Kina25317enn 002 PDF

Improvement of productivity on
hot dip galvanising line

by decreasing strip vibrations
in gas jets cooling systems
(Stripvibrations reduction)
Research and
Innovation
EUR 25317 EN
EUROPEAN COMMISSION
Directorate-General for Research and Innovation
Directorate G Industrial Technologies
Unit G.5 Research Fund for Coal and Steel
E-mail: rtd-steel-coal@ec.europa.eu
RTD-PUBLICATIONS@ec.europa.eu
Contact: RFCS Publications
European Commission
B-1049 Brussels
European Commission
Research Fund for Coal and Steel

Improvement of productivity
on hot dip galvanising line
by decreasing strip vibrations
in gas jets cooling systems
(Stripvibrations reduction)
K. Beaujard
ArcelorMittal Global Research and Development
Voie Romaine, 57283 Maizires-les-Metz, FRANCE
M. Renard
Drever International
LigeScience Park, alle des Noisetiers 15, 4031 Lige-Angleur, BELGIUM
K. Willems
ArcelorMittal Gent
John Kennedylaan 51, 9042 Gent, BELGIUM
A. Cano
ArcelorMittal Sagunto
Carretera de Acceso IV Planta, KM 3,9, 46520 Sagunto, SPAIN
Grant Agreement RFSP-CT-2007-00017

1 July 2007 to 30 June 2010
Final report
Directorate-General for Research and Innovation
2013
EUR 25317 EN
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Cataloguing data can be found at the end of this publication.
Luxembourg: Publications Office of the European Union, 2013
ISBN 978-92-79-24828-3
doi:10.2777/92028
European Union, 2013
Reproduction is authorised provided the source is acknowledged.
Printed in Luxembourg
Printed on white chlorine-free paper
Table of contents
FINAL SUMMARY .................................................................................................................................................5
BACKGROUND .......................................................................................................................................................5
STAKES ..................................................................................................................................................................5
INITIAL OBJECTIVES .............................................................................................................................................5
CONCLUSION ..................................................................................................................................................11
Scientific and technical approach..................................................................................................................11
Innovative content ..........................................................................................................................................12
Industrial interest and scientific / technical prospects ..................................................................................14
Consistency of resources and quality of partnership.....................................................................................14
Community added value and contribution to EU policies.............................................................................14
Exploitation and impact of the research results ............................................................................................15
1.
PROJECT TIME SCHEDULE ....................................................................................................................17
2.
SCIENTIFIC AND TECHNICAL DESCRIPTION OF THE RESULTS................................................19

2.1.
OBJECTIVES OF THE PROJECT ....................................................................................................19
Introduction ....................................................................................................................................................19
Stakes ..............................................................................................................................................................19
Program ..........................................................................................................................................................19
2.2.
COMPARISON OF INITIALLY PLANNED ACTIVITIES AND WORK ACCOMPLISHED ...22
2.3.
DESCRIPTION OF ACTIVITIES AND DISCUSSION....................................................................23
2.3.1.
WP 1 Analysis of Strip vibrations on ArcelorMittal Ghent industrial line 3 ...........................23
2.3.1.1.
Task 1.1 Installation of measuring system.............................................................................................23
o
Strip vibrations measurement system in the cooling tower:............................................................................23
o
Representativeness of the trials run: ...............................................................................................................24
o
Presentation of results:....................................................................................................................................25
2.3.1.2.
Task 1.3 Characterization of line process parameters ...............................................................................25
Effect of the line speed ...........................................................................................................................................25
Effect of the strip traction: analysis of the campaign database .........................................................................26
Effect of strip traction at given line speed and strip formats: ............................................................................28
2.3.1.3.
Task 1.2 Characterization of blowing parameters ................................................................................29
2.3.1.4.
Task 1.4 Synthesis....................................................................................................................................31
2.3.2.
WP 2 Optimisation of the influent parameters on the experimental cooling device at
ArcelorMittal Research site............................................................................................................................32
2.3.2.1.
Task 2.1 Design and manufacturing.......................................................................................................32
2.3.2.1.1. Representativeness of the pilot line...................................................................................................32
2.3.2.1.2. General technical characteristics of pilot line ..................................................................................35
2.3.2.1.3. Plenums front side design of pilot line .................................................................................................35
2.3.2.1.4. Geometrical characteristics ...............................................................................................................36
2.3.2.1.5. Measurement systems of pilot line ....................................................................................................36
2.3.2.1.6. Strip positioning measurement system .............................................................................................37
2.3.2.1.7. Product................................................................................................................................................38
2.3.2.1.8. Influent parameters detected on industrial line...............................................................................38
2.3.2.2.
Task 2.2 Reproduction of vibrations phenomena on the experimental 2/3 scaled cooling device .............38
2.3.2.2.1. Initial tested configuration ................................................................................................................39
2.3.2.2.2. Reproducibility of industrial strip behaviour........................................................................................39
2.3.2.2.3. Reproducibility of vibrations phenomena observed at ArcelorMittal Ghent line .................................41
2.3.2.2.4. Reproducibility of the trials campaign .................................................................................................41
2.3.2.3.
Task 2.3 Modification of the cooling design in accordance with the vibratory mechanism theoretical
model
42
2.3.2.4.
Construction and improvement of vibrations theoretical model ....................................................43
2.3.2.4.1. Observation: 3 major strip behaviours .................................................................................................43
2.3.2.4.2. Collaboration ArcelorMittal - LadHyX Laboratory .......................................................................46
2.3.2.4.3. Experimental validation of theoretical model..................................................................................47
2.3.2.5.
Task 2.4 Test and optimisation of the improved cooling device ......................................................47
2.3.2.5.1. Influence of line velocity ....................................................................................................................47
2.3.2.5.2. Influence of strip tension......................................................................................................................48
2.3.2.5.3. Influence of blowing boxes pressure equilibrium ................................................................................51
2.3.2.5.4. Influence of blowing width ................................................................................................................52
2.3.2.5.5. Influence of a pressure difference between the 2 plenums..............................................................52
2.3.2.5.6. Influence of nozzles length ..................................................................................................................53
2.3.2.5.7. Influence of staggered arrangement .................................................................................................54
2.3.2.5.8. Influence of PAD ................................................................................................................................55
2.3.2.5.9. Task 2.5 Synthesis ..............................................................................................................................62
2.3.3.
WP3 - Installation and optimization of the improved proposed solution in industrial conditions
on Sagunto line...............................................................................................................................................64
2.3.3.1.
Contractor change due to economical crisis (2009)...............................................................................64
2.3.3.2.
Task 3.1 bis: Trials campaign at Sagunto to characterize the initial state before implementing the
innovative technology .................................................................................................................................................64
2.3.3.2.1. Measurement system and Cooling tower configuration..................................................................64
2.3.3.2.2. Effect of blowing pressure of blowing box 1 ....................................................................................66
2.3.3.2.3. Effect of blowing pressure of blowing box 2 ....................................................................................68
2.3.3.2.4. Effect of line speed .............................................................................................................................69
2.3.3.2.5. Synthesis..............................................................................................................................................70
2.3.3.3.
Task 3.1 design & manufacturing of the innovative technology implementation at ArcelorMittal
Sagunto line .................................................................................................................................................................71
2.3.3.4.
Task 3.2 - Assembly and adjustment of the improved cooling device in the industrial line ..............72
2.3.3.5.
Task 3.3 - Preparation of industrial tests....................................................................................................75
2.3.3.6.
Task 3.4 - Installation of vibrations online measuring systems .................................................................77
2.3.3.7.
Task 3.5 - Tests on industrial lines ............................................................................................................77
2.3.3.8.
Task 3.6: Optimisation of the industrial cooling device ............................................................................82
2.3.3.9.
Task 3.7: Synthesis...................................................................................................................................91
2.3.3.10. Global synthesis: Transferability to others concerned lines.................................................................92
2.3.3.10.1. Transfer to cooling tower of other galvanizing lines .....................................................................92
2.3.3.10.2. Transfer to rapid cooling sections of other galvanizing lines and continuous annealing lines...94
3.
CONCLUSION ..............................................................................................................................................97
3.1.
SCIENTIFIC AND TECHNICAL APPROACH ...............................................................................97
3.1.1.
INDUSTRIAL APPROACH .....................................................................................................................97
3.1.2.
Experimental approach.................................................................................................................97
3.1.3.
Scientific and theoretical approach..............................................................................................98
3.1.4.
Innovative content.........................................................................................................................99
3.1.5.
Industrial interest and scientific / technical prospects...............................................................100
3.1.6.
Consistency of resources and quality of partnership .................................................................100
3.1.7.
Community added value and contribution to EU policies .........................................................101
3.1.8.
Exploitation and impact of the research results.........................................................................101
4.
LIST OF FIGURES.....................................................................................................................................103
5.
LIST OF REFERENCES............................................................................................................................107
6.
LIST OF ACRONYMS AND ABBREVIATIONS ...................................................................................109
FINAL SUMMARY
Background
The high standard of hot dip galvanized coating quality for the automotive and industry markets and the
needs for high productivity require a good stability (low vibration level) of the strip on galvanizing lines
(scratch and strip breaking risk, production of low coating weights). This is particularly true in the
cooling zone after the zinc bath and in the tower because, in these zones, the strip is excited by gas
jets cooling equipments using a high blowing speed. Online observations show clearly that the more the
productivity increases, the higher is the gas flow rate and the more the vibratory amplitudes increase.
Today, the only industrial solution is to limit, in critical situations, the cooling capacities and
consequently the line speed (with loss of productivity). Taking into account the needs for productivity
and quality increases, strip vibrations problems can impact in the future all industrial lines because the
cooling systems will be used to the maximum of their capacities or will even have to be boosted.
There is rare information and studies on the vibratory behaviour of a strip in gas jets cooling
equipments. The fluid-structure interactions, at the origin of the vibration problems, and the links
between the design of the cooling equipments, the process parameters and the vibrations are very badly
known. Studies conducted in 2003 by ArcelorMittal Research and Drever, the supplier of the cooling
equipments of many galvanizing lines in Europe, revealed that the more the productivity increases, the
more the capacities of the cooling devices are solicited and the more the vibratory amplitudes of the
strip increase. The industrial consequences are the followings ones:
- Defects of the surface quality like scratches
- Production breaks due to strip breaking
- Bad homogeneity of the zinc thickness (wiping zone)
- Increase of the production costs due to the increase of the zinc coating weight.
Stakes
In the next years all the industrial lines will use the maximum of their capacities and the maximal
capacities of the cooling systems too. The stakes of the strip vibrations reduction are consequently
important and in progress:
Stakes in terms of productivity: Considering the increase of the line speed, the expected
gains are evaluated at 1 to 2 M per line per year. That represents a gain of 50 M per year
considering that 25 galvanizing lines are concerned by the problem of strip vibrations in the
cooling zone.
Stakes in terms of quality: Considering the control of the zinc weight and the current
price of zinc, the expected gains are evaluated at about 0.5 M per line per year. That represents
a gain of about 12.5 M per year for the 25 galvani zing lines which are potentially interested
(2006).
Initial objectives
The objective is not to work on external stabilizing actuators like the application of magnets or
inductive actuators but to work directly on the design of the cooling equipment which is the exciting
source of vibrations.
The present project will lead to an innovative industrial cooling device minimizing the strip vibrations
in the cooling zone. The new solution will enhance the line productivity and increase the coating quality
of the strip. The transferability of the technological solution to other typical cooling devices will be
supported by recommendations reported at the end of the project.
Comparison between initial work program and performed work
ArcelorMittal Research (as coordinator), Drever (as contractor), ArcelorMittal Ghent (as contractor
until end 2008), ArcelorMittal Sagunto (as contractor since beginning 2009) and the LadHyX
laboratory (as sub-contractor) took part to the project with complementary roles. The working program
can be divided into three steps:
WP 1) Analysis of strip vibrations on ArcelorMittal Ghent #3 industrial line equipped

with an experimental measures system of the strip-nozzles distance in the wiping zone
The distance between the strip and the blowing nozzles has been measured on many points across the
strip width and on many positions along the strip length (at the wiping section and between the cooling
boxes on the top of the tower). Those measurements represent the strip vibrations amplitudes. The trials
campaigns allowed characterizing precisely the strip behaviour under various process conditions:
o
a detailed parametric study and a statistical analysis of the strip-nozzles distance have
been carried out with standard production parameters to characterize the vibrations
phenomena at the starting point.
We identified and characterized the major influent line and blowing parameters on the
strip vibrations in the gas jets cooling equipment of the industrial ArcelorMittal Ghent
line N3:
- process parameters like the blowing power, the strip traction or the line speed effect:
o
the standard deviation increases with blowing power and decreases with strip
traction.
The line speed effect did not clearly appear because it is combined with others
process parameters like the strip tension:
- Product parameters like the strip format:

o
the more the strip is large, the more standard deviation is high
We collected the input data required to reproduce the observed vibrations phenomena on the
experimental 2/3 scale cooling device located at ArcelorMittal Maizires.
WP 2)
Optimization of the influent parameters on the experimental cooling device
The observed and characterized vibration phenomena specific for the ArcelorMittal Ghent HDG line
have been reproduced on the semi industrial pilot line (experimental 2/3 scale cooling device). This
experimental device has been designed and developed in collaboration with Drever. The
representativeness of the trials carried out on pilot line to industrial conditions has been validated
(vibrations frequencies reproduced).
Mechanisms of strip instability, major influent process parameters (blowing pressure, impinging surface
depending on the nozzles arrangement, strip-nozzles distance) and geometrical parameters (nozzles
orientation) have been identified and characterized.
Regarding the complete trial plan carried out, the major results are:
o
Influence of process parameters:

o
Blowing pressure: major influent parameter, as well as the velocity homogeneity

across the strip width
Line velocity: no influence
Heterogeneous strip tension: major influence on vibrations mode, especially twist

positioning, but difficult to manage in industrial conditions
Influence of geometrical parameters:

o
Pressure balancing between blowing boxes: no influence
Pressure balancing nozzle width-wise: influent
Strip-Nozzles distance: influent
Nozzle length: major influent parameter: a minimal nozzle length is required.
Blowing width: this can be an influent parameter in the case of low strip width
(when 2 opposite air jets meet on the strip edges).
Staggered nozzles: major influent parameter, easy to implement in industrial

conditions, very good benefits
PAD sheet: major influent parameter. More especially a maximal PAD-Strip

distance is required, and this is easy to implement in industrial conditions
Exhaustive trials tests have been carried out to determine the optimized cooling design and lead to
improved design: staggered nozzles; close to strip PAD sheet.
Regarding the previous results obtained on semi-industrial configuration and taking into account the
transposability of obtained results to industrial lines, the ideal technical solution could be:
o
To stagger the blowing boxes with a step
To put closer to the strip the PAD sheet (~40 mm for industrial line)
An important additional result consists on the identification of the main strip instability mechanism
under air jets. It is a dynamical instability due to aeraulic forces and pressure fluctuations on strip
surface.
We succeed in building a theoretical model of instable and stable domains, based on non-dimensional
parameters and in collaboration with the LadHyX laboratory. This is an innovation by itself. The model
is based on a physical approach and has been validated at laboratory scale pilot facility. Then it has
been extended to the 2/3 scale experimental pilot of Maizires.
The first recommendations have been done for an industrial application at the ArcelorMittal Ghent #3
line. The innovative technical solution selected for the industrial line consists in the following
modifications, with respect to the present situation:
o
Upward displacement of the right-side plenum by 200 mm, corresponding to a half nozzle
pitch;
Upward displacement by 200 mm of the duct connecting the plenum and the fan.
Consequence of 2009 economic crisis: change of contractor

However, one of the project contractors should have to withdraw because of the 2009 economic crisis.
The current financial crisis has affected the load of the galvanizing lines of ArcelorMittal to an
unprecedented extend, and forced the company to take measures to reduce drastically production costs
and working capital. The cost reduction includes total idling of a number of galvanizing lines in order to
maintain the load of the running lines at an acceptable level. In this context, the site of ArcelorMittal
Ghent wished to withdraw from the project and stopped to implement the new cooler design on its
galvanizing line N3. The demand for galvanized automotive steel sheet was expected to restart and
exceed capacity first in South Europe. In this region, the galvanizing line of Sagunto has beneficiated in
the past years of investments that have made the vibrations from the tower cooling emerge as the next
bottleneck. The value of Sagunto as a pilot line is equal to #3 Ghent; both are among the best and
highest capacity European galvanizing lines for exposed automotive steel sheet.
So, because of potential technical benefits of the project and the potential quality and productivity gains
of industrial implementation of the new cooling system developed into the current RFCS project, in
agreement with all the RFCS contractors, the coordinator proposed to conduct the industrial
implementation at ArcelorMittal Sagunto and not at ArcelorMittal Ghent.
The proposal has been presented at the TGS 5 meeting on May 2009 and accepted.
The project was rescheduled has to consider the industrial line changes. An additional task has been
integrated into the planning without extra costs: task 3.1 bis exhaustive industrial campaign at
ArcelorMittal Sagunto line to characterize the initial strip vibrations state before implementing the
designed solution.
WP 3) Installation and optimization of the improved proposed solution in industrial

conditions
The last step is to transfer the new cooling technology to standard industrial conditions and ensure the
good functioning. It requires:
o
To adapt the design, to manufacture and to install the industrial innovative cooling device,
based on the design of the 2/3 scale pilot.
To test and to optimize the new cooling device in industrial standard conditions and to evaluate
the benefits by comparison between the performances of the improved industrial cooling device
and the initial performances described in the status report made at the end of the first step
(WP1).
As the tasks of WP1, especially the characterization of the strip vibrations initial state have been done
on the ArcelorMittal #3 Ghent line, we add to reiterate those complete trials at the ArcelorMittal
Sagunto Galvanizing line.
The trial run campaign has been carried out in standard production conditions and is representative of
current production of the CGL line of ArcelorMittal Sagunto.
The campaign gives the real state of the art of strip vibrations in the cooling tower:
- Standard deviation at the wiping zone: ~ 2 mm
- Standard deviation in the cooling boxes: ~ 4.5 mm
For maximal cooling capacities (40 mbar / 100% for each cooling box) = worth case:
- Peak-to-peak amplitudes in the wiping zone: max. 17 mm + a kind of twist / crossbow strip
positioning
- Peak-to-peak amplitudes in blowing boxes: max. 37 mm + a kind of twist strip positioning +
strip displacement on one plenum side
Process parameters can influence the vibration amplitudes:

- Standard deviation increase with blowing power of both boxes 1 and 2
- To avoid strip displacement on one preferential plenum side, it is important to balance as
much as possible the pressures between the 2 plenums of one blowing box, whatever the
blowing is.
- The line speed effect did not clearly appear because it is combined with others process
parameters like strip traction or immerged rolls settings.
In conclusion, those analysis show high potential to decrease strip vibrations at the wiping zone as well
as in the cooling boxes by optimizing the design of the current cooling system.
The expected gains for Sagunto are:
- Reduction of strip vibrations amplitudes in the blowing boxes: factor 4
- Reduction of strip vibrations amplitudes at the wiping zone
- Line speed enhancement
- Zinc savings thanks better control of transversal and longitudinal coating homogeneity due to
the strip stabilization
The transferability of the new technological solution is ensured by a report of recommendations for
transferability to others industrial lines and through the writing of industrial procedures.
Implementation of the innovative cooling technology
The new cooling technology has been especially designed for the cooling tower configuration of
Sagunto line. Manufacturing and assembly have been done on due time. The implementation has been
also conducted on due time. Optimisation tests occurred and a specific trials campaign has been
conducted to measure the benefits in terms of strip stabilization at the wiping section and at the top of
the cooling tower.
The new cooling technology consists in staggering the blowing nozzles with a half pitch in order to
homogenize the impingement surface on the strip (stabilization factor). The PAD sheets have been
removed. Pressure regulation has been modified to maintain a good pressure balance between two
opposite plenums. All those actions results from the experimental trials conducted on the semiindustrial pilot facility (WP2).
The measurement campaign carried out after the implementation and for standard production conditions
shows only a slight improvement of the strip stabilization. This is in discrepancy with the expected
results. Fifteen hypotheses have been verified to explain the difference between experimental and
industrial approaches. Only one hypothesis could explain the phenomena: the industrial nozzles
staggering could not respect the half pitch (200mm) because of mechanical reasons, so that a staggering
pitch of 160 mm only could be applied. This dissymmetrical staggering could be theoretically an
influencing factor.
Even if the implementation at Sagunto line is in discrepancy with the expected gains, the transposition
to others industrial galvanizing lines started. Indeed, the results obtained in this study for the control of
strip vibrations are integrated in the new design proposed by the partner Drever International for the
galvanizing and annealing lines. The new design dedicated to rapid cooling sections working under
protective atmospheres and with high cooling rates is called Ultra Fast Cooling. Taking into account the
time required between the design and the industrial start of each line, 5 new lines (Greenfield projects)
are equipped with the new cooling design proposed by the partner Drever:
o
2 galvanizing lines and 1 annealing line in ShunYi (Beijing) for Shougang Company
1 galvanizing line and 1 annealing line in Wuhan, for Wisco Company (Cold Rolling Mill 3).
In the after-pot cooling section, staggered nozzles (straight nozzles and PAD nozzles without PAD
sheet) are used, as presented for the pilot line and as used in the modified Sagunto line. In the Shougang
CGL, there are no rolls to stabilize the strip and no casing surrounding the plenums. The control of strip
vibrations is very good. All the Final Acceptance Tests (FAT) have been successfully passed for this
line.
Same good results in terms of control of vibrations are obtained for the Wisco galvanizing line with the
same design.
Transfer to rapid cooling sections of other galvanizing lines and continuous annealing lines
If the implementation of the recommendations did not bring all satisfaction for the Sagunto
configuration, the same recommendations have been implemented by the partner Drever on many new
lines (Greenfield projects for Asiatic companies). Especially the principle of nozzles staggering by a
half pitch is implemented in the many cooling towers: operators do not observe strip instabilities and
are convinced by the benefits of the new technology.
The recommendations of the projects have been integrated in the new design Ultra Fast Cooling
equipment by the internal R&D team of Drever. Many lines are currently equipped with the new
technology:
o
The Shougang continuous annealing line N1 and the galvanizing line N1 are equipped with
the new Ultra Fast Cooling Technology. It is also the case for the new Wisco continuous
annealing line. The CAL N1 and CGL N1 rapid cooling sections contain three zones, the two
last zones having a shorter length than the first one. To get the highest cooling performances,
only the two short-length zones are used. The cooling rate is expressed in C/s for a strip
thickness of 1 mm. The excellent cooling performances of the Ultra Fast Cooling System
without vibrations show the success of the projects recommendations:
o
until 101.6 C/s.mm for the continuous annealing line N1
until 112.4 C/s.mm for the continuous galvanizing line N1
10
This means that a very good control of strip vibrations is required for this technology using high gas
speed and short plenum-strip distance. Straight nozzles in staggered configuration are used in the Ultra
Fast Cooling system. No scratch on the strips is observed during our tests and by the lines managers,
demonstrating the very good performances of the design in terms of strip vibrations control.
Same good results in terms of control of vibrations for the Ultra Fast Cooling technology are obtained
for the Wisco galvanizing line and continuous annealing line with the same design. The transfer of the
know-how stored up during the project by all partners is ensured.
CONCLUSION
Scientific and technical approach
The project has been divided in 3 approaches: Industrial approach, Scientific and theoretical approach
and experimental approach.
Industrial approach
Because we changed one contractor, we finally conducted strip vibrations characterization on two
different industrial lines: Ghent #3 (WP1) and Sagunto (WP3) HDG lines. Both have been equipped
with experimental measurements to analyse on long periods the strip vibrations in the cooling zone to
connect the strip behaviour with some process parameters.
The identification and characterization of the major influent line and blow parameters has been done
during the trials at Ghent and confirmed during the trials campaign at Sagunto:
Order 1 effect of the blowing pressure and blowing velocity
Effect of the pressure balance in the opposite blowing boxes
Order 1 effect of the strip tension
No effect of the line speed (if the blowing power regulation loop is de-correlated to the line
speed)
The good understanding and dynamism between all the parties allow to collect the required data to
design the experimental 2/3 scale cooling device able to reproduce the strip vibrations characterized on
industrial conditions. The trial campaigns conducted on both lines were also the opportunity to collect
database to validate and to fit the theoretical vibrations model.
To answer to the question: How do the vibrations appear and how they can be minimized?, two
complementary approaches were proposed. The first one consists in using the experimental 2/3 scale
cooling device to define a new cooling geometry reducing strip vibrations and the second approach
consists in testing the new solutions with a theoretical model.
Experimental approach
The 2/3 scale experimental pilot has been designed and optimised to reproduce the strip vibration
phenomena observed on the industrial line; especially the vibration modes and frequencies, and the
vibration amplitudes were reproduced. We developed a reliable experimental tool to investigate in
controlled conditions (strip tension for example):
o
The influence of the blowing parameters: Blowing distance, Blowing width
11
The influence of the geometry parameters: Nozzle assembly geometry, Plenum

