The Maintenance Guild will hold their Thirty-Fourth meeting on June 17, 18, and 19, 2013.
The thirty-fourth meeting of the Maintenance Guild will be held in Saukville, Wisconsin with our host Plant being Charter Steel - Saukville. All attendees should plan to be in an all-day round table session on Monday with an evening hospitality mixer. The technical presentations and tour will be on Tuesday and our Golf outing Wednesday morning. Transportation for the Plant tour will be provided for the group.
We will be staying at Four Points by Sheraton Milwaukee North located at 8900 North Kildeer Court, Brown Deer, WI 53209. You can fly into Gen Mitchell International Airport which is 22 miles from the hotel. The room rate for the Guild members will be $115.00 dollars per night. To make your reservations, Click on this link (https://www.starwoodmeeting.com/Book/mntguild) or individuals can call (414) 355-8585 and ask for a room out of the "Maintenance Guild Meeting" block. All reservations will be held after 6PM and guaranteed for late arrival only if accompanied by a first night room deposit or guaranteed to a major credit card.
You need to make the meeting fee payments in advance. The cost for this meeting will be $350.00 (American). Registration and payment can now be made on our website www.maintguild.com or you can fax me a PO number at (330) 479-5061 and I will invoice you for the fees as long as we receive the funds prior to the meeting. This fee will cover the cost of meals, bus transportation, meeting rooms, and equipment. The cutoff date for the block of room we have on hold is May 17, 2013, so make your reservations soon. After this date the rooms will go on a first come first served basis. There are few hotels close to this location so please make your travel arrangements as soon as possible.
Tuesday evening we will have a dinner with a guest speaker from Charter Steel - Saukville, Wisconsin.
For those individuals that are interested there will be a group gathering Wednesday for a round of golf at the Brown Deer Golf club. If you are interested in playing please contact Mark Kropf at(330) 479-5060. I need to know by no later than September 3rd if you plan on golfing so tee times can be secured. We plan to Tee off by 9:00 and finish at 2:00. After the outing all members will be on their own for the rest of the weekend.
We appreciate your support and look forward to seeing you in Saukville, Wisconsin.
Meeting minutes of the September 10, 11, and 12, 2012meeting in Mobile, Alabama
The members of the guild arrived on Monday September 10, 2012 for breakfast at 7:00am and the Round table sessions began at 8:00.
Bob Fabian introduced the executive board and reviewed the details of the meeting. Mark Kropf covered the week’s event schedule and the rules and regulations for nomination of the second vice president.
Next Bob Fabian had everybody introduce themselves and the company they work for. The following company’s were represented; CMC Texas, CMC AL, Nucor Seattle, Electralloy, Timken, Alta Steel, Timken Harrison. Timken Faircrest, SSAB – Mobile, SSAB – Iowa and IPSCO Koppel.
The round table session began at 8:20 with questions from the floor.
What new equipment projects are being installed or worked on in the industry?
New furnace, new caster, new baghouse, furnace, ladle furnace and caster in different mills from America and caster. The discussion developed into the justifications for the new equipment from improved safety, operating, and maintenance.
Is anyone using the XO electrode adding robot? Some shops are and they all had minor start up issues but all have realized increased safety for the adding process. Discussion ranged from electrical plug, limit switch, sensors and some hydraulic issues.
We installed a BSE Carbon injection burner system and are having issues with the elbows and pipe wearing out, what are other shops using? Abresist pipe and elbows with different types of hoses has been the best solution.
What CMMS systems are other shops using? Different systems have been discussed from tab ware, ISS, Maximo and SAP. The one company is installing corporate wide and will do them into groups of 3 to provide installation support. The group discussed the pros and cons of the systems and what different modules provide the information they shops needed. Then it migrated to data tracking to inventory of parts.
The non-conductive unclamp hoses for the electrode arms? The group talked about different types in the market and what was working and what was note.
The group discussed mega doors used to isolate sections of the melt shop so crane work can be performed while the furnace is still operation.
Tap hole change wedge sticking. What are other shops doing to make the tap hole changes easier to avoid wedge sticking. Different ideas were discussed but most shops are dealing with this problem. They then started to talk about tap hole life, breast and refractory maintenance equipment.
What are other shops wearing for work clothing? This topic had a wide variety of responses and based on the shops safety requirements dictated they type of clothing that was required. Carbonite, Nomex along with other FR types of material was discussed.
How are other shops managing fall protection on the furnace gantry arms? Most shops are utilizing “D” rings or utilizing man lifts. They also are using the retractable lanyards to minimize the fall distance that you have with a regular lanyard.
How many shop have their electrical safety programs wrote out and are trained in it. Some shops are and some are still in development.
Crane inspections, what companies are being used and who still does their own in house. Most shops are doing them in house but also bring in the outside inspections for the complete structural inspections. Kone, ACE, D&S, and Kova were a few of the companies mentioned.
