: +9 (0) info@lechler.de Internet: E E E Company Responsable Address h β α Phone γ Fax Pass line Strip width Questionnaire about existing Descaling Nozzle Arrangement Name Date Department Location of descaling installation: n Behind the furnace n RSB n FSB n Interstand descaling Format Dimensions [mm] Nozzle Data Strip top bottom Slab Number of headers Plate Nozzle type Bloom Horizontal distance (E) mm mm Billet Number of nozzles Rounds Vertical spray height (h ) mm mm Material speed m/s Spray angle (α) Pressure at header bar Offset angle (γ) Available max. l/min Impingement angle (β) water flow l/h Room for sketch: Belgium: Lechler S.A./N.V. Avenue Mercatorlaan, Wavre Phone: (0) 0 Fax: (0) 390 info@lechler.be China: Lechler Intl. Trad. Co. Ltd. Beijing Rm. Landmark Tower No. Dong San Huan Bei Lu Phone: (6) 03796, Fax: (6) 037 info@lechler.com.cn Finland: Lechler Oy Kalliotie 0360 Tuusula Phone: (3) 0760 Fax: (3) 076 info@lechler.fi France: Lechler France, S.A. Bât. CAP B 667, Rue Marceau 93 Montreuil cedex Phone: () 9600 Fax: () 9609 info@lechler.fr Great Britain: Lechler Ltd. Fell Street, Newhall Sheffield, S9 TP Phone: (0) 900 Fax: (0) info@lechler.com India: Lechler (India) Pvt. Ltd. Plot B Main Road Wagle Industrial Estate Thane (W) 0060 Phone: () 063 Fax: () lechler@lechlerindia.com Sweden: Lechler AB Spärrgatan SE63 Karlstad Phone: (6) Fax: (6) info@lechler.se Spain: Lechler S.A. Avda. Pirineos 7 Oficina B7, Edificio Inbisa I 700 San Sebastián de los Reyes, Madrid Phone: (3) Fax: (3) info@lechler.es USA: Lechler Inc. Kautz Road St. Charles, IL. 607 Phone: (630) Fax: (630) info@lechlerusa.com Edition 03/ GB.000 LEC S Subject to technical modifications.

Box 3 3 7 Metzingen / Germany Phone: +9 (0) 7 3 960 Fax: +9 (0) 7 3 96333 EMail: info@lechler.

de JType A coreless stabilizer inside the filter stabilizer unit eliminates pressure losses and turbulences.

L A nozzle insert made of tungsten carbide, newly developed using CFD. The orifice behind is optimally protected. S No.

13 Patented SCALEMASTERHP S U P E R I O R Lechler GmbH Precision Nozzles Nozzle Systems P.O. Box Metzingen / Germany Phone: +9 (0) Fax: +9 (0) info@lechler.de Internet: JType A coreless stabilizer inside the filter stabilizer unit eliminates pressure losses and turbulences. A onepart stabilizerfilter unit made completely of stainless steel and newly developed with CFD. L A nozzle insert made of tungsten carbide, newly developed using CFD. The orifice behind is optimally protected. S No. 3 Type Component p = 00 bar Code Order Weight no. (0 psi) Welding nipple Length: L = 66 mm 06S.J0.C Material: AISI Filter stabilizer unit with filter S Material: F =3 06P. 6.Y with filter S Stainless steel F =7 06P. 6.Y Gasket Material: Copper Material code A ł [mm] 3 Nozzle tip.xxx.xx see order table 0.0 Nut (standard) Material: AISI 3 Hex 06S.J Max. permissible operating pressure: 0 bar (SCALEMASTER HPS ) CFD optimized

Patented SCALEMASTERHP S U P E R I O R Lechler GmbH Precision Nozzles Nozzle Systems P.O. Box 3 3 7 Metzingen / Germany Phone: +9 (0) 7 3 960 Fax: +9 (0) 7 3 96333 EMail: info@lechler.

14 Patented SCALEMASTERHP S U P E R I O R Lechler GmbH Precision Nozzles Nozzle Systems P.O. Box Metzingen / Germany Phone: +9 (0) Fax: +9 (0) info@lechler.de Internet: JType Order No. for nozzle tip Water flow rate (V. ) Series Type Code Spray angle Material code A ø [mm] p = 00 bar (0 psi) p = 00 bar (900 psi) p = 00 bar (00 psi) Series Code A ł [mm] Material code ,3 Water flow rate (V ) p = bar 3..9( psi) Flow rate conversion for table. p. = * V V p p =( ) V.. V * p [bar] Ordering Series + Code + Mat.Code = Order no. example: =.9. A ø = equivalent bore diameter Material code : Stainless steel nozzle tip with tungsten carbide insert Fig. Fig. Order no. 06S.J Alignment tip Order no. Order no. Order no. 06S.J S.J S.J Alignment tip Nipple installation So that the correct alignment of the nozzle mouthpiece ( offset angle to the header's longitudinal axis see Fig., ) is guaranteed, the weld nipple on the spray header must be positioned so that its flat inner surfaces are parallel to the header's longitudinal axis. This is best achieved with the alignment aid supplied as an accessory (Fig., Order No. 06S.J90.0). To do this, it is inserted into the flat nipple opening. A rule (or similar) can now be used to easily bring the nipple into the correct parallel position where it can be welded in place. (see Fig. 3) Alignment tip The installation aid (Fig., Order No. 06S.J90.0) is also used as a dummy part to shut off nozzle connections or in pressure tests performed on the spray pipe. Fig. : Alignment tip / dummy part Fig. 3: Installation expample for weld nipple

OPTIMISATION OF NOZZLE ARRANGEMENTS ON DESCALING HEADERS. Jürgen W. Frick Lechler GmbH D Metzingen / Germany

OPTIMISATION OF NOZZLE ARRANGEMENTS ON DESCALING HEADERS Jürgen W. Frick Lechler GmbH D-72555 Metzingen / Germany E-mail : frju@lechler.de ABSTRACT The demand for improved product quality and increased