geometry, PAD sheet
The influence of the process parameters: Line velocity, Strip tension
The influence of the product properties: Thickness and width, Grade
In addition, dedicated measurements have been developed and used to characterize the effect of the
blowing and geometrical parameters. As an example, the hot wire technique has been used to
characterize with high reliability the jets velocity at the exit of the nozzles.
Starting from the database of the measurements of strip vibrations done in the exhaustive trials on pilot
facility and thanks to expert knowledge, we propose a theoretical model able to predictive the strip
instabilities.
Further trial campaigns on the experimental pilot allowed to validate and to fit the model.
Scientific and theoretical approach
In order to understand and predict the physical mechanisms of strip vibrations, a parallel theoretical
approach is necessary. The questions to answer are: What are the physical mechanisms which control
the vibratory behaviour in a gas jets cooling system? What type of interactions exists between fluid and
structure?
To predict the strip instabilities, the theoretical model of strip vibrations has been developed in
collaboration with a subcontractor of ArcelorMittal Research. The objective of this collaboration is to
determine some major characteristics of the flow instability, like the Reynolds Number Re.
Observations have been done on laboratory with a rigid plan mounted in such a way that it allows
rotational and translational motions, with one or two air jets normal to the plan. It was possible to
identify the configurations leading to instability.
Specific measures have been conducted to characterize the vibration eigenmodes (stiffness, frequency,
damping). The strip vibration mechanisms under the gas jets cooling system have also been identified:
o
Vibrations due to recirculation loops between jets
Vibrations due to turbulent flows
Vibrations due to aeroelastic forces coupling inducing dynamical instability
More specifically a physical model has been developed to predict the vibrations due to aeroeleastic
forces because it is the most damaging instability mechanism (contact strip-nozzle).
The trials campaign conducted on the experimental pilot facility under controlled conditions allowed
validating the stability / instability predictive model.
The combination of these two complementary approaches allowed defining the new cooling technology
implemented on the production lines.
Innovative content
The innovative part of the project consists in improving the existing cooling device to achieve higher
line speeds and higher competitiveness.
12
1.
A first project innovation consists in a detailed analysis of the strip vibrations induced
by industrial gas jets cooling equipments. The project provides an exhaustive characterization
of the vibration amplitudes and frequencies due to the cooling boxes. The influence of the strip
format and the major process parameters has been clearly identified. This task allows working
later at the experimental device in very close conditions to industrial lines (strip size, line speed,
strip tension, blowing pressure, etc.) including:
o
The mastering of all process parameters,
The possibility to test easily design modifications of the cooling equipment
The measurement facilities (strip displacements at different points, gas flow analysis).
The transfer of phenomena characterized in industrial conditions to an experimental facility is

an innovation by itself.
2.
This project is innovative for a second reason: this is the first time that an asymmetrical
slots cooling device is implemented on an ArcelorMittal line (Sagunto). The innovation is
actually an improvement of the existing equipment and consists in breaking the symmetrical
structure of the cooling device, which improves the distribution of the jets gas. It suppresses the
coupling effect of opposite gas jets and reduces the vibrations phenomena.
The principles of nozzles staggering, PAD sheets removal, closer strip-to-nozzles distance,
have been deployed and reinforced by the partner Drever through a new cooling equipment
called Ultra Fast Cooling. This equipment is dedicated to the rapid cooling sections of HDG
and CAL lines working under protective atmosphere (Cooling Rate of 118C/s for a strip
thickness of 1 mm). The Ultra Fast Cooling has been implemented on many new industrial lines
around the world (Shougang, Wisco) reducing the vibrations and consequently improving the
productivity and the coating high-quality. According to the Final Acceptance Tests report, the
customers are very satisfied. In this sense, the proposed technology is a successful innovation.
3.
At least, the major project innovation consists in understanding, identifying and
modelling the mechanisms of strip vibration phenomena generated by the gas jets of the
industrial cooling equipments. The previous work of transferability and reproducibility of the
online observed vibrations to the semi-industrial experimental device makes those
investigations possible.
For the first time it appears clearly that the strip instability phenomena can be classified in 3
families depending on the forces exerted on the structure:
o
quasi periodical forces due to recirculation loops between jets
turbulent flows forces
forces due to aeroelastic coupling producing the strongest damages on the coating
quality.
With the help of an expert team (sub-contractor), we built a physical model able to predict the
strip stability / instability depending on the process conditions (gas pressure, nozzle design and
nozzle configurations, strip-to-nozzles distance). We validated the theoretical approach on
the semi-industrial pilot facility. The results show very encouraging results: vibrations mode
can be predicted, as well as vibration amplitudes. The approach of coupling phenomena
between the gas pressure and the structure behaviour is a new approach on HDG lines. A
physical model able to take into account the impact of the gas pressure field on the steel surface
and the impact of strip reactions on the gas flows, on a weak way is an innovation.
The model has been reinforced by various industrial configurations (Ghent and Sagunto) and
this is the first time that this theoretical approach is used for galvanizing lines. Publications
13
have been written and presented during conferences to communicate these achievements [1-4,
25-26].
Industrial interest and scientific / technical prospects
Two complementary approaches have been proposed. The first one consisted in using the experimental
2/3 scale cooling device to define a new cooling geometry reducing strip vibrations and the second
approach consists in understanding the strip vibrations mechanism and building a theoretical model able
to predict the strip vibrations in specific cooling configurations.
The fluid-structure interactions in such equipment was never been studied before this project.
Each of these steps aimed answering the fundamental question: how to reduce the strip vibrations in gas
jets cooling equipments and consequently to increase line productivity and coating quality. That means
to be able to answer to these basic questions, which are frequently asked on that problem and have no
answer today:
o
For existing cooling technology in hot dip galvanizing lines, what is the importance of the
process and geometrical parameters on the vibratory behaviour of the strip? Is it possible to
reduce the vibrations by actions on these parameters while preserving the cooling
performances?
With identical cooling performances, is there a blowing design, which makes it possible to
strongly reduce the strip vibrations?
We answered to those questions with success.
Consistency of resources and quality of partnership
The project nature (pilot project) by itself leads to coordinate various competencies (technical and
scientific experts) and approaches (industrial and experimental). Due to a closed partnership between
the ArcelorMittal Ghent and Sagunto lines people, ArcelorMittal R & D team and Drever International,
we succeed to conduct an exhaustive characterization of the strip vibration phenomena observed in the
cooling sections and during production conditions (WP1). The WP2 was much more focused on the
coordination between researchers (ArcelorMittal Maizires), university competencies (subcontractor),
supplier knowledge (Drever International) and industrial background (ArcelorMittal Ghent). The WP3
consisted in coordinating the competencies of the line managers, the industrial people in charge of
mechanical and electrical maintenance, the technology suppliers, and the ArcelorMittal researchers in
charge of the measurements campaign. Because of the tasks diversity and because of the coordination
of various competencies, the partnerships quality is very high. More especially, the industrial
implementation of the new cooling technology has been done with success and on due time in spite of
one contractor withdrawal and replacement, and in spite of the economical crisis occurred at the end of
2008, which leads to human resources restriction of the ArcelorMittal group.
Community added value and contribution to EU policies
The impact regarding preservation of natural resources, energy and environment had been reinforced
considering the consequences of better controlled zinc coating on surface appearances of galvanized
strips and on the painting / organic layers consumption of automotive suppliers. Even if we were not
able to quantify those benefits on the Sagunto pilot line, the results obtained on the Chinese lines where
the recommendations have been implemented shows that the strip vibrations could be mastered in
14
cooling sections, especially in the cooling tower, reducing the zinc consumption thanks a better
mastering of the zinc coating homogeneity across the strip width as well as along the strip length. Those
results could be easily reproduced on EU lines, on HDG lines as well on CAL lines.
Exploitation and impact of the research results
The first impact of the research results is the worldwide deployment of the recommendations coming
from the WP2. Indeed the principle of staggering nozzles to reduce vibrations amplitudes, the removal
of the PAD sheet, the optimisation of the nozzle-to-nozzle distances have been introduced within the
innovative Ultra Fast Cooling developed in the Drever R&D department and commercialised by Drever
International.
The second impact of the research results consists in the development of modelling tools able to predict
the strip vibration amplitudes and modes for varied experimental and industrial configurations. Based
on the theoretical approach of fluid-structure interaction done within the WP2 tasks, further numerical
tools coupling computations of structural deformation and fluid mechanism have been developed at
ArcelorMittal Maizires Research. Developments are still going on to make the strip vibrations
prediction more robust, especially for industrial configuration taking into account the process parameter
fluctuations.
15
1. PROJECT TIME SCHEDULE

1st year (07-08)
I
II
III IV
Work
packages
Work packages title
WP 1
Analysis of strip vibrations on Arcelor Steel Belgium

industrial line
Industrial reference Database
Installation of measuring system
Disposal measuring system with process database

connection
ArcelorMittal Research
ArcelorMIttal Ghent
ok
Deliverables
Actors
J-S
Task 1.1
O-D J-M
Task 1.2
Characterisation of blowing parameters
Test report
Characterisation of line process parameters
Test report
ArcelorMIttal Ghent
ok
Task 1.3
Synthesis
Database
Synthesis report
ArcelorMIttal Ghent
ok
Task 1.4
Optimisation of the influent parameters on the

experimental cooling device
Improved experimental cooling device
Task 2.1
Design and manufacturing
Experimental 2/3 scaled cooling device
Task 2.2
Reproduction of vibration phenomena on experimental 2/3 scaled

device
Experimental 2/3 scaled cooling device

reproducing the industrial strip vibration phenomena
Task 2.3
Modification of the cooling design in accordance with the previous

developed theoretical model
Asymmetrical experimental improved cooling device

valided by the vibrations theoretical model
Task 2.4
Tests and optimisation
Improved experimental cooling device
Task 2.5
Synthesis
Performances quantification
WP 3
Task 3.1
Installation and optimisation of the improved

proposed solution in industrial conditions
Final industrial improved cooling device
Design and manufacturing
New / improved device
LadHyX (Subcontractor)
O-D J-M
A-J
J-S O-D J-M
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
ok
Analysis of strip vibrations on ArcelorMittal Sagunto industrial

Industrial reference Database
line
ArcelorMIttal Sagunto
Task 3.2
Assembly and adjustment of the improved cooling device in the

industrial line
disposal cooling device

(ready for use)
Task 3.3
Preparation of industrial tests
Test procedures
Task 3.4
Installation of vibrations online measuring systems
Industrial continuous control of strip vibrations
Task 3.5
Tests on industrial lines
Trials plan
Test report
Task 3.6
Optimisation of the industrial cooling device
Final industrial improved cooling device
Task 3.7
Synthesis
Industrial procedures
Recommendations to transpose the solution to others
industrial lines
Synthesis report
Task 3.1 BIS
J-S
3rd year (09-10)

I
II
III IV
ok
ArcelorMIttal Ghent
WP 2
A-J
2nd year (08-09)

I
II
III IV
NB: The contractors change of ArcelorMittal Ghent to ArcelorMittal Sagunto caused some delay on
the technical program (WP3) due to the amendment signature procedure. We also had to add a task
(Task 3.1 bis). However all the contractors succeed by hard work to follow the initial technical
program before the end of the contract.
17
A-J
2. SCIENTIFIC AND TECHNICAL DESCRIPTION OF THE RESULTS

2.1. OBJECTIVES OF THE PROJECT
Introduction
The galvanized steel coils are intended on one hand for the automotive market, that requires a high
quality in terms of surface aspect and on the other hand for the industry market, that requires enhancing
productivity rates. In the two cases a very good stability of the strip is necessary during the complete
process, especially in the cooling tower after the zinc pot.
Very little information and studies on the vibratory behaviour of a strip in gas jets cooling equipments
are available. The fluid-structure interactions, at the origin of the vibrations problems, and the links
between the design of the cooling equipments, the process parameters and the vibrations are very badly
known. Studies conducted in 2003 by ArcelorMittal Research and Drever [1, 10,11], the supplier of the
cooling equipments of many galvanizing lines in Europe, revealed that the more the productivity
increases, the more the capacities of the cooling devices are solicited and the more the vibratory
amplitudes of the strip increase [14, 15, 17, 18]. The industrial consequences are the followings ones:
-defects of the surface quality like scratches
-production breaks due to strip breaking
-bad homogeneity of the zinc thickness (wiping zone)
-Increase of the production costs due to the increase of the zinc coating weight.
Stakes
In the next years all the industrial lines will use the maximum of their capacities and the maximal
capacities of the cooling systems too. The stakes of the strip vibrations reduction are consequently
important and in progress:
-Stakes in terms of productivity: considering the increase of the line speed, the expected gains are
evaluated at 1 to 2 M per line per year. That repr esents a gain of 50 M per year considering that 25
galvanizing lines are concerned by the problem of strip vibrations in the cooling zone.
-Stakes in terms of quality: considering the control of the zinc weight and the current price of zinc, the
expected gains are evaluated at about 0.5 M per li ne per year. That represents a gain of about 12.5 M
per year for the 25 galvanizing lines (2006) which are potentially interested [8, 23, 24].
Objectives
The objective is not to work on external stabilizing actuators like the application of magnet or inductive
actuators but to work directly on the design of the cooling equipment which is the exciting source of
vibrations.
The present project will lead to an innovative industrial cooling device minimizing the strip vibrations
in the cooling zone. The new solution will enhance the line productivity and increase the coating quality
of the strip. The transferability of the technological solution to others typical cooling devices used at
industrial galvanizing lines will be assured with the recommendations report for industrial
transferability realized at the end of the project.
19
Program
ArcelorMittal Research (as coordinator), Drever, Arcelor Steel Belgium (at the projects beginning) and
ArcelorMittal Sagunto for the project second phases, are taking part in the proposal with
complementary roles in three steps, which are briefly described as followed:
1-) Analysis of strip vibrations on ArcelorMittal Ghent industrial line equipped with an
experimental measures system of the strip- blow nozzles distance in the wiping zone.
The distance strip-nozzles faithfully represent the strip vibrations amplitudes. The objectives
are:
o
To carry out a fine parametric study and a statistical analysis of the strip-nozzles
distance with standard production parameters to characterize the vibrations phenomena
at the starting point.
To identify and characterize the major influent line and blow parameters on the strip
vibrations in the gas jets cooling equipment of the industrial ArcelorMittal Ghent line
N3.
To collect data in order to define and design the experimental 2/3 scaled cooling device
planed at ArcelorMittal Research.
The success of the project is based on the good industrial analysis of the strip vibrations
phenomena. The results coming from these parameters characterization are the determining
factor for the next steps: the design of the experimental solution and the transfer to the
industrial line. This first Work Package is the key link of the continuous processing
improvement chain in which this pilot project belongs.
2-) Optimisation of the influent parameters on the experimental cooling device

An innovative technological solution to reduce even to cancel the strip vibrations in the cooling
zone will be firstly defined on an experimental 2/3 scaled cooling device. This experimental
device will be designed and developed in collaboration with Drever.
The characterization of the strip vibrations carried out in the first step on the industrial line is
needed to reproduce faithfully the vibrations phenomena on the experimental cooling device.
Many key points are required to define the optimal innovative cooling technology which will
minimize even cancel the strip vibrations on the experimental cooling device:
o
To design and manufacture a faithful experimental cooling device reproducing the strip
vibrations phenomena characterized in the first step of the pilot project.
To propose and to test experimentally the innovative solutions as for example a new
asymmetrical cooling device. The solutions will be evaluated by a theoretical model.
The retained solution will be tested, optimised and finally designed for the
experimental cooling device. The fact that the new cooling device is designed and
optimised for a 2/3 scaled experimental device assure a good representativeness of the
industrial reality and assure the good transferability of new designed solution to the
industrial line.
3-) Installation and optimisation of the improved proposed solution in industrial conditions
In our approach of continuous improvement quality, applied to the industrial problem of strip
vibrations, the last step is to transfer the new cooling technology to standard industrial
conditions and ensure his good functioning. It requires:
20
To adapt the design, to manufacture and to install the industrial innovative cooling
device, based on the design of the 2/3 scaled experimental cooling device.
To install an industrial continuous measures system connected to the process control

computer. This measures system should continuously measure the strip-nozzles
distance and estimate the performance of the new solution in industrial standard
conditions.
To test and to optimise the new cooling device in industrial standard conditions.
This last step is the heaviest in terms of staff hours and costs and requires the good coordination of the
interdisciplinary competences of all partners. His success depends on the quality of the two previous
steps and will be evaluated by comparison between the performances of the improved industrial cooling
device and the initial performances described in the status report made at the end of the first step
(WP1). The continuous quality improvement chain is closed.
The transferability of the new technological solution is ensured by a report of recommendations for
transferability to others industrial lines and through the writing of industrial procedures.
21
2.2. COMPARISON OF INITIALLY PLANNED ACTIVITIES AND WORK

ACCOMPLISHED
The initial working program has been entirely accomplished on due time as the Figure 1 shows it:
Figure 1: comparison between initially planned activities and accomplished work
The lines in red show the impact of the industrial partner change in terms of time schedule, especial the
impact on the deliverable deadline (1 year). It is important to underline that the table here above does
not show the dates of the tasks starting. So the delay and time schedule difficulties encountered into the
WP 3 do not appear clearly here. The delay of the tasks starting of WP3 is between 6 months and 1
year.
In spite of those difficulties, the respect of the initial foreseen time schedule has been ensured.
22
2.3. DESCRIPTION OF ACTIVITIES AND DISCUSSION

2.3.1. WP 1 Analysis of Strip vibrations on ArcelorMittal Ghent industrial line 3
Objective:
o
To identify and characterize the major influent line and blow parameters on the strip vibrations
in the gas jets cooling equipment of the industrial Arcelor Steel Belgium line N3.
To collect data in order to define and design the experimental 2/3 scaled cooling device planed
at Arcelor Research.
2.3.1.1. Task 1.1 Installation of measuring system
Objective:
- Measurements of the strip-nozzles distance in the wiping zone with experimental measures system
connected to the process database. The distance strip-blow nozzle faithfully represents the strip
vibrations amplitudes.
- Statistical analysis of the strip-nozzles distance measurements with standard production parameters
- Status report of industrial vibrations phenomena on line N3 in Arcelor Steel Belgium plant.
Strip vibrations measurement system in the cooling tower:
Strip vibrations are measured on two points:
Top-roll
- at the top of the cooling tower, between the cooling boxes,

where vibrations are the most important - at the wiping zone,
the most sensitive point of the production line to warranty
the product quality
Blowing
boxes 2
Laser sensors
Blowing
boxes 1
Experimental measurement systems:

- Between the cooling boxes; 3 Laser sensors are placed in
front of the strip, strip width-wise
- At the wiping zone, 3 inductive sensors, called Kaman
sensors, are placed in the front of the strip above the wiping
nozzles.
Kaman sensors
Wiping zone
Zinc
bath
The 3 width-wise sensors measure the strip position [9]. The

vibrations amplitudes are obtained by calculating the
standard deviation of the strip position. The 3 width-wise
sensors give the vibrations amplitudes at the centre of the
strip and at its 2 edges.
Figure 2: Configuration of the vibrations measurement system in the cooling tower
23
Positioning of the sensors:

For the Kaman sensors as well as for the Laser sensors, the positioning is organized in the following
manner:
Edge 1
Center
Edge 2
Strip
Kaman 1
Kaman 2
Kaman 3
Figure 3: Positioning of three Kaman sensors across the strip (top

view)
Figure 4: Three Kaman sensors across the strip
The distance between the Kaman sensors is about 500 mm, so that a large panel of strip width can be
detected.
Process parameters observed:

- Line velocity
- Strip traction
- Blowing pressure Box 1
- Blowing pressure Box 2
- Strip section (Width x Thickness)
Representativeness of the trials run:
The industrial trials campaign has been conducted for a high quantity of coils, about 400 coils. The
campaign has been conducted in standard production conditions in order to identify the starting points
characterizing the line, on which the design of the improved gas jets system will be based.
The totality of the sensors database has been worked and purified so that the transitory phases between
two strips (line speed changes, traction changes and formats changes) do not appear: the results
hereafter represent strip vibrations states by stable production conditions.
24
Presentation of results:
In following paragraphs, results will be shown firstly as a general overview of the influence of one
parameter and in a second step results will be presented more in details in order to evaluate the
influence of combined parameters.
2.3.1.2. Task 1.3 Characterization of line process parameters
Effect of the line speed