Magnet controller problems were discussed and interlocking during maintenance was the key topics of the group’s discussion. ASME B20.30 code was discussed for all below the hook inspections (magnets tongs, spreader beams ect…) Then they shifted to magnet maintenance and repair problems along with magnet on off signals for cranes. The OSHA standards were discussed and what steps are being taken to make sure all parts of the standard is met.
The discussed the emergency water shut off system when there is a water leak detected. The system discussed was a total shut off with a syphoned system and how it functions. They also talked about what the safety process is for bring water back on and safe leak detection so repairs can be made.
Does anyone use a quick connect system on the power cables vs the typical bolt on style? No one in the group used them but knew of them.
A member ask if anyone knew a company that preformed reheat furnace calibrations Onix was one company mentioned.
In a Union shop how do you maintain a sense of urgency to motivate them to be more attentive and productive? No one had an answer for them but they did discuss different incentive plans outside the normal contracts.
Skilled man power shortages are becoming a problem. What is other shops doing to get the young work force interested in the trades again. Pay scale differences for working in the melt shop vs. the rolling mill were discussed and most shops are all paid the same.
The group broke for lunch at 11:45 and resumed at 12:15.
How is your carbon divided to the multiple burner points in the furnace? The conversation went through the different designs in transfer systems as well as the different components in the system from pipe, valves, elbows and controls.
What type of transfer cars are other shops using? This conversation covered everything from position sensors, limit switches and different designs in the various shops.
What type of temp sampler machines are other shops using? XO, BSE, PTI were a few of the ones discussed and there issues good and bad.
What types of on line billet scales are being used? Strain gage vs. measured was discussed.
Who is using magnetic stirring on their ladles? Most shop are using porous plugs.
What type of baghouse bags are being used Gore, Nomex, Polyester, fiberglass, buzzall and hallabare. Conversation covered the bag type benefits each provides.
Is anyone in a lead abatement program and how do you handle the clothing issues. One shop provides individual bins and lockers. For affected clothing. Other shops not in an abatement program still keeps all the clothing handled separately from bin to transportation. Locker rooms are set up to have clean side and dirty side with the showers between with everyone showering before they leave.
Is anyone successful at measuring the hot heal in there furnaces? There is some rocker base load cell systems out there but most shops do visual calculations to determine weight.
What is the percent of maintenance cost verses operating cost including contractors.
Most of the shops ranged from 5 , 11, 15 to as high of 25% due to an extended outage.
Who is using Maximo and what version is being used. There was one or 2 shops but they were not sure on the version.
What are most shop using for scheduled outages weekly, biweekly and or shutdowns.
Some were on a weekly some on bi weekly with most shops have at least 1 week of extended outage, with up to 2 one week outages per year. One shop goes down 12 hours every 5 weeks with 1 seven day outage for big jobs once a year.
Data cleansing, what do other shops doing to clean up their spare parts systems. No had hired this out.
What systems are other shops using for outage planning and scheduling? Most shops are doing it long had with Excel or other computer programs. One shop is using Tab-ware but it does have other modules that would enhance it.
Is anyone using robotic billet marking systems. The group discussed the different systems used in their shops.
What type front doors are other shops using? Conventional slide up type doors, with some shops water-cooled the door shaft and water-cooling the cylinder. We talked about the different sealed door systems from EMPCO, SMS and PTI.
Vault wall secondary is Stainless steel and we blew a hole in it after a 4 week outage. Has anyone else had this happen? 2 other shops had similar failures and they discussed the step they took to solve the problems, such as a 4 year change out schedule.
The round table finished at 4:00 pm.
We then went to nominations for vice president. We had 5 nominations with 2 accepting.
Bob started the safety presentation on the current accidents in his company. The group then went around the room and discussed each shops current accidents and the actions taken in the investigation from corrective actions to reprimands.
After Bob’s presentation the 2nd vice presidents voting was held with John VanValkenburg of Nucor – Seattle receiving the majority votes.
This meeting the members will be on their own for dinner and return to the hotel for the Hospitality room activities from 7 till 11.
The group started off Tuesday with breakfast from 7:00 to 8:00. Bob opened the meeting with updates for the day and reminded everyone that an attendance list will be available for the attendees. All papers will be available for review on our web site.
Bob made the introduction for our first presentation at 8:10. David Harvanek of St. Lawrence Steel Presenting a paper titled “Wear Parts: Maintaining Productivity in the Steel Industry: Chromium Carbide Overlays" David finished his presentation at 8:50 and entertained questions from the floor.
After a short break Bob introduced our second paper. Mat Weghorst of 3M Occupational Health & Environmental Safety, Presenting a Paper Titled "Total Eyewear Solutions”. Mat finished the presentation at 9:50 and took questions from the floor.