The effect of the line speed has been observed during the whole campaign whatever the strip format is.
The results of the strip vibrations measures at the wiping zone as well as between the cooling boxes are
shown hereafter (Figures 5 and 6):
Figure 5: Strip vibrations across the strip width at the wiping zone according to the line speed increase
25
Figure 6: Width-wise strip vibrations between the cooling boxes according to the line speed increase
Results:
The results shown in Figures 5 and 6, group together all the measured points during the trials run: all
strip formats, all production parameters merged. It is an overview of all the results.
Whatever the line speed is, the strip vibrations at the wiping zone (Figure 5) are included in a range of ~
2 mm in the strip centre as well as at the edges. There is a light tendency to see at the wiping zone: the
standard deviation for the edges 1 and 2 are quite constant whereas the standard deviation at the centre
is much more dispersed. It reveals a tendency of crossbow positioning for the strip.
On the contrary, the strip vibrations between the cooling boxes (Figure 6) increase according to the line
speed. It must be stressed that the figure presents the complete data for the 400 coils, with various
production conditions (e.g. various strip formats or various blowing pressure).
Regarding the maximal vibrations amplitudes at the wiping zone and between the cooling boxes, the
ratio between amplitudes at the wiping zone and cooling boxes is about 3.5 whatever the line speed is.
The influence of the line speed on vibrations modes will be seen hereafter.
Effect of the strip traction: analysis of the campaign database

The effect of the strip traction has been investigated during the whole campaign whatever the strip
format is. The strip traction takes into account the strip section (width [mm] x thickness [mm]). The
results of all the measures are shown hereafter (Figures 7, 8 and 9):
There is no real tendency to observe for measures at the wiping zone, except one: for strip traction
between 26 daN/mm and 34 daN/mm, the standard deviation of edges 1 and 2 is more or less constant.
On the contrary, the standard deviation of the strip centre is more dispersed. One possible interpretation
is the so-called long centre effect.
26
Figure 7: Width-wise strip vibrations at the wiping zone according to the strip traction
The increase of the strip traction has not a real influence on vibrations between the cooling boxes
(Figure 8): the standard deviation does not clearly change with the increase/decrease of the traction. It
has to be taking into account that the previous figures include many strip formats, many line speeds,
many blowing power in cooling boxes.
However there is no tendency to see according to the width-wise vibrations. It means the strip
displacements measured by the edges sensors or by the centre sensor do not allow concluding on an
influence of the strip traction on vibrations modes.
Figure 8: Width-wise strip vibrations between the cooling boxes according to the strip traction
27
Effect of strip traction at given line speed and strip formats:

The Figure 9 gives strip vibrations amplitudes according to the strip traction for 3 different strip formats
and for 2 different line speeds.
Figure 9: Width-wise strip vibrations at the wiping zone and between the cooling boxes according to the strip
traction and for 2 different line speeds: V=115 m/min and V= 140 m/min
Format 1:1650mm x 0,7mm
The whole results database is completely based on standard production conditions so that the strip
traction did not vary so much.
However, the above results are very interesting because it is possible to confirm that:
o
The increase of traction reduces vibrations amplitudes. For the same format (cf. format 1), the
traction increase from 23 daN/mm to 27 daN/mm reduces amplitudes at the wiping zone as
well as in the cooling system (factor 2).
The strip thickness increase reduces vibrations amplitudes (cf. format 3)
However, those results show the influence of the strip width on vibrations. When we compare the
formats 1 and 2, so two different widths, vibrations amplitudes at the wiping zone are quite in the same
range whereas strip distortions are to be observed in the cooling system. For a strip traction of ~30.5
daN/mm, the laser sensor of the strip centre detected high vibrations amplitudes whereas the strip
edges amplitudes varied less. It is to conclude that the strip shows distortion modes in the cooling
boxes.
28
Indeed, many observations during measurements campaign highlighted those effects of strip distortion,
especially strip twist positioning. It has not been possible to make measurements of this strip
distortion during the trials run because the high strip displacement quasi induced strip-nozzles contact:
on so short measurement range, the sensors are not able to deliver reliable results.
traction and for different strip formats (Line speed = constant)
The results presented by the Figure 10 are very interesting and complete the previous ones:
- For a constant line speed, the effect of strip traction on vibrations has been observed for 6 different
formats.
Effect of strip width: Whatever the strip thickness, for low widths (1400 mm to 1500 mm), vibrations
amplitudes at the wiping zone as well as in the cooling boxes are quite low whereas amplitudes in
cooling boxes and for higher strip width are noticeably higher.
Effect of traction: for the formats 1650 mm x 0.8 mm and similar format 1650 mm x 0.84 mm, the
effect of traction is quite clear: higher amplitudes (factor 2) at the cooling boxes zone for the lower
traction.
Effect of traction combined with high thickness: for the format 1650 mm x 0.95 mm, a high strip
traction does not have a real effect on vibrations amplitudes at the cooling zone.
2.3.1.3. Task 1.2 Characterization of blowing parameters
The Figure 11 presents the effect of blowing power of the fans in cooling zone 2 on the strip vibrations
(the fan speed in cooling zone 2 being constant). These results for all the coils data do not show a
clear tendency for the blowing power effect, except that the strip vibration amplitudes are generally
higher at the cooling boxes level with respect to the wiping zone.
29
Figure 11: Width-wise strip vibrations at the wiping zone and between the cooling boxes according to blowing
power of cooling box 2 (box 1 fixed)
Over a blowing power of 50%, the strip distortion effect, especially twist positioning in the cooling
boxing is so high that it damages the product quality. Indeed in this twist position the strip edges can
contact the blowing nozzles and induce scratches. Another consequence is knock-on effect at the wiping
zone by propagation: the strip edges touch the wiping nozzles inducing inhomogeneous zinc coating
weight and thus quality damages. That is the reason why blowing power does not exceed 50 %.
power of cooling box 2 (box 1 fixed) for line speed fixed.
In the Figure 12, the selected data for a same line speed of 135 m/min are given. In this case, a clear
tendency can be observed: the vibration amplitude in the cooling zone is increasing linearly with the fan
blowing power, whereas this amplitude remains constant in the wiping zone. The blowing power is
30
limited to 50% in the cooling zone 2 due to a strip-plenum contact above this 50% value, due to a strip
twist shape which increases with the blowing power.
2.3.1.4. Task 1.4 Synthesis
The trial run campaign has been carried out in standard production conditions and is completely
representative of current production of the HDG line of ArcelorMittal Ghent.
The campaign conducted gives the real state of the art of strip vibrations in the cooling tower:
o
Standard deviation at the wiping zone: ~ 2 mm
Standard deviation in the cooling boxes: ~ 9 mm
Process parameters can influence the vibrations amplitudes:

o
Standard deviation increase with blowing power
Standard deviation decrease with strip traction
The line speed effect did not clearly appear because it is combined with others process parameters like
strip traction.
Process parameters can influence the vibrations amplitudes: the more the strip is large, the more
standard deviation is high.
In conclusion, those analysis show high potential to decrease strip vibrations at the wiping zone as well
as in the cooling boxes by optimising the design of the current cooling system.
31
2.3.2. WP 2 Optimisation of the influent parameters on the experimental cooling device

at ArcelorMittal Research site
Objectives
o
To build at the ArcelorMittal Research site an experimental 2/3 scaled cooling device able to
reproduce the strip vibrations detected and characterized on the industrial galvanizing line N3
at ArcelorMittal Steel Belgium plant,
To optimise this experimental cooling device adapted to the industrial situation of strip
vibrations: definition of an innovative 2/3 scaled cooling device.
Program
o
Optimisation of the influent parameters on the experimental cooling device:
An innovative technological solution to reduce even to cancel the strip vibrations in the cooling
zone will be firstly defined on an experimental 2/3 scaled cooling device. This experimental
device will be designed and developed in collaboration with Drever.
The characterization of the strip vibrations carried out in the first step on the industrial line is needed to
reproduce faithfully the vibrations phenomena on the experimental cooling device.
Many key points are required to define the optimal innovative cooling technology which will minimize
even cancel the strip vibrations on the experimental cooling device:
- To design and manufacture a faithful experimental cooling device reproducing the strip
vibrations phenomena characterized in the first step of the pilot project.
- To propose and to test experimentally the innovative solutions as for example a new
asymmetrical cooling device. The solutions will be evaluated by a theoretical model. The retained
solution will be tested, optimised and finally designed for the experimental cooling device. The fact that
the new cooling device is designed and optimised for a 2/3 scaled experimental device assure a good
representativeness of the industrial reality and assure the good transferability of new designed solution
to the industrial line.
2.3.2.1. Task 2.1 Design and manufacturing
Objective
o
Using of the industrial strip vibrations analysis carried out in the WP1, development and design
of a 2/3 scaled experimental cooling device, representative to the industrial cooling device,
Manufacturing of the 2/3 experimental cooling device,
Cooling device assembly at the 2/3 scaled experimental plant
2.3.2.1.1.
Representativeness of the pilot line
The experimental pilot at ArcelorMittal Maizires has been updated and equipped with the air blowing
systems .
The design of this cooling equipment is very similar to the corresponding industrial devices installed by
Drever International in ArcelorMittal galvanizing lines. Cooling devices consist of two movable
plenums containing several slot nozzles.
32
The geometrical characteristics of a typical industrial plenum are the following: slot width 11 mm, pitch
(distance between two nozzles) 400 mm, nozzle length 275 mm.
The reduced-scale cooling device in the pilot line is designed with these geometrical characteristics
with a scale ratio of 2/3. The industrial distance between the nozzles and the strip is usually 100 mm in
rapid cooling sections and 125 mm in towers. Movable plenums are designed for the cooling equipment
in the pilot line, allowing to test the effect of nozzles-strip distance on strip vibration behaviour.
However the strip format and the strip tension have been chosen in order to reach similar vibrations
amplitudes and frequencies as those observed on industrial lines [2,3].
Top-Roll
Blowing
boxes
are
supplied with air from the
back side
6m
12
6 m
Blowing
boxes
are
equilibrated from each other
on 3 points
Hot air is evacuated on

laterally
Wiping system
Bain Zn
Figure 13: Drever after pot cooling design at ArcelorMittal Ghent 3

Figure 14: ArcelorMittal Ghent #3
33
Figure 15: ArcelorMittal Ghent 3

Detailed schema of the after pot cooling design
Figure 16: Schematic overview

of the experimental cooling
device
Figure 17: Upper view of the

equipped pilot line, with strip
and guide-rolls
34
2.3.2.1.2.
General technical characteristics of pilot line
Global geometry:
Distance between top-roll and bottom-roll: 9m
Dimensions of blowing boxes:
h = 2 000mm
w = 1 400mm
System flexibility:
Movable plenums
Movable guide-rolls
Flexible front side nozzles design
Distance between strip and nozzles: 25 to 125
mm
Air blowing system:
2 separate air supply systems for each blowing
box
Blowing power: 2 x 28 000 Nm3/h
Blowing pressure: 2 x 0 to 100 mbar
Process parameters:
Figure 18: Drawing of the equipped pilot line, with strip line
pass (red line) and guide-rolls
Strip tension: until 3000 kgf

Line velocity: 0-1000m/min
Product characteristics:
Steel product: Tin mini-coil
Width: until 1400 mm
Thickness: 0.05 until 1.2 mm
2.3.2.1.3.
Plenums front side design of pilot line
The geometrical characteristics of a typical industrial plenum are the following:

-
slot width 11 mm,
pitch (distance between two nozzles) 400 mm,
nozzle length 275 mm.
The reduced-scale cooling device in the pilot line is designed with these geometrical characteristics
with a scale ratio of 2/3.
35
Figure 19: Different configurations of blowing plenums front side tested on pilot line. 1- 2 x 8 nozzles opposite to
each others; 2- Variation of nozzles length; 3- Air PAD system
2.3.2.1.4.
Geometrical characteristics
Slot width : 8 mm,

Pitch (distance between two nozzles): 267 mm,
Nozzle length : 184 mm,
Blowing width: 1400 mm (against 2000mm in industrial line),
Modularity of front side.
2.3.2.1.5.
Measurement systems of pilot line
Continuous process parameters acquisition

Continuously acquired signals:
-
Strip tension measurement (at 10 m): 2 points on strip edges
Strip positioning measurement
Strip velocity measurement at guiding rolls (S-Bloc)
Measurement of dance roll position
Measurement of centring roll position
Detection of weld path
Measurement of motors intensity, couple
Pressure in each blowing box
36
Fans rotation velocity
Figure 20: Control cabin of experimental pilot line
2.3.2.1.6.
Strip positioning measurement system
Continuous strip position measurement:

-
Strip position: at the 2 strip edges + strip centre
Standard deviation
Peak-to-peak
Spectral analysis
Acquisition frequencies: 64 Hz
Measurement range is 50-300 mm with a resolution of 0.2 mm. The sensors have been calibrated on
specific installation at ArcelorMittal Research.
Figure 21: Strip positioning

measurement system
Air flows characterizing:

-
Hot wire measurement system
Air velocity range: 0-150 m/s
Figure 22: Hot wire measurement system
37
2.3.2.1.7.
Product
The tested strip format is typically 950 x 0.25 mm.

The low thickness has been chosen in order to favourite high strip vibrations amplitudes. Indeed two
possibilities are identified: to reduce the specific strip tension or to reduce the strip thickness. Because
of difficulties to transport the strip in dynamic conditions by very low tensions, it has been decided to
reduce strip thickness even thought typical galvanized product is thicker. The strip width has been
chosen based on a similar industrial ratio strip width / blowing width.
2.3.2.1.8.
Influent parameters detected on industrial line
As shown in the previous 6-months technical report, influent parameters on strip vibrations amplitude
increase have been identified during the industrial campaign:
- Standard deviation increase with blowing power
- Standard deviation decrease with strip tension
- The line speed effect did not clearly appear because it is combined with others process
parameters like strip tension.
- Process parameters can influence the vibrations amplitudes: the more the strip is large, the
more standard deviation is high.
The campaign conducted gives the real state of the art of strip vibrations in the cooling tower for
standard production parameters:
- Standard deviation in the cooling boxes: ~ 9 mm
That is the reason why the effects of strip tension, line velocity and blowing power have to be
investigated. The flexibility and representativeness of the reduced-scaled pilot allow to test those
parameters.
2.3.2.2. Task 2.2 Reproduction of vibrations phenomena on the experimental 2/3 scaled
cooling device
Objective
- Experimental validation of the 2/3 scaled experimental cooling device by comparison with the
industrial database (WP1). The experimental device must be representative and faithful to the
real industrial cooling device.
38
2.3.2.2.1.
Initial tested configuration
Distance between strip and nozzles is fixed at 67 mm

(=100 mm in industrial line).
Blowing width is 1400 mm
Specific tension: 1.8 kg/mm2
Line velocity: 0 m/min
Blowing pressure: from 0 to 40 mbar
Figure 23: initial configuration: plenum nozzles configuration

4 straight nozzles + 1 PAD (aerodynamic stabilizer) per side
2.3.2.2.2.
Reproducibility of industrial strip behaviour
The Figures 24 and 25 show the increase of vibrations amplitudes of strip displacement function of the
blowing pressure increase. The behaviour is not linear. The maximal amplitudes are detected in the strip
centre. A light gap between the 2 edges appears what can be induced, for example, by strip flatness
defects or blowing pressure heterogeneity strip width-wise. It can be a case of edges fluttering
phenomenon.
At 40 mbar, peak-to-peak measurements are more than 100mm what can induce strip-nozzles contacts.
To avoid destroying the strip, the blowing pressure has not been increase during the first trial run.
cart type centre
amplitude max centre
cart type rc
amplitude max rc
amplitude max rh
cart type rh
120
strip displacement peak to peak (mm)
35
strip displacement RMS (mm)
30
25
20
15
10
5
100
80
60
40
20
0
0
10
15
20
25
30
35
40
Figure 24: strip displacement as function of blowing

pressure
10
15
20
25
30
35
blow ing Pressure (mbar)
blow ing Pressure (mbar)
Figure 25: peak to peak values as a function of

blowing pressure
39
40
The Figures 26 and 27 give an idea about vibrations observed during a 20 s time for 2 different
blowing pressures: 19 and 39 mbar. They are compared to the theoretical pass-line:
Two different strip behaviours are observed for the 2 cases:
-
at 19 mbar : irregular vibrations with vibration power density spectrum from 0 to 2 Hz

vibrations
at 39 mbar : regular vibrations in the centre as well as at the edges with vibration power
density spectrum concentrated around 2.4 Hz
distance centre [mm]
distance rive cabin [mm]
distance rive halle [mm]
ralative strip position (mm)
70
65
theorical strip line pass
60
55
50
45
40
35
30
40
41
42
43
44
45
46
47
48
49
50
51
time (s)
52
53
54
55
56
57
58
59
60
59
60
Figure 26: evolution of the strip position with time at P=19 mbars => irregular strip vibrations
relative strip position (mm)
120
100
80
60
40
20
0
40
41
42
43
44
45
46
47
48
49
50
51
time (s)
52
53
54
55
56
57
58
Figure 27: Evolution of the strip position with time at P=39 mbar => regular strip vibrations
50
8000
45
7000
40
6000
35
5000
30
25
4000
20
3000
15
2000
10
1000
5
0
0
0.5
1.0
centre
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.
21/07/2004;10:27:12.0
Figure 28: power density vibratory spectrum P=19

mbar
0.5
centre
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.
21/07/2004;11:27:52.0
Figure 29: power density vibratory spectrum P=39

mbar
40
The strip vibratory behaviour observed in the pilot line is very similar than the one observed on
industrial lines (at the top of the cooling tower of ArcelorMittal Ghent for example): regular increase
of strip vibrations until possible contact to nozzles (Figure 27: maximal strip displacement of 100 mm
whereas the distance between two nozzles is 120 mm); twist positioning (Figure 26); low vibrations
frequencies < 5 Hz (Figure 28).
The reproducibility of strip behaviour has been verified.
2.3.2.2.3.
Reproducibility of vibrations phenomena observed at ArcelorMittal Ghent

line
During the industrial vibrations characterization campaign, it has been often seen a strip twist shape
increasing with the blowing pressure.
This phenomenon has been reproduced on the experimental pilot line as shown in Figure 30:
Twist
positioning
200
180
160
140
120
100
80
60
40
20
0
0
10
20
30
40
time (s)
50
60
70
Figure 30: evolution of the strip position with time in a twist situation
The Figure 30 shows relative position of strip centre (blue curve) and strip edges (yellow and pink
curves) during 80 minutes. The blowing pressure is not high: 30 mbar, what is representative of
industrial conditions. The specific traction is 1kg/mm.
In those conditions, we clearly see that one strip edge and the strip centre are quasi at the same
position: this is the phenomenon that we called strip twist shape. This mechanism takes place with a
mechanism of buckling and is very spontaneous.
Intermediate conclusion:
Those observations are exactly similar to the strip behaviour observed on industrial lines. If it can be
reproduced on experimental pilot line, the origins of this mechanism are not completely understood.
2.3.2.2.4.
Reproducibility of the trials campaign
We verified the reproducibility of the strip behaviour for several trials time on experimental pilot. Four
trials have been carried out in identical conditions and at different time periods. Those four trials are
identified on the followings figures with number 1 to 4. Figure 31 presents the vibrations amplitude
41
80
depending on the blowing pressure in the cooling boxes. The values are RMS values for the central
sensor and maximal values for the all three sensors. The curves show an excellent reproducibility of
the trials, for the RMS values as well as the maximal vibrations amplitudes (peak-to-peak values).
1
2
RMS Centre [A.U.]
Peak-Peak all points [A.U.]
3
4
1
2
5
4
3
2
3
4
5
4
3
2
1
0
0
10
20
30
40
50
60
10
20
30
40
50
60
Blowing Pressure [mbar]
Blowing Pressure [mbar]
Figure 31: RMS and peak-to-peak strip vibrations amplitudes as a function of the blowing pressure for tests
performed at 4 different time periods
2.3.2.3. Task 2.3 Modification of the cooling design in accordance with the vibratory
mechanism theoretical model
Objectives
-
Improvement of a theoretical model of the strip vibrations phenomena providing the criteria of
the vibrations starting point.
Design of a new experimental 2/3 scaled cooling device minimizing the strip vibrations.
Validation by the theoretical model.
Tests of different complementary modifications of the cooling device configuration to

decrease strip vibrations.
42
2.3.2.4. Construction and improvement of vibrations theoretical model
Observation: 3 major strip behaviours
2.3.2.4.1.
The first trials conducted on the pilot line shown 3 major vibratory / instability behaviours:
ralative strip position (mm)
70
65
theorical strip line pass
60
55
50
45
40
35
30
40
41
42
43
44
45
46
47
48
50
51
time (s)
52

120
49
100
80
60
40
20
0
40
41
42
43
44
45
46
47
48
49
50
51
time (s)
52

200
180
strip position (mm)
160
140
120
100
80
60
40
20
0
40
41
42
43
44
45
46
47
48
49
50
51
tim e (s)
Figure 32: RMS values as a function of time at 4 different time periods. Identification of 3 major strip
behaviours:
- irregular + centred or a) mode in Figure 33
- regular + centred or c) mode in Figure 33
- irregular + twist or b) mode in Figure 33
43
Figure 33: schematic view of the 3 major observed strip behaviours:

a) irregular + centred : several simultaneous modes
b) irregular + twit : several modes + strip instability type twist
c) regular + centred : vibrations with 1 mode
The hypothesis to explain this twist shape (Figures 32 and 33 b) is related to the fluid flows and
especially to the pressure heterogeneity.
Pressure characterizations in the strip width direction and into the plenums have been conducted and
show no heterogeneity. However the issue of strip vibrations under gas jets is a problematic of fluidstructure coupling, as shown is the following Figure:
Wall jets
Figure 34: Schema of interaction between gas jets fluid

and the strip structure
There exist 3 types of unsteady forces coming from the flows and applied on the structure:
- Quasi periodical forces dues to vortex (recirculation cells)
- Forces due to turbulent flows
- Forces due to aeroelastic coupling
44
Instability due to vortices (recirculation cells)
A simple calculation conducts to conclude that the frequency of vortex is around 10-40 kHz whereas
the resonance frequency of the system {strip; blowing nozzles} is lower than 30 Hz. The factor 100
between the two frequencies leads to conclude that the instability of the strip does not come from the
fluid vortex (Figure 35).
Figure 35: Illustration of vortex mechanism
Instability due to turbulent flows:
The mechanism of forces fluctuations applied on the strip surface because of turbulent flows, is well
known and plays a part in the instability mechanism but does not explain the suddenness of the
phenomenon observed on line or on experimental pilot device.
Vibrations
amplitudes
Vibrations due
to fluttering
phenomena
FluidStructure
Interaction
Vibrations due to
turbulences
Figure 36: Schema of strip vibrations

amplitudes function of strip-nozzle distance
Strip-Nozzle distance
Instability due to aeroelastic forces:
Aeroelastic forces are defined as the interaction between the aerodynamical forces coming from the
fluid and the elastic reaction of the structure [20, 21, 22]. Those forces fluctuate in the neighbourhood
of the strip surface and lead to stabilize or destabilize the strip movements and vibrations. The
classical vibrations are disturbed by the aeroelastic force: it induces possible instabilities. There exist 2
kinds of instabilities:
- Static instability. The static instability is due to high pressure fluctuations and is easy to
observe: it conducts the structure to the buckling phenomenon.
- Dynamical instability. The dynamic instability is due to fine pressure fluctuations and
conducts the structure to the fluttering phenomena.
45
The comparison between theoretical approach and experimental approach on pilot line conduct to
favour the hypothesis 3: aeroelastic coupling should be the key mechanism explaining the strip
vibrations. In order to investigate this hypothesis ArcelorMittal Research built a collaboration with the
LadHyX laboratory, with experts on fluid-structure coupling.
2.3.2.4.2.
Collaboration ArcelorMittal - LadHyX Laboratory
Within the framework of this collaboration a simple installation composed of on reduced scaled nozzle
and one 1-DDL -dimensionally stable sheet has been built. The aim of the laboratory experimental
device is to understand the influence of geometrical aspect on vibrations amplitudes induced by
spontaneous instability. Such a laboratory installation is very flexible and supports in a first time, a
simplified approach.
Results:
Experiments were carried out to study the effect of strip-nozzle distance as well as the pressure,
geometrical ratios and to identify the mechanism of strip instability.
The experimental approach allows determining:
the stable and instable domains
The following curves (Figure 37) represent the strip damping function of the non-dimensional stripnozzles distance and lead to determine an instable domain:
Figure 37: Strip damping function versus an adimentional strip-nozzle distance H
The strip damping is negative in the instable area whereas it is positive in the stable area. When the
damping is negative, the air of wall jets (Figure 34) is continuously giving energy to the strip at each
strip vibration cycle. This energy is transformed by the coupled fluid-structure system into vibrations
amplitudes increase. This phenomenon is typically called dynamical instability phenomena [19].
46
The major influent parameters
Laboratory experiments allow investigating the influence of the strip-nozzle distance, pressures, the
nozzle opening section. They have been identified as order-1 parameters.
2.3.2.4.3.
Experimental validation of theoretical model
The mechanism of strip vibrations has been identified and influent parameters have been investigated
on laboratory installations with LadHyX. The next step aims at validating those observations and
conclusions on semi-industrial configuration on reduced-scale experimental pilot device.
The tested configuration to validate the results coming from the LadHyX collaboration is made of 1
blowing nozzle per blowing box, classical geometrical parameters (blowing length, nozzles opening
section).
The preliminary tests show good correlation between laboratory trials at the LadHyX and trials on
experimental pilot device at ArcelorMittal Maizires Research centre: same range of amplitudes, same
major vibrations modes, emergence of instability at very low frequencies.
influence of strip-nozzle distance
The strip nozzle distance has been made varied while the blowing pressure is kept constant. The
objective is to investigate the influence of nozzle strip distance on dynamical instability phenomena.
Indeed, the dynamical fluid-elastic instability has been observed (instantaneous instability and
increasing amplitudes) for the following configuration on industrial pilot line:
- strip-nozzles distance: 20 mm
- Pressure: 20 mbar
Those results are consistent with the interpolation of the laboratory experimental pilot to the semiindustrial ArcelorMittal Maizires device: the instable domain has been reproduced.
2.3.2.5. Task 2.4 Test and optimisation of the improved cooling device
Objectives
-
Optimisation of the improved cooling device in terms of gas flows, nozzles
design, blowing characteristics to minimize or even cancel strip vibrations.
2.3.2.5.1.
Influence of line velocity
Many trials were carried out to minimize the vibrations amplitudes. The first set of trials consisted in
investigating the influence of the line speed. The semi-industrial pilot line is the ideal device to make
vary the line speed from 0 to 200 m/min (usual line velocities range on HDG lines) under variable
blowing pressures:
47
peak to peak centre (P blowing = 29 mbars - guide rolls open)

peak to peak centre (P blowing = 35 mbars - guide rolls open)
peak to peak centre (P blowing = 60 mbars - guide rolls 10 mm)
RMS centre (P blowing = 29 mbars - guide rolls open)

RMS centre (P blowing = 35 mbars - guide rolls open)
RMS centre (P blowing = 60 mbars - guide rolls 10 mm)
25
120
20
15
10
100
80
60
40
20
0
0
50
100
150
200
250
50
100
150
200
250
line spee d (m/min)
line spe ed (m/min)
Figure 38: strip displacement (RMS) function of strip

speed
Figure 39: peak-to-peak as a function of strip

speed
The Figures 38 and 39 show the evolution of vibrations amplitudes (standard deviation and peak-topeak values) as a function of line velocity and for different blowing pressures. Low variations of
amplitudes can be observed but no specific strip behaviour is highlighted. Those results have been
confirmed many times for further trials campaigns outside of this project.
As a conclusion, line velocity is not a major influent parameter on vibrations.
Influence of strip tension
2.3.2.5.2.
o Effect of strip tension increase

The Figures 40 and 41 show the influence of blowing pressure on vibrations amplitudes (standard
deviation or RMS and peak-to-peak values) and that, for 3 different specific tensions homogeneously
distributed along the strip width:
- 0.96 kg/mm
- 1.73 kg/mm
- 2.77 kg/mm
The curves are not linear and for a blowing pressure > 5 mbar, the curves seem to follow an
exponential behaviour.
RMS centre (T moy = 0.96 kg/mm2)
E
i l (RMS
(T
0 96 k /
peak to peak centre (T moy = 0.96 kg/mm2)

E
i l(
k
k
(T
0 96 k /
2) )
40
110
35
2) )
120
30
25
20
15
10
5
100
90
80
70
60
50
40
30
20
10
0
0
10
15
20
25
30
35
40
45
50
blowing pressure (mbar)
10
15
20
25
30
35
40
45
blowing pressure (mbar)
Figure 41: peak-to-peak values function of

blowing pressure
Figure 40: strip displacement (RMS) function of

blowing pressure
48
50
When the specific tension is multiplied by a factor 2 for constant blowing pressures, the standard
deviation and peak-to-peak values decrease by a factor 2.
Spectral analysis:
Whatever the specific tensions (0.96 kg/mm; 1.73 kg/mm; 2.77 kg/mm), the observations are
similar: the spectral analysis show irregular power density vibratory spectrum for low pressures and
the power density vibratory spectrum is concentrated in a narrow range when the pressure increases.
Case of higher pressure (30, 40 and 50 mbar), the whole energy of the system {strip-air blowing jets}
is concentrated around one specific frequency (see Figures 42, 43, 44; on the right side). However
those specific frequencies increase with the blowing pressure increase.
One hypothesis to explain those observations is that vibrations are induced by air jet flows turbulence
in case of lower pressures. Then vibrations are induced by turbulent flows. But the second observed
phenomenon (concentration of energy around one frequency) is due to dynamic instability.
3000
400
350
2500
irregular regular
2000
strip vibrations
when
blowing pressure
1500
increase
300
250
200
150
1000
100
500
50
0
0.5
centre
1.0
1.5
2.0
2.5
3.0
0.5
centre
3.5
4.0
4.5
5.
21/07/2004;10:00:40.0
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.
21/07/2004;10:11:26.0
Figure 42: power density vibratory spectrum T=0.96 kg/mm2 P=19.4 mbar and P=29.3 mbar
x axis: Frequencies in [Hz] & y axis: Power Spectral Density
250
8000
225
7000
200
125
irregular 6000
regular
5000
strip
vibrations
when
4000
blowing pressure
increase
100
3000
175
150
75
2000
50
1000
25
0
0.5
centre
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.
21/07/2004;11:25:32.0
0.5
centre
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.
21/07/2004;11:27:52.0
49
150
8000
irregular7000
regular
strip vibrations
when
6000
blowing
pressure
5000
increase
125
100
75
4000
3000
50
2000
25
1000
0
0
0.5
centre
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.
21/07/2004;17:19:51.0
0.5
centre
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.
21/07/2004;17:22:05.0
- Strip tension plays a major part on vibration stabilization but this parameter is quite difficult
to manage in industrial conditions. This conclusion coming from semi-industrial trials is in
agreement with observations made during the industrial vibrations characterization campaign.
- The role of blowing pressure as vibrations mechanism selector has been identified:
The mechanism of vibrations during low blowing pressures is manifested by turbulent signals
on a large range of frequencies whereas it is manifested by precised frequencies during high
blowing pressures showing vibratory instability. Those observations are in accordance with
the strip vibrations instability model which has been presented here above.
o Effect of heterogeneous strip tension across the width

The Figure 45 illustrates the influence of the heterogeneous strip tension across the width on
vibrations amplitudes. A tension gap between the edges can be induced by a strip flatness defect or by
a non-homogenous strip temperature across the strip width. On the left side graph, a small strip tension
gap 4% - is measured between edges.
Figure 45: Effect of difference between strip tension edges on strip vibration amplitude
For a blowing pressure of 40 mbar, the strip shows vibrations amplitude slightly higher on the strip
centre than on the edges: the standard deviation average for the 3 sensors is 4.4 A.U. On the right side
50
figure, the strip tension gap between the edges is higher: 17%. For the same blowing pressure (40
mbar), the strips behaviour is completely different. The global vibration amplitude increases: the
standard deviation average is about 5.6 A.U., i.e. 28% higher than the case of low tension difference
between the strip edges. However we can observe that the vibration amplitude increase is more
important on the sensor located on the operator side (Cabin edge) than on the motor side (Hall edge).
The heterogeneous width-wise strip tension favours the twist positioning.
The heterogeneous strip tension across the strip width is a major influent parameter on vibrations. It
plays a role on vibrations modes selector.
The heterogeneous strip tension across the width can be connected to industrial conditions like flatness
defects or width-wise thermal heterogeneities, which induce tension heterogeneities.
2.3.2.5.3.
Influence of blowing boxes pressure equilibrium
The industrial configuration of ArcelorMittal Ghent HDG line displays connections between two
blowing boxes of each strip face (Figure 46). Those connections play the role of pressure balancing
between the 2 blowing boxes in order to limit the propagation of pressure fluctuations from one strip
side to the other one. In order to investigate the influence of this geometrical configuration, such
connecting tube have been manufactured and implemented on the experimental pilot line.
Measurements have been done only for one Laser sensor at the strip centre.
Results are shown on Figure 47.
strip (center) standard deviation (mm)-d=67 mm-with tubes
strip (center) standard deviation (mm)-d=67 mm-without tubes
strip displacement standard deviation (mm)
30
25
20
15
10
0
0
Figure 46: Connecting tubes between the two opposite

blowing boxes
10
20
30
blow ing pressure (m bars)
40
50
Figure 47: Influence of the connecting tubes between

the opposite blowing boxes
The connecting tubes do not affect significantly the vibrations amplitudes. However those trials have
been also done with pressure differences from one blowing box compared to the other one. The
conclusion is similar: no significant effect of the balancing tubes.
51
2.3.2.5.4.
Influence of blowing width
One hypothesis to explain the fluttering phenomenon on strip edges is the interaction between two
opposite air jets. In order to investigate the parameters different blowing widths are tested. The strip
width is fixed and does not change during the trials run: 950 mm.
The tested blowing widths are: 800 mm, 900 mm, 1 000 mm, 1 100 mm, 1 200 mm, 1 400 mm.
(Figures 48 and 49)
strip (center) standard deviation (mm)-d=67 mm-straight nozzles-l=1400
25
20
(mm)-d=67 mm-straight nozzles-l=1400

80
mean twist between strip edges (mm)
30
mean tw ist betw een strip edges

blowing width > strip width
15
blowing width < strip

10
70
60
50
40
30
20
10
0
10
20
30
40
50
60
blowing pressure (mbars)
10
20
30
40
50
Figure 48: Effect of blowing width on vibrations

amplitudes
Figure 49: Effect of blowing width on peak- topeak values
The strip stability is better when the strip blowing width is lower than the strip width (effect on strip
vibrations and twist instabilities). The blowing width is a major influent parameter on vibrations. It is
related to the fluttering phenomenon on strip edges.
2.3.2.5.5.
Influence of a pressure difference between the 2 plenums
The Figure 50 presents the effect of a pressure difference between the two plenums on the strip
vibration amplitude, for a plenum configuration containing 6 nozzles including a pressure PAD. The
results show the very limited effect of a plenum pressure difference of 5%. Higher plenum pressure
differences are not considered in this study because they are not realistic in industrial lines.
52
60
strip (centre) standard deviation (mm)- delta(P1-P2) = 0%-with PAD

strip (centre) standard deviation (mm)- delta(P1-P2) = 5%-with PAD
strip (centre) standard deviation (mm)- delta(P1-P2) = 0%-without PAD
strip (centre) standard deviation (mm)- delta(P1-P2) = 5%-without PAD
50
45
40
35
RMS
[mm]
30
25
20
15
10
5
0
0
10
20
30
40
50
60
70
Blowing pressure [mbar]
Figure 50: Effect of a delta pressure of 5 % between the 2 plenums for a configuration of 2 x 6 nozzles with and
without PAD sheets
2.3.2.5.6.
Influence of nozzles length
The geometrical parameter nozzles length has been investigated. Two different nozzles lengths have
been tested: initial length = 275 mm and tested length = 55 mm (Figure 51).
strip (center) standard deviation (mm)-d=67 mm-straight nozzles
strip (center) standard deviation (mm)-d=67 mm-straight short nozzles
strip (center) standard deviation (mm)-d=67 mm-nozzles in staggered row s
25
strip (center) standard deviation (mm)-d=67 mm-short nozzles in staggered row s
20
15
10
0
0
20
40
60
80
100
Figure 51: Tested configuration equipped with shorter

nozzles length (55 mm)
Figure 52: Influence of shorter nozzles length (55mm)

on vibrations instability
53
As shown on the pink and yellow curves on the Figure 52, the reduction of nozzles lengths has a
negative impact on strip vibrations. However, two further major effects have been observed:
- The strip stability in terms of twist positioning is better due to the reduction of the air
exhaust free volume.
- But with a lower exhaust volume in the nozzle zone, the vibration amplitudes increase
The nozzle length seems to be a major influent parameter, easy to implement on industrial condition.
As a recommendation, it is important to design sufficiently long nozzles (in the range of 200-250 mm).
2.3.2.5.7.
Influence of staggered arrangement
As the blowing width has been identified as influent parameter on strip stability, a simple way to
reduce the fluttering effect is to eliminate the opposite air jets by staggering the nozzles.
The Figure 54 shows the results of 4 different tested configurations (Figure 53):
- Initial configuration: classical nozzles arrangement with PAD sheet
- Classical nozzles arrangement without PAD sheet
- Straight nozzles
- Staggered straight nozzles
Indeed, the PAD sheet has been identified as negative influent parameter when the PAD-Strip distance
is high.
PAD sheet
Figure 53: 3 different tested configurations: a) straight nozzles b) staggered straight nozzles c) classical nozzles
arrangement with PAD sheet
54
Results:
strip (all points) peak to peak (mm)-d=67 mm-straight nozzles
strip (center) standard deviation (mm)-d=67 mm-straight nozzles
strip (all points) peak to peak (mm)-d=67 mm-nozzles in staggered row s
strip (center) standard deviation (mm)-d=67 mm-nozzles in staggered row s
strip (all points) peak to peak (mm)-d=67 mm-w ith PAD sheet
strip (center) standard deviation (mm)-d=67 mm-w ith PAD sheet
strip (all points) peak to peak (mm)-d=67 mm-w ithout PAD sheet
135
strip (center) standard deviation (mm)-d=67 mm-w ithout PAD sheet
30
25
20
15
10
120
105
90
75
60
45
30
15
0
20
40
60
80
100
20
40
60
80
100
Figure 54: Standard deviation and peak-to-peak measurements for the 4 different tested configurations
In this strip-nozzles distance, the staggering of straight nozzles has clearly a positive influence on strip
stabilization (turquoise blue curve of Figure 54). The standard deviation is still < 3 mm whatever the
blowing pressure is. The peak-to-peak measurements in that case increase lightly and continuously
with the blowing pressure but is still very low compared to in initial configuration (yellow curve) and
the other tested configurations. The strip stabilization allows performing the trials run until the
maximal blowing pressure that can be delivered by the pilot fans: 100 mbar, without risk of stripnozzles contact.
The benefits of nozzle staggering are easy to calculate: for the blowing pressure of 40 mbar, the ratio
between peak-to-peak values between the staggered configuration and the initial one is about 4. That
means that vibrations maximal amplitudes can be decreased by a factor 4.
2.3.2.5.8.
Influence of PAD
As the industrial cooling design of ArcelorMittal HDG line 3 includes the implementation of PAD
sheets, the influence of this geometrical parameter has been investigated on the pilot line.
Indeed, the PAD sheet or AeroDynamical Bearings aims to form an air padding between the strip and
the metallic sheet (Figure 55) in order to stabilize it [12,13].
The influence of the implementation of PAD sheet has been tested, as well as the staggering of the
PAD sheets and the distance between the PAD sheet and the strip.
Influence of PAD sheet:
Firstly, two different configurations have been tested (Figure 55):

- Initial design with staggered nozzles, and with staggered PAD nozzles with PAD metallic
sheet (full red curve)
- Straight staggered nozzles without PAD (full yellow curve)
55
By the comparison between the full red curve and full yellow curve of the Figure 56, the PAD sheet
does not play a major part on vibrations until a pressure of about 50 mbar. But for higher pressures
(50-90 mbar) the peak-to-peak values of the full red curve (configuration with staggered PAD sheet)
are lower than the yellow one.
D =67 mm
Standard Nozzles design / staggered / without PAD sheet
Standard Nozzles design / staggered / with PAD sheet
Straight nozzles / staggered
Straight Nozzles / Staggered / Symmetrical PAD sheet / with sheet
Straight nozzles / Staggered / symmetrical PAD moved forward / without sheet,
Straight Nozzles / Staggered / Symmetrical PAD sheet / without sheet
Straight nozzles / Staggered / symmetrical PAD moved forward / with sheet,
Peak-Peak all points [mm]

80
70
60
50
40
30
20
10
0
0
20
40
60
80
100
Pressure [mbar]
Figure 55: Configuration on experimental pilot device

with staggered straight nozzles and symmetrical PAD
Figure 56: Peak-to-peak value function of blowing

pressure for 7 tested configurations
The PAD seems to play its stabilization role for high blowing pressure.
Influence of staggered PAD sheet:
Secondly, two different configurations have been tested (Figure 56):

- Straight staggered nozzles with symmetrical PAD nozzles with PAD metallic sheet (full dark
blue curve)
- Initial design with staggered nozzles, and with staggered PAD nozzles with PAD metallic
sheet (full red curve)
By the comparison between the full red curve and full dark blue curve, the symmetrical PAD sheet
seems to play a negative role on vibrations as the peak-to-peak value increase continuously with the
pressure. The PAD sheet should be symmetric in order to stabilize the strip.
The current PAD sheet is not optimised and is more destabilizing than stabilizing.
Influence of staggered PAD blowing nozzles without PAD sheets
We demonstrated the effect of staggered arrangement of the nozzles in the cooling device for the
limitations of strip vibrations. In those conditions, it appears interesting to test configurations which
can be used in industrial lines. The Figure 57 shows a standard plenum configuration containing PAD
56
sheets, with staggered arrangement obtained by a displacement of half nozzle pitch for the entire
nozzles set including the PAD sheet.
The Figure 58 presents the tests results obtained with this configuration, with and without the PAD
sheets. A comparison with the standard design i.e. non-staggered arrangement with and without
PAD sheets is also given in this figure. The distance between the nozzle and the strip d = 85 mm
represents a classical distance generally used in galvanizing lines. The configuration with staggered
nozzles arrangement and without the PAD sheets provides a very interesting solution for the control of
strip vibrations in the after pot cooling section of galvanizing line.
Figure 57: Staggered standard design with staggered

PAD
After Pot Cooling section (d=85 mm)

Staggered standard design, without PAD sheet
Staggered standard design, with PAD sheet
Standard design, without PAD sheet
Standard design, with PAD sheet
180
Peak-Peak all points [mm]
160
140
Figure 58: Peak-to-peak measurements for 4 different

configurations:
120
100
- Staggered standard design with staggered PAD
80
- Staggered standard design with staggered PAD

nozzles without PAD sheets
60
40
- Classical design with PAD

20
- Classical design without PAD sheets
0
0
20
40
60
Pressure [mb]
80
100
Influence of Strip - PAD sheet distance:
Thirdly the influence of strip-PAD distance has been investigated. As the PAD sheet seems to be
efficient for higher pressure, one way to increase the efficiency if the PAD by lower pressures is to
reduce the strip-PAD distance.
57
Figure 59: Schematic configuration for the investigation on the effect

of the strip-PAD distance on vibrations amplitudes
Two strip-PAD distances have been investigated:

- Initial distance: 67 mm (red curve with rhombuses)
- Advanced positioned PAD: 27 mm.
90
80
70
60
50
40
30
20
10
0
0
20
40
60
blow ing pres sure (mbars )
80
100
mean tw ist betw een strip edges (mm)-d=67 mm-nozzles in staggered row s + PAD in
opposite (d strip=27 mm)
opposite w ithout PAD sheet (d strip=27 mm)
opposite w ithout PAD sheet (d strip=45 mm)
opposite(d strip=60 mm)
opposite w ithout PAD sheet(d strip=60 mm)
60
mean twist between strip edges (mm)
strip (all points) peak to peak (mm)-d=67 mm-nozzles in staggered row s + PAD in opposite
(d strip=27 mm)
w ithout PAD sheet (d strip=27 mm)
(d strip=45 mm)
w ithout PAD sheet (d strip=45 mm)
strip (all points) peak to peak (mm)-d=100 mm-nozzles in staggered row s + PAD in
strip (all points) peak to peak (mm)-d=100 mm-nozzles in staggered row s + PAD in
opposite w ithout PAD sheet(d strip=60 mm)
100
50
40
30
20
10
0
0
20
40
60
blowing pre ssure (m bar s)
80
100
Figure 60: Effect of the strip-PAD distance for 3 different strip to blowing nozzles distances
The comparison between the 2 curves with same colours on the Figure 60 leads clearly to conclude
that the PAD sheet is efficient as soon as the PAD-strip distance is reduced. For a strip-PAD distance
of 25 mm, the peak-to-peak measurements stay in a range of 15-20 mm whatever the blowing
pressure.
The PAD sheet has been identified as a major geometrical parameter to stabilize the strip when it is
positioned close to the strip. A 25 mm distance between the strip and the PAD sheet on the
experimental pilot device (and strip-nozzles distance = 67 mm) corresponds to a distance of about 37.5
mm in industrial conditions (and strip-nozzles distance = 100mm) because of the scale of the
experimental pilot.
58
Flow velocity characterization at the exit of blowing nozzles
Flow velocity characterizations have been realised with the 1 D hot wire equipment in order to detect
potential flows velocity differentials between the blowing nozzle centre and its edges.
Tested configuration:
- 2 x 4 right nozzles without PAD sheet
- Strip-Nozzles distance: 85 mm
- Opening section of blowing nozzle: 8 mm
- Blowing pressures tested: from 0 to 100 mbar
- Spectral density analysis conditions:
- Measures per sensor: 6553600
- Sample frequency for blow velocity: 2500 Hz
- Sample frequency for strip displacement sensors: 2500 Hz
- Acquisition time for spectral analysis: 44 min
- Frequency resolution: 0.0763 Hz
Flow velocity profiles from the nozzle to the strip at the nozzle centre:
Figure 61: Flow velocity profiles from the nozzle to the strip at the nozzle centre and for different blowing
pressures. Legend : X is the distance between the nozzle and the strip; e is the nozzle opening section, Umax is
the flow velocity just at the exit of the nozzle, Umoy is the measured velocity at a distance X from the nozzle
wall : Umoy = U(X,0)
Velocity profiles are presented in a non-dimensional form.