After a short break Bob introduced our third paper Chris Farmer of Process Technology International Inc. Presenting a Paper Titled “Operational and Maintenance of the PTI Slag Door and Sampling Device”. Chris finished the presentation at 10:50 and took questions from the floor.
After a short break Bob introduced our fourth and final paper by Stacy Sergeant & Steve Moore of Rosemount Measurement Presenting a Paper on Smart Wireless Solutions: “See More. Do More”. Stacey finished the presentation at 11:45 and took questions from the floor.
At 11:50 the members enjoyed the lunch buffet and at 12:40 we boarded our bus for the tour of the SSAB Steel facility and the SMS Millcraft facility.
We returned to the hotel at 4:30 to prepare for the evening dinner. At 6:00 the members gathered in the Ballroom for a hospitality mixer. At 7:00 dinner was served. At 8:30 we were able to hear our guest speaker Scott Waine Maintenance Manager Melt Shop/Caster talk about the safety in his facility along with how our technical papers closely related to the direction his department is moving. Bob Fabian presented a plaque of appreciation to our quest speaker and host of the 33st Maintenance Guild meeting. Bob then introduced Dan Avalos as our new 1st Vice President and John VanValkenburg of Nucor – Seattle as the new 2nd Vice President.
On Wednesday September 12th, at 9:00 the members attending enjoyed a Golf outing at “Rock Creek Golf Club” that completed the week’s events.
Maintenance Guild 33rd Meeting Agenda
Monday, September 10, 2012
7:00 HOTEL BREAKFAST BUFFET
SIGN IN WITH YOUR BUSINESS CARD
8:00 - 8:30 INTRODUCTION BY BOB FABIAN FOR GENERAL BUSINESS, OPEN FLOOR FOR NOMINATIONS
& 2013 MEETING DISCUSSION.
8:30 - 9:30 ROUND TABLE DISCUSSIONS
9:30 - 10:00 BREAK
10:00 - 12:00 ROUND TABLE DISCUSSIONS
12:00 - 1:00 LUNCH BUFFET
1:00 - 1:15 VOTING FOR 2ND VICE-PRESIDENT
1:15 - 2:30 ROUND TABLE DISCUSSIONS
2:30 - 2:45 BREAK
2:45 - 3:15 SSAB PLANT SAFETY PRESENTATION
3:15 - 3:30 QUESTIONS
3:30 - 4:30 ROUND TABLE DISCUSSIONS AND 2ND VP RESULTS
5:00 – 6:00 MEMBERS ARE ON THERE OWN FOR DINNER
6:00 – 11:00 HOSPITALITY SUITE WITH HOURSDORVES PROVIDED BY SUPPLIER GROUP (At Hotel)
Tuesday, September 11, 2012
7:00 – 7:45 HOTEL BREAKFAST BUFFET IN THE
7:45 – 8:00 SIGN IN WITH YOUR BUSINESS CARD
8:00 – 8:10 INTRODUCTION: BOB FABIAN 8:10 - 8:50 PRESENTATION: DAVID HARVANEK OF ST. LAWRENCE STEEL
PRESENTING A PAPER TITLED “WEAR PARTS: MAINTAINING PRODUCTIVITY IN THE STEEL INDUSTRY:
CHROMIUM CARBIDE OVERLAYS"
9:10 - 9:50 PRESENTATION: MAT WEGHORST OF 3M OCCUPATIONAL HEALTH & ENVIRONMENTAL
SAFETY PRESENTING A PAPER TITLED "TOTAL EYEWEAR SOLUTIONS".
10:10 – 10-50 PRESENTATION: CHRIS FARMER OF PROCESS TECHNOLOGY INTERNATIONAL INC.
PRESENTING A PAPER TITLED “OPERATION AND MAINTENANCE OF THE PTI SLAG DOOR AND SAMPLING DEVICE”
11:10 - 11:50 PRESENTATION: STACY SERGEANT & STEVE MOORE OF ROSEMOUNT MEASUREMENT
PRESENTING A PAPER ON SMARTWIRELESS SOLUTIONS: “SEE MORE. DO MORE.”
12:00 LUNCH BUFFET
1:00 – 4:30 BOARD BUS OUTSIDE HOTEL PROMPTLY FOR THE TOUR OF THE SSAB ALABAMA STEEL PLANT
5:00 RETURN TO THE HOTEL
6:00 -6:30 GATHER IN THE BALLROOM FOR HOSPITALITY
6:30 - 8:30 DINNER – BALLROOM
GUEST SPEAKER: SCOTT WAINE MAINTENACE MANAGER MELT SHOP/CASTER
8:30 - 11:00 HOSPITALITY SUITE WITH BEVERAGES
Wednesday September 12, 2012
9:00 - 1:30 GOLF OUTING AT “ROCK CREEK GOLF CLUB”
MEMBERS ARE ON THERE OUR FOR THE REST OF THE WEEK