There is to see a perfect superposition of all velocity profiles whatever the blowing pressure is. As
excepted the flow velocity is decreasing in the nozzle-strip direction.
59
Flow velocity profile from the nozzle to the strip at the nozzle edge:
Figure 62: Flow velocity profiles from the nozzle to the strip at the nozzle edges and for different blowing
the flow velocity jus tat the exit of the nozzle, Umoy is the measured velocity at a distance X from the nozzle
wall : Umoy = U(X,0)
There is a perfect superimposition of all velocity profiles whatever the blowing pressure is. By
comparing the 2 previous graphs (Figures 61 and 62) there is a velocity gradient from the nozzle
centre to the nozzle edge. The homogeneity is not completely ensured in the transversal direction and
depends on the plenums air supply configuration. It could have an influence on strip vibrations
behaviours, especially on twist positioning. Based on the symmetrical hypothesis, similar tests for the
second strip edge have not been carried out.
Two Laser measurements across the width (strip centre motor edge) have been simultaneously
realized in order to detect a potential connection between flow velocity frequencies and strip
displacement frequencies.
The third Laser called cabin Laser sensor has not been analysed because the flow velocity
measurement have been realized for a half strip (symmetry based on strip neutral line).
Common peaks are detected between 1Hz and 2.5 Hz, for the 2 Laser sensors and the velocities
spectral analysis.
Spectral density analysis of flow velocity

Tested conditions: Blowing pressure = 30 (=30%), 40 (=40%) and 50 (=50%) mbar; Strip tension =
547 daN
60
1 2.5 Hz
5 - 6 Hz
18 Hz
Figure 63: The spectral density analysis of flow velocity signals show typical frequencies around 1-2,5 Hz ; 5-6
Hz and 18 Hz.
Superimposition of spectral density analysis of flow velocity and spectral density analysis of
strip displacements:
Conditions: Blowing power: 50 mbar; strip tension: 547 daN
Figure 64: Superposition of spectral density analysis of flow velocity signal (black curve) and spectral density
analysis of strip displacements(red, green and blue curves)
Conclusion:
The blowing velocity at the nozzle exit depends usually on blowing pressure, design of the plenum
internal walls, air supply pipes geometry, nozzles design. The characterization of the jets velocity
shows a dependency between the energy induced by the flow velocity (black curve on Figure 64) and
the energy transferred to the strip (red, green and blue curves).
61
2.3.2.5.9.
Task 2.5 Synthesis
Objectives
-
Quantification of the improved designed cooling device performances
2.3.2.5.9.1. Summary of main results
Regarding the complete trial plan carried out, the main results are:
Influence of process parameters:
- Blowing pressure: major influent parameter, as well as the velocity homogeneity across strip width
- Line velocity: no influence
- Heterogeneous strip tension: major influence but difficult to manage in industrial conditions; major
influence on vibrations mode, especially twist positioning, but difficult to manage in industrial
conditions
Influence of geometrical parameters:
- Pressure balancing between blowing boxes: no influence

- Pressure balancing nozzle width wise: influent
- Strip-Nozzles distance: influent
- Nozzle length: major influent parameter: a minimal nozzle length is required.
- Blowing width: can be major influent in the case of narrow strip (opposite air jets on the strip edges).
- Staggered nozzles: major influent parameter, easy to implement in industrial conditions, very good
benefits
- PAD sheet: major influent parameter especially the PAD-Strip distance, easy to implement in
industrial conditions
2.3.2.5.9.2. Innovative technical solution
Regarding the previous results obtained on semi-industrial configuration and taking into account the
application of obtained results to industrial lines, the ideal technical solution could be:
- To stagger the blowing boxes with a step
- To put closer to the strip the PAD sheet (~40 mm for industrial line)
- To reduce the nozzle to nozzle distance with respect of global opening surface on one
plenum
- To adapt the nozzles opening section
62
2.3.2.5.9.3. First recommendations for an industrial implementation
The first recommendations can be done for an industrial application.

The innovative technical solution selected for the industrial line Ghent consists in the following
modifications, with respect to the present situation shown in Figure 65:
o
Upward displacement of the right-side plenum by 200 mm, corresponding to a

half nozzle pitch;
Upward displacement by 200 mm of the duct connecting the plenum and the fan.
Figure 65: Current blowing technology implemented at ArcelorMittal Ghent Hot Dip Galvanizing line.
The results of these modifications are presented in Figure 66. Dedicated pieces will be manufactured
in order to perform these modifications.
Figure 66: Proposed modifications at the blowing technology implemented at ArcelorMittal Ghent Hot Dip
Galvanizing line.
63
2.3.3. WP3 - Installation and optimization of the improved proposed solution in

industrial conditions on Sagunto line
2.3.3.1. Contractor change due to economical crisis (2009)
The economical crisis of 2008-2010 has affected the load of the galvanizing lines of ArcelorMittal to
an unprecedented extend, and forced the company to take measures to reduce drastically production
costs and working capital. The cost reduction measures include total idling of a number of galvanizing
lines in order to maintain the load of the running lines at an acceptable level.
In this context, the site of ArcelorMittal Ghent wishes to retire from the project and not to implement
the new cooler design on its galvanizing line N3.
The demand for galvanized automotive steel sheet is expected to restart and exceed capacity first in
South Europe. In this region, the galvanizing line of Sagunto has beneficiated in the past years of
investments that have made the vibrations from the tower cooling emerge as the next bottleneck. The
value of HDG Sagunto as a pilot line is equal to HDG3 Ghent; both are among the best and highest
capacity European galvanizing lines for exposed automotive steel sheet.
So, because of potential technical benefits of the project and the potential quality and productivity
gains of industrial implementation of the new cooling system developed into the current RFCS project,
in agreement with all the RFCS contractors, the coordinator proposed to conduct the industrial
implementation at ArcelorMittal Sagunto and not at ArcelorMittal Ghent.
The proposal has been presented at the TGS 5 meeting on May 2009 and accepted.
However an additional task (task 3.1 bis) has been introduced into the work program to evaluate the
technical feasibility study to implement the innovative technology on ArcelorMittal Sagunto line
2.3.3.2. Task 3.1 bis: Trials campaign at Sagunto to characterize the initial state before
implementing the innovative technology
An exhaustive strip vibrations characterization campaign has been conducted to evaluate the initial
state of the Sagunto line before the technology implementation.
Identical work as the one done for the ArcelorMittal Line of Ghent #3 has been done for the Sagunto
one.
2.3.3.2.1.
Measurement system and Cooling tower configuration
The strip displacement measurement systems used to characterize vibrations at Sagunto line have
identical as the ones used for Ghent line #3 characterization (2.2.1):
Strip vibrations are measured on two points (Figure 67):
- at the top of the cooling tower, between the cooling boxes, where vibrations are the most
important
- at the wiping zone, the most sensitive point of the production line to warranty the product
quality
64
Experimental measurement systems:

- Between the cooling boxes; 3 Laser sensors are placed in front of the strip, strip width-wise
- At the wiping zone, 3 inductive sensors, called Kaman sensors, are placed in the front of the
strip above the wiping nozzles.
The 3 width-wise sensors measure the strip position. The vibrations amplitudes are obtained by
calculating the standard deviation of the strip position. The 3 width-wise sensors give the vibrations
amplitudes at the centre of the strip and at its 2 edges.
Laser sensors position
Kaman sensors position
Figure 67: Configuration of the Sagunto cooling tower and position of the measurement systems
Process parameter observed:

- Blowing pressure Box 1 (others process parameter kept stable and constant: Line speed :
150m/min; Strip format: 1440mm x 0.7mm )
- Blowing pressure Box 2 (others process parameter kept stable and constant)
- Line velocity
Product:
- Thickness: ~0.5 2.0 mm
- Width: ~750 to 1850 max
- Maximal blowing capacities (Box 1 and 2): 40 mbar = 100 %
65
2.3.3.2.2.
Effect of blowing pressure of blowing box 1
The effect of the blowing pressure of the cooling box 1 has been observed during the whole campaign
whatever the strip format is. The results of the strip vibrations measurements at the wiping zone are
shown hereafter (Figures 68 and 69) as well as at the top of the cooling tower (Figure 70):
Vibration amplitude at the Wiping zone
20
2.0
Pic Pic (mm)
Standard Deviation
(mm)
Opr.
centre
1.5
Opr.
15
centre
10
moteur
moteur
1.0
25
50
75
100
Moy
puissance caisson 1 (m/mn)
25
50
75
puissance caisson 1 (m/mn)
100
Moy
Figure 68 & Figure 69: Standard deviation and peak to peak distance at the wiping zone (Kaman sensors
measurements) on 3 points for different box 1 blowing pressures (%) and for stable other production
parameters:
- blue curve: operator side
- pink curve: strip centre
- yellow curve: motor side
- black/grey curve: average trend
Figures 68 and 69 show a stabilizing effect measured at the wiping zone for a blowing pressure at the
box 1 ~50 % whereas the blowing power of the box 2 has been kept constant at 20% =8 mbar.
Vibration amplitudes in the tower
30
4.0
(mm)
40
20
3.0
10
2.0
0
0
25
50
75
Blowing power box 1 (%)
100
Peak to peak
Standard Deviation (mm)
5.0
Figure 70: Standard deviation and peak

to peak distance at the top of the cooling
tower (Laser sensors measurements) on 3
points for different box 1 blowing
pressures (%) and for stable other
production parameters:
- blue curve: peak to peak
- red curve: standard deviation
We do not see the same stabilizing effect on the measurement located at the top of the cooling tower.
Figure 70 shows, on the contrary, that the standard deviation and peak to peak measures continuously
increase with the blowing pressure.
Further trials have been conducted to explain the stabilization effect at 50 % observed at the wiping
zone. This effect is explained by an unbalanced pressure between the plenums facing the strip into the
cooling box 1. Indeed, a difference of ~1.3 mbar is observed between both plenums, especially for a
power > 50 % (= 20 mbar).
66
A hypothesis is that the unbalanced pressure between the opposite plenums can induce a strip
displacement regarding its initial pass line (Figures 71 and 72). As a consequence, the strip
displacement induces tension increase. It has been previously shown that the strip tension is order-1
factor on strip stabilization.
At 75% of the Box 1 blowing power, a 1.4 mbar difference has been observed between the 2 plenums
and a difference of 2.3 mbar at maximal fans power (=100%).
D Strip
placement
de bande
wiping zone
displacement
at the
tour
Ddisplacement
placementdein
bande
danslatower
Strip
the cooling
75
100
3.0
placement
placement
40.0
1.0
Displacement
[mm]
(mm)60.0
Displacement [mm]
(mm)4.0
2.0
0.0
0
25
50
75
100
Power
Guarantied not gar.

[mbar]
[mbar]
21.9
20.5
38
35.7
20.0
0.0
0
25
50
75
100
Blowing
power
Box11(%)
(%)
Puissance
caisson
Puissance
Blowing
power
caisson
Box11(%)
(%)
Figure 71 & Figure 72: Averaged strip displacement at the wiping zone (Kaman signals) and at the top of the
cooling tower (Laser sensors) for different box 1 blowing power. Reference0 is the averaged strip position at
minimal acceptable blowing power (10%)
A stabilizing effect is observed for a blowing pressure ~50 %, probably due to local strip tension
increase generated by the deviation of the strip from its pass-line. At higher pressures, vibrations
amplitudes are increasing, as expected, until 35 mm (Figure 70, blue curve). As well, an important
strip displacement has been observed on one plenum direction: 40 mm at 75 % blowing power (Figure
71).
67
delta P
[mbar]
1.4
2.3
2.3.3.2.3.
Effect of blowing pressure of blowing box 2
The effect of the blowing pressure of the cooling box 2 has been observed during the whole campaign
whatever the strip format is. The results of the strip vibrations measures at the wiping zone are shown
hereafter (Figures 73 and 74) as well as at the top of the cooling tower (Figure 75):
20
Vibration amplitudes at the Wiping zone
2.3
Operator side
Peak to peak [mm]
Standard Deviation
(mm)
Vibration amplitudes at the Wiping zone
2.1
1.8
Strip centre
1.6
Motor side
1.3
Operator side
.
15
Strip centre
10
Motor side
5
0
25
50
2
75
25
50
100
100
Average
Blowing power Box 2
Average
Blowing power Box 2
75
2
measurements) on 3 points for different box 2 blowing pressures (%) and for stable others production
parameters:
- black/grey curve: average trend
40
4.5
35
30 )
4.0
3.5
25
20
3.0
15
2.5
10
5
0
2.0
0
25
50
75
Blowing power Box 2 [%]
100
)
Peak to peak [mm]
Standard Deviation [mm]
Vibrations amplitudes in the tower

5.0
Figure 75 Standard deviation and peak to

peak distance at the top of the cooling tower
(Laser sensors measurements) on 3 points for
different box 2 blowing pressures (%) and for
stable others production parameters:
- blue curve: peak to peak
- red curve: standard deviation
Figures 73, 74, 75 are clearly showing the increase of amplitudes with the blowing power. The effect
of stabilization at 50 % is not observed. The blowing power of box 1 is kept constant = 20% = 8
mbar.
Strip displacement measurements have been done for various box 2 blowing pressures (Box 1 = 20%
= 8 mbar) and results are presented hereafter:
68
Strip displacement at the wiping zone
Strip displacement in the cooling tower
Power
guarantiedNot guar.
(mbars) (mbars) delta P
Strip displacement [mm]
3.0
2.0
1.0
0.0
0
25
50
75
100
0.0
0
25
50
75
10
2.1
0.6
1.5
25
4.4
3.2
1.2
50
11.4 11.1
0.3
75
22.8 23.8
-1
100
38
-3
100
-10.0
-20.0
41
minimal acceptable blowing power (10%)
At 75% of the Box 2 blowing power, a 1 mbar difference has been observed between the 2 plenums
and a difference of 3 mbar at maximal fans power (=100%).
Figures 76 and 77 show that the strip displacement at the top of the cooling tower is inversed
compared to the blowing box 1 displacement effect. Indeed the unbalanced pressures between the 2
plenums of previous case induced a strip displacement in the opposite side of the Laser sensors (Figure
67) whereas Figure 75 shows negative figures. In the case of Box 2 trials, the strip displacement is
done in the direction of the Laser sensors.
Vibrations amplitudes at the top of the tower are very sensitive to pressure balance between 2 plenum
of one cooling box.
2.3.3.2.4.
Effect of line speed
The effect of the line speed has been observed during the whole campaign whatever the strip format is.
The results of the strip vibrations measures at the wiping zone are shown hereafter (Figures 78 and
79):
Vibration amplitude at the wiping zone

Standard Deviation [mm]
Displacement [mm]
10.0
4.0
2.2
2.0
1.8
1.6
Operator side

Strip centre
1.4
1.2
1.0
100
Figure 78: Standard deviation at the wiping

zone (Kaman sensors measurements) on 3
points for different line velocities and for
identical others production parameters:
Motor side
115
130
145

- black curve: average trend
160
Average
Line velocity [m/mn]
69
Vibration amplitudes at the wiping zone
Peak to Peak [mm]
20
Operator side
15
Strip centre
Figure 79: Peak to peak distance at the

wiping zone (Kaman sensors
measurements) on 3 points for different
line velocities and for identical others
production parameters:
10

Motor side
100
115
10
145
160
Average
- black curve: average trend
Line velocity [m/mn]
For those standard production conditions, no significant effect of the line speed has been observed.
2.3.3.2.5.
Synthesis
The trial run campaign has been carried out in standard production conditions and is representative of
current production of the HDG line of ArcelorMittal Sagunto.
The campaign conducted gives the real state of the art of strip vibrations in the cooling tower:
- Standard deviation in the cooling boxes: ~ 4.5 mm
For maximal cooling capacities (40 mbar / 100% for each cooling box) = worth case:
- Peak-to-peak amplitudes at the wiping zone: max. 17 mm + a kind of twist / crossbow strip
positioning
- Peak-to-peak amplitudes at blowing boxes: max. 37 mm + a kind of twist strip positioning +
strip displacement on one plenum side
Process parameters can influence the vibrations amplitudes:

- Standard deviation increase with blowing power of both boxes 1 and 2
- To avoid strip displacement on one preferential plenum side, it is important to balance as
much as possible the pressures between the 2 plenums of one blowing box, whatever the
blowing is.
The line speed effect did not clearly appear because it is combined with others process parameters like
strip traction or immerged rolls settings.
In conclusion, those analysis show high potential to decrease strip vibrations at the wiping zone as
well as in the cooling boxes by optimising the design of the current cooling system.
70
Expected gains for Sagunto:

- Reduction of strip vibrations amplitudes in the blowing boxes: factor 4
- Reduction of strip vibrations amplitudes at the wiping zone
- Line speed enhancement
- Zinc savings thanks better control of transversal and longitudinal coating homogeneity due
to the strip stabilization
2.3.3.3. Task 3.1 design & manufacturing of the innovative technology implementation at
ArcelorMittal Sagunto line
Objective:
o
Using of the 2/3 scaled designs characteristics of the new cooling device defined in the WP2,
development and design of the final improved industrial cooling device taking considering the
line constraints (bulk, free volumes)
Manufacturing of the final improved industrial cooling device
Results:
Application of recommendations from tasks 2.3, 2.4, 2.5 to the Sagunto cooling tower configuration
Removal of PAD sheet
As previously demonstrated on the experimental scaled facility, the PAD sheet is efficient only when
it is positioned closed to the strip (~25 mm in experimental conditions, id est ~ 37.5 mm in industrial
conditions). On the Sagunto configuration, the PAD sheets are positioned at ~ 125 mm to the strip.
The recommendations to reduce strip vibrations are:
- to move the PAD sheets at a strip distance = 37.5 mm
or
- to remove the PAD sheets
The decision made by the line managers was to completely remove the PAD sheets, especially because
the whole plenums could not be move closer to the strip.
Nozzles staggering
The nozzles staggering has been identified as the major influent parameter and the easiest to
implement in industrial conditions. The recommendations are:
- to stagger all the nozzles of one plenum
or
- to stagger the nozzles with a half pitch, so that the impacting jets are impacting the strip from one
face to the opposite face on a symmetrical way
The decision has been made to stagger the 2 blowing boxes 1 & 2.
71
Pressure balancing between 2 opposite plenums
As detected within the task 3.1 bis (additional industrial trials to characterize the current vibrations
state on Sagunto line), a low pressure imbalance between 2 opposite plenums (until ~3 bar at 40 mbar,
id est 7.5 %) can induce a constant strip displacement and could provoke the strip instability ignition.
So that the negative effect of the opposite plenums imbalance can be multiplied if the same imbalance
is observed into the second cooling box.
The recommendations are:
to check the pressure balance between 2 opposite plenums, for both blowing box 1
and blowing box 2
to adjust the regulation loop, the verify the measurement sensors if needed
Final cooling design
Based on the common decision between all contractors, Drever has made the drawings of final cooling
design.
The plenums modifications include:
o
the complete removal of nozzles steel sheets on the plenum front,
the dismantling / reassembly of the guiding rolls
the dismantling / reassembly of the air inlet piping system
the dismantling / reassembly of the air exhaust piping system
the dismantling / reassembly of the fans motor support
the assembly of additional pieces manufactured by Drever to warranty the nozzles staggering
the reassembly of the nozzles and steel sheets on the plenum front
the adjustments on the plenum front to warranty the air tightness
It is important to precise that the current cooling tower configuration of Sagunto is adapted for a
galvannealed treatment, so that the blowing boxes are fully embodied into a closed casing, what makes
the modifications more difficult (difficult access for the pieces manufacturing, for operators, for the
pieces transport).
2.3.3.4. Task 3.2 - Assembly and adjustment of the improved cooling device in the industrial
line
Objective:
o
Cooling device assembly at the galvanizing line at ArcelorMittal Sagunto
Adjustments until the new cooling device is ready to run
72
Results:
The implementation of the new cooling design has been prepared many weeks before the yearly stop
line. The assembly of the new cooling technology took a few days and occurred with success. The
Figure 80 shows the results: nozzles are staggered; PAD sheets are removed into the two blowing
boxes.
Figure 80: the final configuration of the cooling tower at

Sagunto
Encountered difficulties during engineering investigations due to the existing line configuration
One major issue encountered during the engineering study of the blowing boxes revamping consisted
in respecting the staggering pitch of a half step. The distance between 2 nozzles is 400 mm, so that a
half step means 200 mm. The recommendations of the previous experimental investigations are to
respect a staggering step of 200 mm. In the specific case of Sagunto, because of non removable
mechanical parts positioned in the top-roll area, the staggering pitch was limited on 160 mm instead of
200 mm, as the Figure 81 sums it up.
73
Staggerin
g pitch =
200 mm
Staggerin
g pitch =
160 mm
RECOMMENDED
INDUSTRIALIZATION
Figure 81: the final configuration of the cooling tower at Sagunto
Figure 82: Picture taking during the

implementation of the innovative cooling
technology on the Sagunto cooling
tower: nozzles staggering, PAD
removal.
Adjustment of blowing pressure regulation

Based on the results of the trials campaign conducted within the task 3.1 and showing the impact of a
light imbalance between two opposite plenums at high blowing pressures, the pressure regulation
loops have been controlled and adjusted.
Indeed the light pressure imbalance in blowing boxes 1 & 2, observed are not due to possible
unsymmetrical air inlet pipes, what could induce differential pressure losses on one strip face
compared to the other. This hypothesis has been verified:
o
Both sides of fan inlet are symmetric (same design: duct length & size, elbow size, etc).
Both sides of fan outlet are symmetric (same design: duct length & size, elbow size,
etc).
Fans are identical
74
Pressure taps of both sides are symmetric (same taps position and pressure transmitter
located on tower platform at same altitude atmospheric reference pressure).
On other emitted hypothesis consisted on possible deviation of the pressure sensors. But the pressure
transmitters calibration shows no influence.
A cross-interlock has been introduced into the regulation software so that the pressure imbalance has
been immediately corrected as the Figure 83 shows it:
Figure 83: Screenshot of the blowing pressure balance

between plenums after regulation adjustments at Sagunto
The pressure imbalance was not detected before the line speed increase (tests at 150 m/min). Now
with the line speed increasing, both blowing boxes 1 & 2 are used at their full capacity. After
adjustment of the cross-interlock within the regulation software, the pressure imbalance has been
corrected (<< 0 mbar).
2.3.3.5. Task 3.3 - Preparation of industrial tests
Objective:
o
Elaboration of online tests to evaluate the performances of the new industrial cooling device in
standard conditions and in critical conditions (critical values of blowing and line process
parameters defined in the WP1)
Elaboration of the test procedures.
Results:
The trial plan has been built considering the previous characterization campaigns, in particular, the
strip format, steel grades, process parameters have been kept as much as possible identical as the first
trials campaign:
75
Figure 84: Identical product and process parameters during the trials campaigns on Sagunto line.
The trials have been conducted on standard production conditions for the strip formats: 1438 x 0.647
mm; 1829 x 0.636 mm and for 1561 x 0.79 mm whereas a specific strip format has been chosen to
evaluate the strip vibrations under critical conditions. Indeed this strip format is well-known by the
line operators to be very sensitive in terms of vibrations amplitudes.
The product and process parameters have been carefully chosen so that we aim to compare:
o
the benefits of the pressure regulation adjustments (campaign 2009 versus first campaign
2010)
the benefits of the new cooling design (campaign 2009 versus second campaign 2010)
The process parameters that we will make vary during the trials campaign will still be:
o
the effect of the blowing pressure in blowing Box 1 (pressure in box 2 is kept constant),
the effect of the blowing pressure in blowing Box 2 (pressure in box 1 is kept constant),
the effect of combined blowing pressure in blowing Box 1 + 2
For each trial, the strip position, standard deviation (or RMS) and peak-to peak values are measured.
The good preparation of the trials and the perfect coordination between all contractors ensures good
reproducible conditions with the previous trials campaigns.
76
2.3.3.6. Task 3.4 - Installation of vibrations online measuring systems
Objective:
o
Assembly of the industrial online measuring system of the strip vibrations. The control system
will continuously measure the strip-nozzles distance in the wiping zone (similar principle as
the experimental measuring system used for the analyses of the WP1). The industrial
measuring system should resist at the standard industrial conditions and will be connected to
the process control computer system.
Tests and adjustments
Results:
As it has been done for the previous trials campaign, an identical strip vibrations measurement system
has been installed at the wiping zone, just above the wiping nozzles. The system is still composed with
3 Kaman sensors across the strip width. The installation has been done with great care so that the
Kaman alignment is warranted.
A similar measurement device has been implemented at the top of the tower just under the blowing
nozzles.
The measurement devices positioning is kept identical as the one presented in the Figure 65.
2.3.3.7. Task 3.5 - Tests on industrial lines
Objective:
o
Based on the previous trials plan, measurements of the strip vibrations by varying the blowing
and process line parameters. Comparison with the results obtained with the experimental
improved cooling device.
Determination of the optimal industrial blowing and line process parameters (blowing
velocity, pressure, cooling device positioning)
Results:
o
Effect of blowing box 1
The effect of the blowing pressure of the cooling box 1 has been observed during the whole industrial
campaign on 2 strip formats. Results will be presented for 1 format only (1438 x 0.647 mm), id est for
2 days of continuous production in normal conditions (no stop lines, no process incident, constant line
velocity). The same tendencies have been observed for the second format (1829 x 0.636 mm). The
results of the strip vibrations measures at the wiping zone are shown hereafter (Figure 85 a) and b)) as
well as at the top of the cooling tower (Figure 86 a) and b)). The trial campaign after modification is
presented in full curves.
The dotted curves represented the vibrations reference before modifications (trials campaign of 2008).
77

effect of box 1 - SD

effect of box 1 - Peak-Peak
KAM AN
ET rive cabin 08
KAM AN
ET centre 08
KAM AN
ET halle 08
KAM AN
ET cabin 10
KAM AN
ET centre 10
KAM AN
ET hall 10
2,5
1,5
KAM AN
M ax PP 08
20,5
15,5
10,5
KAM AN
max PP 10
5,5
0,5
0,5
0
10
20
30
40
50
10
20
30
40
50
pressure box 1 (mbars)
Figure 85: Effect of the blowing pressure on blowing box 1 (inferior) on strip vibrations at the wiping zone
Sagunto line after modification (full curves). Comparison with the reference trials conducted on 2008 (dotted
curves).
a) Standard deviation; b) Peak to peak amplitudes
The blowing box 1 is generating more vibrations at the wiping zone after the modification of the
cooling design than the reference case (campaign of 2008 on strip format 1438 x 0.647 mm). More
especially, the increase of the blowing pressure makes increase the vibrations amplitudes on the strip
edges (at cabin edge and at the motor edge) at the wiping zone whereas the vibrations at the strip
centre are quite low and stable after modifications, whatever the blowing pressure is (Figure 85 a). The
peak-to-peak measurements (Figure 85 b) show the same tendency: until a blowing pressure of 20
mbar, maximal vibrations amplitudes are quasi equivalent before and after the modification.
Vibration amplitude under cooling boxes


5,5
LASER
ET rive cabin 08
LASER
ET centre 08
LASER
ET halle 08
LASER
ET cabin 10
LASER
ET cent 10
KAM AN
ET hall 10
5,0
4,5
4,0
3,5
3,0
2,5
2,0
1,5
1,0
0,5
0
10
20
30
40
45,5
40,5
LASER
M ax PP 08
35,5
30,5
25,5
20,5
15,5
LASER
max PP 10
10,5
5,5
0,5
0
50
10
20
30
40
50
Figure 86: Effect of the blowing pressure on blowing box 1 (inferior) on strip vibrations at the top of the cooling
tower on Sagunto line after modification (full curves). Comparison with the reference trials conducted on 2008
(dotted curves).
We observe different phenomena at the top of the cooling tower (Figure 86 a) and b)). The standard
deviation at the strip centre reduced after the modification, whatever the blowing pressure is. On the
contrary, the standard deviations at the strip edges are continuously increasing with the blowing
pressure: the standard deviation after modification is significantly higher on the strip edges than the
initial state.
The Figure 83 b) shows the averaged peak-to-peak measurements between the 3 laser measurements.
The curves show the same tendency: at high pressure (40 mbar), the maximal vibrations amplitudes
78
can reach 35.5 mm. Based on the confrontation of the 2 measurements (standard deviation on 3 points
and averaged peak-to-peak), we can conclude that the strip edges generate high vibrations amplitudes
on the top of the cooling tower.
The averaged vibrations amplitudes are quasi equivalent before and after the modifications of the
cooling technology. The strip edges seem to be very sensitive on the pressure of the blowing box 1 and
generate high amplitudes also after the modification. On the contrary, the strip centre seems to be
more stable after the modification.
Effect of blowing box 2
The effect of the blowing pressure of the cooling box 2 has been observed during the whole industrial
campaign on 2 strip formats. Results will be presented for 1 format only (1438 x 0.647 mm), id est for
2 days of continuous production in normal conditions (no stop lines, no process incident, constant line
velocity). The same tendencies have been observed for the second format (1829 x 0.636 mm). The
results of the strip vibrations measures at the wiping zone are shown hereafter (Figure 87 a) and b)) as
well as at the top of the cooling tower (Figure 88 a) and b)). The trial campaign after modification is
presented in full curves.
The dotted curves represented the vibrations reference before modifications (trials campaign of 2008).


KAM AN
ET rive cabin 08
KAM AN
ET centre 08
2,5
1,5
KAM AN
M ax PP 08
20,5
KAM AN
ET halle 08
KAM AN
ET cabin 10
KAM AN
ET centre 10
15,5
10,5
KAM AN
max PP 10
5,5
KAM AN
ET hall 10
0,5
0,5
0
10
20
30
40
50
10
20
30
40
50
Figure 87: Effect of the blowing pressure on blowing box 2 superior) on strip vibrations at the wiping zone
curves).
The blowing box 2 is not generating more vibrations at the wiping zone after the modification of the
cooling design than the reference case (campaign of 2008 on strip format 1438 x 0.647 mm).
Whatever the blowing pressure is until 40 mbar, the standard deviations of the 3 Kaman measurements
show a reduction of vibration of ~ 10 to 25 % between the initial state and the state after
modifications. During the trial, a specific test has been conducted at the maximal fan power 45mbar.
The standard deviations at this pressure are globally equivalent. The Figure 88 b) confirms the
previous observations.
79


effect of box 2- Peak-Peak
5,5
4,5
4,0
3,5
3,0
2,5
2,0
1,5
1,0
45,5
40,5
30,5
25,5
20,5
15,5
10
20
30
40
LASER
max PP 10
10,5
5,5
0,5
0,5
0
LASER
M ax PP 08
35,5
PP (mm)
LASER
ET rive cabin 08
LASER
ET centre 08
LASER
ET halle 08
LASER
ET cabin 10
LASER
ET cent 10
KAM AN
ET hall 10
5,0
50
10
20
30
40
50
Figure 88: Effect of the blowing pressure on blowing box 2 (superior) on strip vibrations at top of the cooling
tower at Sagunto line after modification (full curves). Comparison with the reference trials conducted on 2008
(dotted curves).
We can observe similar phenomena at the top of the cooling tower. The laser measurements shows on
Figure 88 a) an improvement of the strip centre vibrations whatever the pressure is, whereas the strip
edges are more sensitive to vibrations after the modifications. Figure 88 b) shows a global
improvement of the strip stability after the modifications excepted for the exceptional pressure of 45
mbar.
The blowing box 2 is not generating vibrations. The modifications of the blowing design seem to have
a positive effect on the strip stabilization, especially for the strip centre. The edges effect is still
observed: the strip edges are very sensitive to vibrations even if we were careful to select the same
steel grade and strip format for both trials campaigns.
Effect of combined blowing boxes 1 + 2
The effect of the combined cooling box 1 and cooling box 2 has been observed in the same conditions.
Please, note that the pressures in boxes 1 and 2 are increasing in identical proportions.
effect of boxes 1+2 - SD
2,5

effect of box 1 + 2 - Peak-Peak
KAM AN
ET rive cabin 08
KAM AN
ET centre 08
KAM AN
ET halle 08
KAM AN
ET cabin 10
KAM AN
ET centre 10
1,5
20,5
KAM AN
M ax PP 08
15,5
10,5
KAM AN
max PP 10
5,5
KAM AN
ET hall 10
0,5
0,5
0
10
20
30
40
50
pressure box 1 et 2 (mbars)
10
20
30
40
50
pressure box 1 & 2 (mbars)
Figure 89: Effect of the combined blowing pressure on blowing box 1 (inferior) and box 2 (superior) on strip
vibrations at the wiping zone on Sagunto line after modification (full curves). Comparison with the reference
trials conducted on 2008 (dotted curves).
80
At the wiping zone, whatever the blowing pressure in both boxes 1 and 2 is, the standard deviation at
the strip centre is improved after the cooling technology modifications (Figure 89 a) light green curve
compared to the violin curve). The standard deviations on strip edges are lightly increasing after the
modifications. One hypothesis could be the effect of existing long edges that we cannot easily detect
on this industrial line.

effect of box 1 & 2 - SD

effect of box 1 & 2- Peak-Peak
5,5
LASER
ET rive cabin 08
LASER
ET centre 08
5,0
4,5
4,0
45,5
40,5
3,0
2,5
2,0
1,5
30,5
25,5
20,5
15,5
0,5
0
10
20
30
40
LASER
max PP 10
10,5
KAM A N
ET hall 10
1,0
LASER
M ax PP 08
35,5
LASER
ET halle 08
LASER
ET cabin 10
LASER
ET cent 10
3,5
5,5
0,5
50
10
20
30
40
50
vibrations at the top of the cooling tower on Sagunto line after modification (full curves). Comparison with the
reference trials conducted on 2008 (dotted curves).
The Figure 90 b) shows the negative effect of the simultaneous increase of the blowing pressure in the
both blowing boxes 1 and 2. At 40 mbar, the peak-to-peak amplitudes increased by 10 mm after the
modifications.
However, the detailed measurements on the 3 lasers positioned across the strip show clearly the strip
edges effect: the dark green (hall side) and kaki curves (cabin side) of Figure 90a) are
systematically shifted by ~1 mm compared to the light green curve (strip centre).
The pressure increase of combined blowing 1 and 2 generates light higher vibrations amplitudes after
the modifications of the cooling design. One explanation could be the existing strip edges effect,
which we observe at the wiping zone as well as at the top of the tower. If we focus the observation on
the strip centre and the wiping zone only, the positive effect of the modification is more convincing: at
20 mbar, reduction of the standard deviation from 1.7 mm before the modification to 1.4 mm after the
improvement.
Conclusion of the trial campaign after the implementation of the cooling

technology improvement
We took specific care in preparing the trials campaigns in the 3 past years (campaigns from 2008 to
2010:
o
on selected product (steel grades and product properties, formats, zinc coating weight,
product aspect and quality at the line entry),
on process parameters (line speed, wiping parameters, bath material, strip tension)
on measurement systems (Kaman sensors, laser sensors, acquisition system, frequent

calibration, alignment).
81
The trials conditions are reproducible, the measurement procedure is robust.
However, the comparison of the initial trials campaign before modification and the trials campaign
after modification of the blowing technology shows disappointing results compared to the expectations
from the experimental characterization campaign:
o
The effect of the blowing box 1 is negative for high blowing pressures at the wiping zone as
well as at the top of the cooling tower, whatever the pressure is. A light improvement is
observed at the strip centre.
The effect of blowing box 2 is more positive. The modifications of the blowing design seem
to have a positive effect on the strip stabilization, especially for the strip centre. The edges
effect is still observed: the strip edges are very sensitive to vibrations even if we were careful
to select the same steel grade and strip format for both trials campaigns.
The effect of combined blowing boxes 1 & 2 generates high vibrations amplitudes at the strip
edges.
To explain the vibrations amplitudes at the strip edges, we can highlighted the hypothesis that the
strips selected for the trials are impacted by an edges effect, what means that the strip edges are
elongated compared to the strip centre. This unsymmetrical strip profiles is negative for the strip
stabilization along the whole cooling tower due to the non-optimisation of the strip tension across its
width.
More generally and even the strip edges effect, the vibrations amplitudes at the wiping zone as well at
the top of the cooling tower are higher than the minimal expected benefits of the proposed innovative
technology ( 3.3.2.5.7 influence of staggered arrangement). Indeed the nozzles staggering should
have reduced the vibrations amplitudes (peak-to-peak) at the top of the cooling tower by a factor 4.
This is not the case.
From the industrial point of view, if the vibrations amplitudes have not been significantly reduced
(expected factor 4), the averaged vibrations amplitudes are quasi identical as the initial state (trials
campaign of 2008, 2009 and 2010 before modifications). The modifications of the cooling
technologies do damage neither the productivity nor the product quality.
However, we all together listed hypothesis to verify in order to explain the discrepancies between the
experimental results conducted on the semi-experimental device and the industrial configurations (see
the following task 3.6).
2.3.3.8. Task 3.6: Optimisation of the industrial cooling device
Objective:
o
Optimisation of the improved cooling device in terms of blowing parameters to minimize or

even cancel strip vibrations in standard industrial conditions.
82
Results:
Based on the results presented in the previous paragraph, all the contractors worked on establishing a
list of hypothesis to be verified, in order to explain the discrepancies between expectations and real
benefits and to be able to propose improvements.
2 work axes have been commonly defined:
- Axis 1: to verify the trials conditions and the modifications done
- Axis 2: to understand the discrepancies between experimental approach and industrial conditions.
Within the work axis 1, we defined 11 hypotheses that we verified. The following table (Figure 91)
sums up the hypothesis and the checks that we carried out. When more investigations are needed the
action plan is also mentioned.
Figure 91: list of hypotheses to be checked to explain the discrepancy between expected gains and real
measurements
83
After verifying each hypothesis, we selected the three following probable hypotheses to be
investigated more in details:
o
Hypothesis N1:
o
Hypothesis N3:
o
the staggering pitch of a 1/2 step is not respected on industrial conditions (160 mm
instead of 200 mm requested)
the confinement due the galvannealed tower configuration influences the fluid flows
in the strip neighbourhood and generates vibrations. In that case, the confinement
would be an order 1 influencing parameter before the nozzles staggering.
Hypothesis N5:
o
the orientation of the previous PAD nozzles influences the impinging flows on the
strip surface and generates vibrations
To better understand why the modifications on the cooling equipment did not conduct to the reduction
by a factor 4 of the strip vibrations amplitudes, we decided to conduct further trials on the
experimental pilot facility.
o
1st additional trial campaign: Influence of the PAD nozzles
orientation
Trials conditions:
As the previous trials campaign on the scaled guiding pilot, trials conditions are:
o
Strip: 0.25 mm x 950 mm
Distance between strip and nozzles: from 25 to 100 mm
Blowing width is 1400 mm.
Specific tension: 1.8 kg/mm
Measurement: 3 laser across the strip width
Acquisition time: 3 min
84
Tested configurations:
Figure 92: Four different configurations have been tested to determine the effect of the PAD Nozzles orientation:
a) initial design with oriented PAD nozzles but without PAD sheets; b) straight nozzles; c) the initial design a)
is staggered; d) the design b) straight nozzles is staggered
The comparison between the configurations C) staggered initial design with oriented PAD nozzles
and D) classical straight nozzles (Figure 92) will answer to the question: Do the oriented PAD
nozzles influence the vibrations amplitudes?
The configuration A) is equivalent to the Sagunto design after removing all PAD sheets and
configuration C) is equivalent to the Sagunto design after modification. The comparison between A)
and C) will answer to the question: do the staggered oriented PAD nozzles increase the vibrations
amplitudes ?
Results:
Configuration
A
Configuration
B
Configuration
C
Configuration
D
P = 40
mbar
50 mm
85 mm
30 mm
25 mm
P = 60
mbar
75 mm
Out of
measurement
range
amplitudes too
high
38 mm
35 mm
Figure 93: Example of averaged peak-to-peak measurements (for the 3 laser) for a strip-to-nozzle distance = 67
mm (= 100 mm for industrial conditions) and for 2 pressures: 40 and 60 mbar.
85
Figure 94: Example of the detailed curves of the averaged peak-to-peak measurements (for the 3 laser) and for 3
different strip-to-nozzle distances =25, 67, 100 mm on configurations C) = staggered standard design without
PAD sheet and D) = staggered straight nozzles
Based on the Figure 94, it is easy to conclude that the order 1 stabilizing parameter is the nozzles
staggering, whatever the PAD nozzles are oriented or not. The comparison between C) and D) shows
quasi no effect of the oriented nozzles at high pressure (60mbar). The comparison between A) and C)
shows the staggering effect of the oriented nozzles: ~factor 2 on the peak-to-peak measurements at
high pressure (60 mbar).
On experimental conditions, the PAD nozzles orientation increases the strip stabilisation as well as the
straight nozzles staggering. This hypothesis cannot be kept to explain the phenomena observed at
Sagunto line.
o
2nd additional trials campaign: Influence of the confinement of the
cooling technology due to galvannealed configuration
Trials conditions:
As the previous trials campaign on the scaled guiding pilot, trials conditions are:
o
Strip: 0.25 mm x 950 mm
Distance between strip and nozzles: 67 mm
Specific tension: 1.8 kg/mm2
86
The following figure (Figure 95) describes the tested confined configuration. As much as possible, the
confinement has been done to reproduce the closed galvannealed cooling tower.
strip
Plenum (SIDE VIEW)
Plenum (TOP VIEW)
Lateral air exhaust

hole (open or closed)
Total
confinement of
the
blowing
Lateral air exhaust
hole (open or closed)
Total confinement of
the blowing boxes
Figure 95: Diagram of the tested confined configuration on the experimental facility. On the left, the diagram is
from the top view; on the right from the side view.
Results:
strip displacement standard deviation (mm
45
40
standard deviation (mm) - no confinement + PAD sheet

standard deviation (mm) - no confinement + no PAD sheet
standard deviation (mm) - confinement + PAD sheet
standard deviation (mm) - confinement + no PAD sheet
standard deviation (mm)- confinement total + PAD sheet
standard deviation (mm) - confinement total + no PAD sheet
strip (cabin edge)

strip (cabin edge)
strip (cabin edge)
strip (cabin edge)
50
45
strip (center)
strip (center)
strip (center)
strip (center)
strip (center)
strip (center)
50
35
30
25
20
15
10
5
40
standard deviation (mm)

- no confinement + PAD sheet

- no confinement + no PAD sheet
- confinement + PAD sheet
- confinement + no PAD sheet
strip (cabin edge) standard deviation (mm)- conf inement total + PAD sheet
strip (cabin edge) standard deviation (mm) - confinement total + no PAD sheet
35
30
25
20
15
10
5
10
20
30
40
50
60
70
80
90
10
20
30
40
50
60
70
80
90
Figure 96: Standard deviation of the strip displacement for configurations with and without confinement. Curves
on the left show the standard deviation for the strip centre whereas the curves on the right show the standard
deviation for the strip edges.
On the Figure 96, the yellow, red and pink curves represent the trials carried out with the PAD sheets,
whereas the blue and green curves represent trials without the PAD sheets. To quantify the effect of
87
the confinement, we have to compare on both diagrams the yellow curve with the red one and the
green curve with the blue one.
It is clear to see that the confinement has no effect on the strip stabilization.
Intermediate conclusion: the confinement has no effect on the strip stabilization
o
3rd additional trials campaign: Influence of the unsymmetrical
nozzles staggering
Trials conditions:
On the contrary to the previous trials campaign on the scaled guiding pilot, trials conditions are:
o
Shorter steel sheet ( ~2 m) instead of a strip (9 m)
0.25 mm x 950 mm
Distance between strip and nozzles: from 50 mm to 100 mm
Specific tension: 40 kg/mm2
B
<
pitch
pitch
Figure 97: 3 different tested configurations to evaluate the effect of the unsymmetrical nozzles staggering:
A) configuration of 2 x 2 facing straight nozzles
B) configuration of 2 x 2 staggered nozzles with a pitch (= symmetrical nozzles staggering)
C) configuration of 2 x 2 staggered nozzles with a pitch < pitch (= unsymmetrical nozzles
staggering)
88
The configuration A) (Figure 97) corresponds to the initial configuration of Sagunto; the configuration
B) corresponds to the recommended nozzles staggering, whereas the configuration C) corresponds to
the implemented configuration at Sagunto cooling boxes. The comparison between the 3 trials should
answer to the question: does the unsymmetrical nozzles staggering influence the strip stability?
Results:
The trials have been conducted within an internal ArcelorMittal research program, so that the trials
have been done out of the contractual technical program (> July 2010).
Moyenne Ecart-type - 2 buses en vis--vis // Dbb = 50-75-100

mm
0,50
0,45
0,40
[mm]
0,35
0,30
50,00
0,25
75,00
0,20
100,00
0,15
0,10
0,05
0,00
0,00
10,00
20,00
30,00
40,00
50,00
60,00
70,00
80,00
[m bar]
Moyenne Ecart-type - 2 buses quinconce // Dbb = 50-75-100 mm

0,50
0,45
0,40
[mm]
0,35
0,30
50,00
0,25
75,00
0,20
100,00
0,15
0,10
0,05
0,00
0,00
10,00
20,00
30,00
40,00
50,00
60,00
70,00
80,00
[m bar]
Moyenne Ecart-type - 2 buses en semi-quinconce // Dbb = 50-75100 mm
0,50
0,45
0,40
[mm]
0,35
0,30
50,00
0,25
75,00
0,20
100,00
0,15
0,10
0,05
0,00
0,00
10,00
20,00
30,00
40,00
50,00
60,00
70,00
80,00
[m bar]
89
Figure 98: Standard deviation of the strip position

measured for the 3 configurations A) B) C).
Average of the 5 laser signals measuring the strip
position across the width. The blowing pressure is
increasing from 20 to 70 mbar. 3 strip-to-nozzles
distances have been tested: 50, 75 and 100 mm.
Moyenne Pic Pic - 2 buses en vis--vis // Dbb = 50-75-100 mm
10,00
9,00
8,00
[mm]
7,00
6,00
50,00
5,00
75,00
4,00
100,00
3,00
2,00
1,00
0,00
0,00
10,00
20,00
30,00
40,00
50,00
60,00
70,00
80,00
[m bar]
Moyenne Pic Pic - 2 buses quinconce / Dbb = 50-75-100 mm

10,00
9,00
8,00
[mm]
7,00
6,00
50,00
5,00
75,00
4,00
100,00
3,00
2,00
1,00
0,00
0,00
10,00
20,00
30,00
40,00
50,00
60,00
70,00
80,00
[m bar]
Moyenne Pic Pic - 2 buses en semi-quinconce // Dbb = 50-75100 mm
10,00
9,00
8,00
[mm]
7,00
6,00
50,00
5,00
75,00
4,00
100,00
3,00
2,00
1,00
0,00
0,00
10,00
20,00
30,00
40,00
50,00
60,00
70,00
Figure 99: Peak-to-peak measurements of the strip

position measured for the 3 configurations A) B)
C). Average of the 5 laser signals measuring the
strip position across the width. The blowing
pressure is increasing from 20 to 70 mbar. 3 stripto-nozzles distances have been tested: 50, 75 and
100 mm.
80,00
[m bar]
The graphs 98 and 99 show respectively the standard deviation and the peak-to-peak amplitudes of the
strip vibrations for the 3 configurations mentioned here above. The blowing pressure has been made
varied from 20 to 70 mbar, whereas the strip to nozzles distance has been made varied from 50 mm
to 100 mm. The trials conditions are similar for the 3 tested geometrical blowing configurations.
The comparison of the 3 graphs does not show a clear effect of the unsymmetrical nozzles staggering
on the strip vibrations.
The unsymmetrical nozzle staggering has no clear effect on the strip vibration.
90
2.3.3.9. Task 3.7: Synthesis
Objectives:
o
Elaboration of the operating industrial procedures
Quantification of the innovative cooling device performances in industrial conditions
Elaboration of the recommendations to transpose the innovative cooling device to others

typical cooling devices used at industrial galvanizing lines
Global synthesis of the project
If the experimental approach conducted on a 2/3 scaled pilot facility allow us to design an improved
cooling device reducing the strips vibrations by a factor 4, its adaptation on the industrial conditions of
the Sagunto line appears disappointing.
Results:
o
Operating industrial procedures
During the yearly line stop of the Sagunto line, the blowing boxes at the top of the cooling tower have
been entirely removed after the galvannealed casing has been opened. This delicate procedure
includes:
o
the guiding removal to have an access to the blowing boxes
the complete removal of the PAD sheets (unsoldering operations in extreme confined
conditions)
the complete removal of the plenums front sides composed with the nozzles
the removal of the plenum to be staggered
the removal of the ducts and pipes feeding the plenums
After the cleaning operations, the assembly operations can start, including following tasks:
o
the assembly of the staggered plenums and nozzles taking into account the mechanical
constraints due to existing platform and fans motors
the assembly of the ducts and pipes
the adaptation to warranty the plenums tightness
the assembly of the guiding rolls
the verification of the strip pass line
the assembly of the casing
the mechanical tests to ensure the structure holding
Re-start tests have been conducted with an incremental approach: from low blowing pressure to
maximal, whereas the measurement systems have been implemented at the wiping zone and on the top
of the tower.
91
Quantification of the innovative cooling device performances in industrial conditions
Based on the trials campaigns conducted after the implementation, the innovative cooling technology
does not show significant improvement in terms of strip stabilisation. Even if the strip centre seems to
be more stable after the modification, the long edges effect remains on both strip edges, so that the
global impression is neither optimistic nor pessimistic. The product qualities as well as the
productivity have not been impacted by the implementation. No clear impact on the Zinc coating
homogeneity at the wiping zone has been observed; so that the expected gains in terms of zinc saving
could not be observed.
Recommendations to transpose the innovative cooling device to others typical cooling

devices used at industrial galvanizing lines
Even if the implementation at Sagunto line is in discrepancy with the expected gains, the transposition
to others industrial galvanizing lines started.
2.3.3.10. Global synthesis: Transferability to others concerned lines
The results obtained in this study for the control of strip vibrations are progressively used in the new
Drever International galvanizing and annealing lines. Taking into account the time required between
the new cooling design and the industrial start of each line, 5 new lines have been started in China
equipped with the new cooling design:
o
2 galvanizing lines and 1 annealing line in ShunYi (Beijing) for Shougang company
1 galvanizing line and 1 annealing line in Wuhan, for Wisco company (Cold Rolling Mill 3)
On a paralleled way, R&D studies are also performed by Drever International on detailed design
improvements of multi-jets cooling equipments. These activities ensure Drever to develop optimised
technology, the Ultra Fast Cooling (UFC) System, combining high cooling performances and control
of strip vibrations.
To illustrate the performances of these new lines, the results obtained in the cooling zones in the tower
of galvanizing lines and in the rapid cooling section of galvanizing and annealing lines are presented.
2.3.3.10.1.
Transfer to cooling tower of other galvanizing lines
The Figure 100 shows one of the two Shougang ShunYi galvanizing lines.
The Shougang ShunYi CGL N1 is equipped with a vertical annealing furnace, galvannealing soaking
furnace, after pot cooling, final cooling and water tank. This line is designed to process cold rolled
strips for the production of galvanized sheet for the automotive industry (steel qualities from CQ to
DP-HSS 780 and TRIP-HSS 780, both GA and GI). The strip width range is 800 1870 mm and the
thickness range is 0.4 2.5 mm. The maximum line speed is 180 m/min. The annual production is
475,000 tons.
In the after-pot cooling section, staggered nozzles (straight nozzles and PAD nozzles without PAD
sheet) are used, as presented for the pilot line and as used in the modified Sagunto line. In the
Shougang CGL, there are no rolls to stabilize the strip and no casing surrounding the plenums. So, the
recommendations of the project are transferred to this industrial configuration.
92
Figure 100: Sketch of the Shougang ShuYi CGL N1
No laser measurement could be performed in the Shougang after-pot cooling zone because of
confidentiality reason.
The exploitation of the continuous coating thickness measurement could not be possible to quantify
the effect of strip stabilization in terms of coating uniformity across the strip width as well along the
strip length (waviness). As the Figure 101 shows it, we were able to collect only punctual pictures of
the coating weight cartography across the strip width, what is not enough to conduct statistics.
Figure 101: Zinc coating weight

repartition across the strip width
at Wisco CGL
93
However, the visual control of strip vibrations is very good as the Final Acceptance Tests (FAT) have
been successfully passed for this line.
The Ultra Fast Cooling system that equipped the Shougang CAL line is similar to the one installed
into the Shougang CGL. The main lines and products characteristics are presented into the Figure 99.
The Final Acceptance Tests report of the Shougang CAL mentioned clearly that the cooling equipment
is able to achieve high cooling rates at high blowing velocity by:
o
Very low strip to nozzles distance (74 mm, 55 mm, 46 mm)
Opened guiding rolls and high line speed (~ 200 m/min)
By 20% H2 and high pressure (10kPa)
Without vibrations.
Indeed the vibrations are recorded by a video camera located between 2 cooling boxes of the rapid
cooling section (see Figure 100). In addition, the inspector (automatic marks detector) located at the
exit of the line systematically did not detect any defects at the strip surface generated by potential strip
to nozzles contacts due to high vibrations amplitudes. Those trials have been carried out on about 40
coils.
The tests of vibrations show that the strip processed through the furnace without touching the blowing
nozzles by a maximal pressure of 11 kPa (= maximal pressure delivered by the blowing fan). No
marks have been detected, what proves the efficiency of the innovative cooling technology in terms of
strip stabilization in hard process conditions (confinement, high temperature range, low strip to
nozzles distance, etc.).
Same good results in terms of control of vibrations are obtained for the Wisco galvanizing line with
the same design.
2.3.3.10.2. Transfer to rapid cooling sections of other galvanizing lines and continuous
annealing lines
As mentioned previously, the Shougang continuous annealing line N1 (CAL N1) and the Shougang
galvanizing line N1 (CGL N1) are equipped with the new Ultra Fast Cooling Technology. It is also
the case for the new Wisco continuous annealing line.
The Shougang CAL N1 and CGL N1 rapid cooling sections contain three zones, the two last zones
having a shorter length than the first one. To get the highest cooling performances, only the two shortlength zones are used. Figure 102 gives the characteristics of the production, the hydrogen content in
the rapid cooling section, the cooling length and the strip cooling temperature range. The cooling rate
is expressed in C/s for a strip thickness of 1 mm. The table presents the excellent cooling
performances of the Ultra Fast Cooling System: 101.6 C/s.mm for the CAL N1 and 112.4 C/s.mm
for the CGL N1.
94
Line
Strip Thickness
Strip width
Steel grade
Line speed
Production
LSD
RCS Hydrogen content
Cooling length
Entry Temperature
Exit Temperature
mm
mm
m/min
T/h
mm*m/min
%
m
C
C
CAL N1
CGL N1
1.8
1260
DP 590
90
96
162.0
22.0
10.6
700
301
1.48
1253
CQ
95
83
140.6
20.0
5.35
714
457
Cooling rate for 1 mm thick

C/s
101.6
112.4
Figure 102: Ultra Fast Cooling performances for Shougang ShunYi CAL N1 and CGL N1
In order to get these excellent cooling rates, the Ultra Fast Cooling technology developed by Drever
and based on the nozzles staggering by a half pitch uses the following features:
o
high hydrogen content in the cooling zone,
high plenum pressure (up to 10 kPa), i.e. high gas speed,
short plenum-strip distance, e.g. 30-40 mm
This means that a very good control of strip vibrations is required for this technology using high gas
speed and short plenum-strip distance. Straight nozzles in staggered configuration are used in the Ultra
Fast Cooling system. No scratch on the strips is observed during our tests and by Shougang in these
lines, demonstrating the very good performances of the design in terms of strip vibrations control.
Figure 103: Zoom of the Ultra Fast Cooling in Shougang CAL (from video camera records)
Same good results in terms of control of vibrations for the Ultra Fast Cooling technology are obtained
for the Wisco galvanizing line and continuous annealing line with the same design.
95
3. CONCLUSION
3.1. SCIENTIFIC AND TECHNICAL APPROACH
The project has been divided in 3 approaches: industrial approach, scientific and theoretical approach
and experimental approach.
3.1.1. Industrial approach

Because we changed one contractor, we finally conducted strip vibrations characterization on two
different industrial lines: Ghent #3 (WP1) and Sagunto (WP3) HDG lines. Both have been equipped
with experimental measurements to analyse on long periods the strip vibrations in the cooling zone to
connect the strip behaviour with some process parameters.
The identification and characterization of the major influent line and blow parameters have been done
during the trials campaign at Ghent and confirmed during the trials campaign at Sagunto:
Order 1 effect of the blowing pressure and blowing velocity
Effect of the pressure balance in the opposite blowing boxes
Order 1 effect of the strip tension
No effect of the line speed (if the blowing power regulation loop is de-correlated to the line
speed)
The good understanding and dynamism between all the parties allow to collect the required data to
design the experimental 2/3 scale cooling device able to reproduce the strip vibrations characterized on
industrial conditions. The trial campaigns conducted on both lines were also the opportunity to collect
database to validate and to fit the theoretical vibrations model.
To answer to the question: How do the vibrations appear and how they can be minimized?, two
complementary approaches were proposed. The first one consists in using the experimental 2/3 scale
cooling device to define a new cooling geometry reducing strip vibrations and the second approach
consists in testing the new solutions with a theoretical model.
3.1.2. Experimental approach

The 2/3 scaled experimental pilot has been designed and optimised to reproduce the strip vibrations
phenomena observed on the industrial line, especially the vibrations modes and frequencies, and the
vibrations amplitudes could have been reproduced. We developed a reliable experimental tool to
investigate in controlled conditions (strip tension for example):
the influence of the blowing parameters:
Blowing distance
Blowing width;
97
The influence of the geometry parameters:
Nozzle assembly geometry
Plenum geometry
PAD sheet
The influence of the process parameters:
Line velocity
Strip tension
The influence of the product properties:
Thickness and width
Grade
In addition, dedicated measurements have been developed and used to characterize the effect of the
blowing and geometrical parameters. As an example, the hot wire technique has been used to
characterize with high reliability the jets velocity at the exit of the nozzles.
Starting from the database of the measurements of strip vibrations done in the exhaustive trials on pilot
facility and thanks to expert knowledge, we propose a theoretical model able to predictive the strip
instabilities.
Further trial campaigns on the experimental pilot allowed to validate and to fit the model.
3.1.3. Scientific and theoretical approach

In order to understand and predict the physical mechanisms of strip vibrations, a parallel theoretical
approach is necessary. The questions to answer are: What are the physical mechanisms which control
the vibratory behaviour in a gas jets cooling system? What type of interactions exists between fluid
and structure?
To predict the strip instabilities, the theoretical model of strip vibrations has been developed in
collaboration with a subcontractor of ArcelorMittal Research. The objective of this collaboration is to
determine some major characteristics of the flow instability, like the Reynolds Number Re.
Observations have been done on laboratory with a rigid plan mounted in such a way that it allows
rotational and translational motions, with one or two air jets normal to the plan. It was possible to
identify the configurations leading to instability.
Specific measures have been conducted to characterize the vibration eigenmodes (stiffness, frequency,
damping). The strip vibration mechanisms under the gas jets cooling system have also been identified:
o
Vibrations due to recirculation loops between jets
Vibrations due to turbulent flows
Vibrations due to aeroelastic forces coupling inducing dynamical instability
More specifically a physical model has been developed to predict the vibrations due to aeroeleastic
forces because it is the most damaging instability mechanism (contact strip-nozzle).
98
The trials campaign conducted on the experimental pilot facility under controlled conditions allowed
validating the stability / instability predictive model.
The combination of these two complementary approaches allowed defining the new cooling
technology implemented on the production lines.
3.1.4. Innovative content

The innovative part of the project consists in improving the existing cooling device to achieve higher
line speeds and higher competitiveness.
1.
A first project innovation consists in a detailed analysis of the strip vibrations induced
by industrial gas jets cooling equipments. The project provides an exhaustive characterization
of the vibration amplitudes and frequencies due to the cooling boxes. The influence of the
strip format and the major process parameters has been clearly identified. This task allows
working later at the experimental device in very close conditions to industrial lines (strip size,
line speed, strip tension, blowing pressure, etc.) including:
o
The mastering of all process parameters,
The possibility to test easily design modifications of the cooling equipment
The measurement facilities (strip displacements at different points, gas flow analysis).
The transfer of phenomena characterized in industrial conditions to an experimental facility is

an innovation by itself.
2.
This project is innovative for a second reason: this is the first time that an
asymmetrical slots cooling device is implemented on an ArcelorMittal line (Sagunto). The
innovation is actually an improvement of the existing equipment and consists in breaking the
symmetrical structure of the cooling device, which improves the distribution of the jets gas. It
suppresses the coupling effect of opposite gas jets and reduces the vibrations phenomena.
The principles of nozzles staggering, PAD sheets removal, closer strip-to-nozzles distance,
have been deployed and reinforced by the partner Drever through a new cooling equipment
called Ultra Fast Cooling. This equipment is dedicated to the rapid cooling sections of HDG
and CAL lines working under protective atmosphere (Cooling Rate of 118C/s for a strip
thickness of 1 mm). The Ultra Fast Cooling has been implemented on many new industrial
lines around the world (Shougang, Wisco) reducing the vibrations and consequently
improving the productivity and the coating high-quality. According to the Final Acceptance
Tests report, the customers are very satisfied. In this sense, the proposed technology is a
successful innovation.
3.
At least, the major project innovation consists in understanding, identifying and
modelling the mechanisms of strip vibration phenomena generated by the gas jets of the
industrial cooling equipments. The previous work of transferability and reproducibility of the
online observed vibrations to the semi-industrial experimental device makes those
investigations possible.
For the first time it appears clearly that the strip instability phenomena can be classified in 3
families depending on the forces exerted on the structure:
o
quasi periodical forces due to recirculation loops between jets
turbulent flows forces
99
forces due to aeroelastic coupling producing the strongest damages on the coating
quality.
With the help of an expert team (sub-contractor), we built a physical model able to predict the
strip stability / instability depending on the process conditions (gas pressure, nozzle design
and nozzle configurations, strip-to-nozzles distance). We validated the theoretical approach
on the semi-industrial pilot facility. The results show very encouraging results: vibrations
mode can be predicted, as well as vibration amplitudes. The approach of coupling phenomena
between the gas pressure and the structure behaviour is a new approach on HDG lines. A
physical model able to take into account the impact of the gas pressure field on the steel
surface and the impact of strip reactions on the gas flows, on a weak way is an innovation.
The model has been reinforced by various industrial configurations (Ghent and Sagunto) and this is
the first time that this theoretical approach is used for galvanizing lines. Publications have been
written and presented during conferences to communicate these achievements [1-4, 25-26].
3.1.5. Industrial interest and scientific / technical prospects

Two complementary approaches have been proposed. The first one consisted in using the experimental
2/3 scale cooling device to define a new cooling geometry reducing strip vibrations and the second
approach consists in understanding the strip vibrations mechanism and building a theoretical model
able to predict the strip vibrations in specific cooling configurations.
The fluid-structure interactions in such equipment was never been studied before this project.
Each of these steps aimed answering the fundamental question: how to reduce the strip vibrations in
gas jets cooling equipments and consequently to increase line productivity and coating quality. That
means to be able to answer to these basic questions, which are frequently asked on that problem and
have no answer today:
o
For existing cooling technology in hot dip galvanizing lines, what is the importance of the
process and geometrical parameters on the vibratory behaviour of the strip? Is it possible to
reduce the vibrations by actions on these parameters while preserving the cooling
performances?
With identical cooling performances, is there a blowing design, which makes it possible to
strongly reduce the strip vibrations?
We answered to those questions with success.
3.1.6. Consistency of resources and quality of partnership

The project nature (pilot project) by itself leads to coordinate various competencies (technical and
scientific experts) and approaches (industrial and experimental). Due to a closed partnership between
the ArcelorMittal Ghent and Sagunto lines people, ArcelorMittal R & D team and Drever
International, we succeed to conduct an exhaustive characterization of the strip vibration phenomena
observed in the cooling sections and during production conditions (WP1). The WP2 was much more
focused on the coordination between researchers (ArcelorMittal Maizires), university competencies
(subcontractor), supplier knowledge (Drever International) and industrial background (ArcelorMittal
Ghent). The WP3 consisted in coordinating the competencies of the line managers, the industrial
people in charge of mechanical and electrical maintenance, the technology suppliers, and the
ArcelorMittal researchers in charge of the measurements campaign. Because of the tasks diversity and
because of the coordination of various competencies, the partnerships quality is very high. More
especially, the industrial implementation of the new cooling technology has been done with success
and on due time in spite of one contractor withdrawal and replacement, and in spite of the economical
crisis occurred at the end of 2008, which leads to human resources restriction of the ArcelorMittal
group.
100
3.1.7. Community added value and contribution to EU policies

The impact regarding preservation of natural resources, energy and environment had been reinforced
considering the consequences of better controlled zinc coating on surface appearances of galvanized
strips and on the painting / organic layers consumption of automotive suppliers. Even if we were not
able to quantify those benefits on the Sagunto pilot line, the results obtained on the Chinese lines
where the recommendations have been implemented shows that the strip vibrations could be mastered
in cooling sections, especially in the cooling tower, reducing the zinc consumption thanks a better
mastering of the zinc coating homogeneity across the strip width as well as along the strip length.
Those results could be easily reproduced on EU lines, on HDG lines as well on CAL lines.
3.1.8. Exploitation and impact of the research results

The first impact of the research results is the worldwide deployment of the recommendations coming
from the WP2. Indeed the principle of staggering nozzles to reduce vibrations amplitudes, the removal
of the PAD sheet, the optimisation of the nozzle-to-nozzle distances have been introduced within the
innovative Ultra Fast Cooling developed in the Drever R&D department and commercialised by
Drever International.
The second impact of the research results consists in the development of modelling tools able to
predict the strip vibration amplitudes and modes for varied experimental and industrial configurations.
Based on the theoretical approach of fluid-structure interaction done within the WP2 tasks, further
numerical tools coupling computations of structural deformation and fluid mechanism have been
developed at ArcelorMittal Maizires Research. Developments are still going on to make the strip
vibrations prediction more robust, especially for industrial configuration taking into account the
process parameter fluctuations.
101
4. List of Figures
Figure 1: comparison between initially planned activities and accomplished work ............................................ 22
Figure 2: Configuration of the vibrations measurement system in the cooling tower .......................................... 23
Figure 3: Positioning of three Kaman sensors across the strip (top view) ........................................................... 24
Figure 4: Three Kaman sensors across the strip .................................................................................................. 24
Figure 5: Strip vibrations across the strip width at the wiping zone according to the line speed increase.......... 25
Figure 6: Width-wise strip vibrations between the cooling boxes according to the line speed increase.............. 26
Figure 7: Width-wise strip vibrations at the wiping zone according to the strip traction .................................... 27
Figure 8: Width-wise strip vibrations between the cooling boxes according to the strip traction ....................... 27
traction and for 2 different line speeds: V=115 m/min and V= 140 m/min .......................................................... 28
traction and for different strip formats (Line speed = constant)........................................................................... 29
power of cooling box 2 (box 1 fixed)..................................................................................................................... 30
power of cooling box 2 (box 1 fixed) for line speed fixed. .................................................................................... 30
Figure 13: Drever after pot cooling design at ArcelorMittal Ghent 3.................................................................. 33
Figure 14: ArcelorMittal Ghent #3....................................................................................................................... 33
Figure 15: ArcelorMittal Ghent 3......................................................................................................................... 34
Figure 16: Schematic overview of the experimental cooling device ..................................................................... 34
Figure 17: Upper view of the equipped pilot line, with strip and guide-rolls....................................................... 34
Figure 18: Drawing of the equipped pilot line, with strip line pass (red line) and guide-rolls ............................ 35
Figure 19: Different configurations of blowing plenums front side tested on pilot line. 1- 2 x 8 nozzles opposite
to each others; 2- Variation of nozzles length; 3- Air PAD system....................................................................... 36
Figure 20: Control cabin of experimental pilot line ............................................................................................. 37
Figure 21: Strip positioning measurement system ................................................................................................ 37
Figure 22: Hot wire measurement system............................................................................................................. 37
Figure 23: initial configuration: plenum nozzles configuration 4 straight nozzles + 1 PAD (aerodynamic
stabilizer) per side................................................................................................................................................. 39
Figure 24: strip displacement as function of blowing pressure ............................................................................ 39
Figure 25: peak to peak values as a function of blowing pressure ....................................................................... 39
Figure 26: evolution of the strip position with time at P=19 mbars => irregular strip vibrations...................... 40
Figure 27: Evolution of the strip position with time at P=39 mbar => regular strip vibrations ......................... 40
Figure 28: power density vibratory spectrum P=19 mbar ................................................................................... 40
Figure 29: power density vibratory spectrum P=39 mbar ................................................................................... 40
Figure 30: evolution of the strip position with time in a twist situation ............................................................... 41
Figure 31: RMS and peak-to-peak strip vibrations amplitudes as a function of the blowing pressure for tests
performed at 4 different time periods.................................................................................................................... 42
Figure 32: RMS values as a function of time at 4 different time periods. Identification of 3 major strip
behaviours: ........................................................................................................................................................... 43
Figure 33: schematic view of the 3 major observed strip behaviours: ................................................................. 44
Figure 34: Schema of interaction between gas jets fluid and the strip structure.................................................. 44
Figure 35: Illustration of vortex mechanism......................................................................................................... 45
Figure 36: Schema of strip vibrations amplitudes function of strip-nozzle distance ............................................ 45
Figure 37: Strip damping function versus an adimentional strip-nozzle distance H ............................................ 46
Figure 38: strip displacement (RMS) function of strip speed ............................................................................... 48
Figure 39: peak-to-peak as a function of strip speed............................................................................................ 48
Figure 40: strip displacement (RMS) function of blowing pressure ..................................................................... 48
Figure 41: peak-to-peak values function of blowing pressure .............................................................................. 48
Figure 42: power density vibratory spectrum T=0.96 kg/mm2 P=19.4 mbar and P=29.3 mbar................... 49
Figure 45: Effect of difference between strip tension edges on strip vibration amplitude................................... 50
Figure 46: Connecting tubes between the two opposite blowing boxes................................................................ 51
Figure 47: Influence of the connecting tubes between the opposite blowing boxes.............................................. 51
Figure 48: Effect of blowing width on vibrations amplitudes ............................................................................... 52
Figure 49: Effect of blowing width on peak- to-peak values................................................................................. 52
103
Figure 50: Effect of a delta pressure of 5 % between the 2 plenums for a configuration of 2 x 6 nozzles with and
without PAD sheets ............................................................................................................................................... 53
Figure 51: Tested configuration equipped with shorter nozzles length (55 mm).................................................. 53
Figure 52: Influence of shorter nozzles length (55mm) on vibrations instability ................................................. 53
Figure 53: 3 different tested configurations: a) straight nozzles b) staggered straight nozzles c) classical nozzles
arrangement with PAD sheet ................................................................................................................................ 54
Figure 54: Standard deviation and peak-to-peak measurements for the 4 different tested configurations .......... 55
Figure 55: Configuration on experimental pilot device with staggered straight nozzles and symmetrical PAD . 56
Figure 56: Peak-to-peak value function of blowing pressure for 7 tested configurations .................................... 56
Figure 57: Staggered standard design with staggered PAD................................................................................. 57
Figure 58: Peak-to-peak measurements for 4 different configurations: ............................................................... 57
Figure 59: Schematic configuration for the investigation on the effect of the strip-PAD distance on vibrations
amplitudes ............................................................................................................................................................. 58
Figure 60: Effect of the strip-PAD distance for 3 different strip to blowing nozzles distances ............................ 58
Figure 61: Flow velocity profiles from the nozzle to the strip at the nozzle centre and for different blowing
the flow velocity just at the exit of the nozzle, Umoy is the measured velocity at a distance X from the nozzle
wall : Umoy = U(X,0) ........................................................................................................................................... 59
Figure 62: Flow velocity profiles from the nozzle to the strip at the nozzle edges and for different blowing
the flow velocity jus tat the exit of the nozzle, Umoy is the measured velocity at a distance X from the nozzle
wall : Umoy = U(X,0) ........................................................................................................................................... 60
Figure 63: The spectral density analysis of flow velocity signals show typical frequencies around 1-2,5 Hz ; 5-6
Hz and 18 Hz......................................................................................................................................................... 61
Figure 64: Superposition of spectral density analysis of flow velocity signal (black curve) and spectral density
analysis of strip displacements(red, green and blue curves) ................................................................................ 61
Figure 65: Current blowing technology implemented at ArcelorMittal Ghent Hot Dip Galvanizing line. .......... 63
Figure 66: Proposed modifications at the blowing technology implemented at ArcelorMittal Ghent Hot Dip
Galvanizing line. ................................................................................................................................................... 63
Figure 67: Configuration of the Sagunto cooling tower and position of the measurement systems ..................... 65
parameters: ........................................................................................................................................................... 66
Figure 70: Standard deviation and peak to peak distance at the top of the cooling tower (Laser sensors
parameters: ........................................................................................................................................................... 66
minimal acceptable blowing power (10%)............................................................................................................ 67
parameters: ........................................................................................................................................................... 68
Figure 75 Standard deviation and peak to peak distance at the top of the cooling tower (Laser sensors
parameters: ........................................................................................................................................................... 68
minimal acceptable blowing power (10%)............................................................................................................ 69
Figure 78: Standard deviation at the wiping zone (Kaman sensors measurements) on 3 points for different line
velocities and for identical others production parameters: .................................................................................. 69
Figure 79: Peak to peak distance at the wiping zone (Kaman sensors measurements) on 3 points for different
line velocities and for identical others production parameters: ........................................................................... 70
Figure 80: the final configuration of the cooling tower at Sagunto...................................................................... 73
Figure 81: the final configuration of the cooling tower at Sagunto...................................................................... 74
Figure 82: Picture taking during the implementation of the innovative cooling technology on the Sagunto
cooling tower: nozzles staggering, PAD removal. ................................................................................................ 74
Figure 83: Screenshot of the blowing pressure balance between plenums after regulation adjustments at Sagunto
.............................................................................................................................................................................. 75
Figure 84: Identical product and process parameters during the trials campaigns on Sagunto line................... 76
Figure 85: Effect of the blowing pressure on blowing box 1 (inferior) on strip vibrations at the wiping zone
curves)................................................................................................................................................................... 78
104
Figure 86: Effect of the blowing pressure on blowing box 1 (inferior) on strip vibrations at the top of the cooling
tower on Sagunto line after modification (full curves). Comparison with the reference trials conducted on 2008
(dotted curves). ..................................................................................................................................................... 78
Figure 87: Effect of the blowing pressure on blowing box 2 superior) on strip vibrations at the wiping zone
curves)................................................................................................................................................................... 79
Figure 88: Effect of the blowing pressure on blowing box 2 (superior) on strip vibrations at top of the cooling
tower at Sagunto line after modification (full curves). Comparison with the reference trials conducted on 2008
(dotted curves). ..................................................................................................................................................... 80
vibrations at the wiping zone on Sagunto line after modification (full curves). Comparison with the reference
trials conducted on 2008 (dotted curves). ............................................................................................................. 80
vibrations at the top of the cooling tower on Sagunto line after modification (full curves). Comparison with the
reference trials conducted on 2008 (dotted curves). ............................................................................................. 81
Figure 91: list of hypotheses to be checked to explain the discrepancy between expected gains and real
measurements........................................................................................................................................................ 83
Figure 92: Four different configurations have been tested to determine the effect of the PAD Nozzles orientation:
.............................................................................................................................................................................. 85
Figure 93: Example of averaged peak-to-peak measurements (for the 3 laser) for a strip-to-nozzle distance = 67
mm (= 100 mm for industrial conditions) and for 2 pressures: 40 and 60 mbar.................................................. 85
Figure 94: Example of the detailed curves of the averaged peak-to-peak measurements (for the 3 laser) and for 3
different strip-to-nozzle distances =25, 67, 100 mm on configurations C) = staggered standard design without
PAD sheet and D) = staggered straight nozzles............................................................................................. 86
Figure 95: Diagram of the tested confined configuration on the experimental facility. On the left, the diagram is
from the top view; on the right from the side view. ............................................................................................... 87
Figure 96: Standard deviation of the strip displacement for configurations with and without confinement. Curves
on the left show the standard deviation for the strip centre whereas the curves on the right show the standard
deviation for the strip edges.................................................................................................................................. 87
Figure 97: 3 different tested configurations to evaluate the effect of the unsymmetrical nozzles staggering:...... 88
Figure 98: Standard deviation of the strip position measured for the 3 configurations A) B) C). Average of the
5 laser signals measuring the strip position across the width. The blowing pressure is increasing from 20 to 70
mbar. 3 strip-to-nozzles distances have been tested: 50, 75 and 100 mm............................................................. 89
Figure 99: Peak-to-peak measurements of the strip position measured for the 3 configurations A) B) C).
Average of the 5 laser signals measuring the strip position across the width. The blowing pressure is increasing
from 20 to 70 mbar. 3 strip-to-nozzles distances have been tested: 50, 75 and 100 mm. ..................................... 90
Figure 100: Sketch of the Shougang ShuYi CGL N1 ........................................................................................... 93
Figure 101: Zinc coating weight repartition across the strip width at Wisco CGL .............................................. 93
Figure 102: Ultra Fast Cooling performances for Shougang ShunYi CAL N1 and CGL N1 ............................ 95
Figure 103: Zoom of the Ultra Fast Cooling in Shougang CAL (from video camera records) ............................ 95
105
5. List of References
[1] M. Renard, J. Muller, D. Van de Vyver, F. Gurniki, K. Beaujard , Control of strip vibrations in gas
jets cooling areas, Proceedings of Galvatech07, 7th International Conference on Zinc and Zinc Alloy
Coated Sheet Steels, Osaka (Japan), November 18-22, 2007, pp. 57-62
[2] M. Renard, K. Beaujard Control of strip vibrations in cooling equipments of galvanizing lines; 5th
China International Steel Congress, Shanghai (China), June 1-4, 2008
[3] M. Renard, K. Beaujard; Control of strip vibrations in cooling equipments of galvanizing lines,
Revue de Mtallurgie; March 2009; pp 118-123
[4] Michel Renard, Edgar Dosogne, Jean-Pierre Crutzen, Jean-Marc Raick, Ma jia ji , Lv jun and Ma
bing zhi; improvement of Cooling Technology through Atmosphere Gas Management; Asia-Pacific
Galvanizing Conference 2009, Korea, November 8-12, 2009
[5] C. Mu-Tsang and A. Ashraf, Computers & Structures, Vol. 66, No. 6, (1998) p. 785
[6] ABAQUS Inc, Abaqus 6.9 Theory Manual, version 6.5, 2004
[7] V. D. Pshenichnyi and L.R. Yablonik, Spectral characteristics of the pulsation effect of a plane
turbulent jet on a solid surface (1975)
[8] European Steel Technology Platform, a vision of the future of the steel sector, March 2006 (see
http://www.cordis.lu/coal-steel-rtd/steel/events_stp.htm)
[9] Bilimoria Y. Strip shape measurement and control at Inlands Hot Dip Galvanizing line,
Galvanizers Association Meeting, Niagara Falls (1990)
[10] Dubois M. Strip vibration and temperature at the top roll, Galvanizers Association Meeting,
closed session, unpublished (1990)
[11] Gaignard S., Dubois M. Characterization of strip vibration at the wiping nozzles, Galvatech
2004, Chicago, pp. 207-216
[12] Shimokawa Y., Ishikawa H., Sakai K., Nitto H. - Vibration prevention of a strip by air cushion
method, ISJ International, 1983, pp. 1167-1174
[13] Shimokawa Y., Ishikawa H., Sakai K., Nitto H. - Studies of vibration prevention by the air
cushion method for the application to commercial stripe lines, ISJ International, 1983, pp. 1175-1182
107
[14] Improved quality of galvanised products by controlled wiping, ECSC Steel RTD Programme,
Contract number 7210-PR/281, CRM, Aceralia, CSM
[15] Hot dip galvanizing: stabilizing and cooling the strip in the wiping area, ECSC Steel RTD
Programme, Contract number 7210-PR/282, CRM, Aceralia, BFI
[16] Renard M., Gouriet J.B., Planquart P., van Beek J., Buchlin J.M. Thermal and dynamic study
of rapid cooling in continuous galvanizing lines, Galvatech 2004, Chicago, pp. 449-456
[17] George S., Scott L. New technologies for post-pot cooling equipment, Galvatech 2001, pp.461468
[18] Kim, H S; Lee, M S - Instability of the flow field in a gas jet cooler, RIST Journal of R&D. Vol.
18, no. 3, pp. 218-224. Sept. 2004
[19] Price, M; Barker, H A; Evans, K J - Dynamic distributed parameter model of steel strip,
Ironmaking and Steelmaking (UK). Vol. 24, no. 1, pp. 99-103. 1997
[20] Lemaitre C., de Langre E. ,Hmon P. - Instability of a long ribbon hanging in axial airflow - J. of
Fluids and Structures, 2004
[21] E. de Langre. Fluides et Solides. Ecole polytechnique, 2001, diffusion Ellipse
[22] M. Padoussis Fluid-structure interaction, vol II. Elsevier, 2003
[23] Base Metals Market Briefing February 2006, http://www.gfmsmetalsconsulting.com/publications_BMMB.htm
[24] 10th Zinc & its Markets Seminar in Sheraton Park Lane Hotel - London - 24-26 May 2006
[25] Michel Renard, Edgar Dosogne, Jean-Pierre Crutzen, Jean-Marc Raick, Ma jia ji , Lv jun and Ma
bing zhi; High cooling performances of Cooling Technology; Galvatech Conference 2011, Genoa
(Italy), June 21-24, 2011
[26] Makhlouf Hamide, Karen Beaujard; Predictive model of strip vibrations in gas jets cooling
scetions; Galvatech Conference 2011, Genoa (Italy), June 21-24, 2011
[27] Jean-Marc Raick, Jean-Pierre Crutzen, Edgard Dosogne, Michel Renard; Atmosphere control
during continuous heat treatment of metal strips; WO 2004024959 (A1)
[28] Jrme Muller, Akli Elias, Thierry Petesch, Ivan Santi, Paul Durighello,
Method and device for blowing a gas onto a moving strip; EP2100673 (B1)
108
Karen Beaujard;
6. List of acronyms and abbreviations

WP
Work Package
e.g.
Exempli gratia, for example
SD
Standard Deviation
HDG
Hot Dip Galvanizing
CAL
Continuous Annealing Lines
PAD
Pressure Aerodynamical Damper
RMS
Root Mean Square
Vs
Versus, compared with
Umoy
averaged velocity
Umax
maximal velocity
A.U.
Arbitrary Unit
UFC
Ultra Fast Cooling
mm
millimetre
mpm
meter per minute
mbar
millibar
109
European Commission
EUR 25317 Improvement of productivity on hot dip galvanising line by decreasing strip vibrations
in gas jets cooling systems(Stripvibrations reduction)
Luxembourg: Publications Office of the European Union
2013 109 pp. 21 29.7 cm
ISBN 978-92-79-24828-3
doi:10.2777/92028
HOW TO OBTAIN EU PUBLICATIONS

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KI-NA-25317-EN-N
The high quality standard of coated steels requires good stability of the strip,
particularly in the cooling tower after the zinc bath, where the gas jets of the
cooling equipment excite the strip.
The objective of the pilot project is to increase the line productivity and coating
quality by decreasing the vibrations along the cooling path, not with external
stabilising actuators but by the improvement of existing cooling technologies.
We applied a methodology mixing industrial trials, experiments on a semiindustrial facility and a theoretical approach.
Despite the unforeseen withdrawal of the initial line due to financial difficulties
in the European steel industry, we choose a newindustrial line.
Thus the major achievements are as follows.
Actual state of vibration amplitudes under industrial conditions and the
effect of the major process parameters.
A model coupling physical and numerical approaches, able to predict the
vibration amplitudes and frequencies for specific process parameters and
configurations.
A new cooling technology that significantly reducesstrip vibration amplitudes
was designed and tested before being implemented on the chosen industrial
line (revamping of existing cooling equipment).
The principles of those findings extended by the partner Drever to a new
efficient cooling equipment dedicated to fast cooling sections (protective
atmosphere). Many new lines are equipped with this innovative equipment.
Acceptance tests show significant benefits.
The project ended with success: the innovation has been implemented
worldwide on many HDG lines. There are great benefits: strip stability, cooling
efficiency and product quality. The results are shared with the community: six
publications [14, 2526] and two patents [2728].
Studies and reports
doi:10.2777/92028

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Improvement of productivity on

hot dip galvanising line

Research Fund for Coal and Steel

Grant Agreement RFSP-CT-2007-00017

Europe Direct is a service to help you find answers

More information on the European Union is available on the Internet (http://europa.eu).

PROJECT TIME SCHEDULE ....................................................................................................................17

SCIENTIFIC AND TECHNICAL DESCRIPTION OF THE RESULTS................................................19

LIST OF ACRONYMS AND ABBREVIATIONS ...................................................................................109

Comparison between initial work program and performed work

WP 1) Analysis of strip vibrations on ArcelorMittal Ghent #3 industrial line equipped

- Product parameters like the strip format:

Optimization of the influent parameters on the experimental cooling device

Influence of process parameters:

Blowing pressure: major influent parameter, as well as the velocity homogeneity

Line velocity: no influence

Heterogeneous strip tension: major influence on vibrations mode, especially twist

Influence of geometrical parameters:

Pressure balancing between blowing boxes: no influence

Pressure balancing nozzle width-wise: influent

Strip-Nozzles distance: influent

Nozzle length: major influent parameter: a minimal nozzle length is required.

Staggered nozzles: major influent parameter, easy to implement in industrial

PAD sheet: major influent parameter. More especially a maximal PAD-Strip

To stagger the blowing boxes with a step

Consequence of 2009 economic crisis: change of contractor

WP 3) Installation and optimization of the improved proposed solution in industrial

Process parameters can influence the vibration amplitudes:

Implementation of the innovative cooling technology

until 101.6 C/s.mm for the continuous annealing line N1

until 112.4 C/s.mm for the continuous galvanizing line N1

The influence of the blowing parameters: Blowing distance, Blowing width

The influence of the geometry parameters: Nozzle assembly geometry, Plenum

The influence of the process parameters: Line velocity, Strip tension

The influence of the product properties: Thickness and width, Grade

Scientific and theoretical approach

Vibrations due to recirculation loops between jets

Vibrations due to turbulent flows

Vibrations due to aeroelastic forces coupling inducing dynamical instability

The mastering of all process parameters,

The possibility to test easily design modifications of the cooling equipment

The transfer of phenomena characterized in industrial conditions to an experimental facility is

quasi periodical forces due to recirculation loops between jets

turbulent flows forces

Industrial interest and scientific / technical prospects

We answered to those questions with success.

Consistency of resources and quality of partnership

Community added value and contribution to EU policies

Exploitation and impact of the research results

1. PROJECT TIME SCHEDULE

Work packages title

Analysis of strip vibrations on Arcelor Steel Belgium

Industrial reference Database

Installation of measuring system

Disposal measuring system with process database

Characterisation of blowing parameters

Characterisation of line process parameters

Optimisation of the influent parameters on the

Improved experimental cooling device

Design and manufacturing

Experimental 2/3 scaled cooling device

Reproduction of vibration phenomena on experimental 2/3 scaled