Meeting minutes of the October 8th, – 10th 2018 meeting in Boardman, Ohio
The members of the guild arrived on Monday October 8, 2018 for breakfast at 7:00am.
Mark Kropf reviewed the details of the meeting along with the voting guidelines and covered the week’s event schedule.
The following companies were represented; AK Steel Mansfield, Electralloy, Algoma Steel, CMC Alabama, CMC Texas, Charter Steel Cleveland, Charter Steel Saukville, North American Höganäs, ArcelorMittal Dofasco, WINOA, Electralloy, Ellwood quality steel & Vallorec Star.
Sean started the round table session by review a new process in the round table development to organize the round table topics by grouping began at 8:10 with questions from the floor.
What are other shops doing to handle the influx of new hires with safety training to minimize the accidents rate with new hires. Other shops or experiencing similar issues. Other shops are using mentors for them to go to for any issues, another shop pushes the near miss program to try and catch potential short fall in training. Another shop talked about the weekly walk through and discuss with the areas workers potential safety problems to highlight those items with the group. The conversation went on for quite a while and all in attendance shared their safety programs and the benefits and shortfalls in those programs.
How often do you change out the Tilt Cylinders blocking valve and the tilt cylinders? The group shared the different schedules and plans that there shops use. They discussed the different hydraulic system functions and protection equipment.
Are other shops going back to apprenticeship programs? And if so how are they set up. The group discussed the different training systems they use but most are going back to training internally using cooperative type plans with local tech schools supporting and setting training courses.
Took a break at 9:15
We started back at 9:30
What thoughts do other shop have on synthetic oils for side gate applications? Our suppliers is recommending glycol over the phosphate esters. Is there concerns on seal types? The group shared what issues they had with the different seal material with the different lubricants.
We are going to install a new scrap crane, what do other shops recommend? Most shop have moved to Zenar cranes for this type of application. Morgan, Whitting, Kone & P&H where some of the other cranes discussed and there shortfalls.
Does anyone have experience with Spray cooled roofs? One shop present did and they discussed the pros and cons of that type of cooling.
Are other shops having Shell temp issues and what did you do to control them. We have high temperatures that causes the Lower shell to fail from stress cracking and warping. The group discussed the different things they did to help. Predominantly most shops improved air movement and cleaning. Majority of the shops used a 516 grade 70 plate for the high temp areas vs the A36 plate.
Does anyone have automatic argon hook ups systems? A couple of shops have them and the group discussed there pros and cons. Worley-Parson and PTI were some of the systems mentioned.
Who has coal additions through the roof? And how do you control the fire blow back. A couple shops used air curtains at the roof level some used a chimney design to prevent the fire from going up the chute. And some had flappers to close it off. The conversation moved into conveyor belt issues from repair types mechanical splice vs vulcanized.
Does anyone change water flow during the heat based on water temperature? No one present had done this. One shop talked about pulling pumps back during idle time. The Empco temp adjusting valves were discussed as well.
Took a break at 11:00
We started back at 11:10
Does anyone have any experience with the spray coatings in the duct work or alternative materials? The group discussed some of the different coatings used some had success some did not. They discussed the Inconel overlay and it defiantly works well but the cost makes it cost prohibitive. They discussed the Ameri-bronze material and the place that it worked and at others that it didn’t.
Does anyone have over temp problems with their caster straighteners and oscillator cylinder? We have a lot or radiant heat from the billets. The group have a long discussion on different ideas to shield and or cool these areas.
Who does the group recommend for a new furnace designs. Intecho, Danieli, Primetals, Tenova, & BSE were a few discussed.
Has any shops moved there Mobile equipment generators for the motor to cable drives.
How do other shops qualify a person to do Lockout Tag out? And do you allow outside contractors do their own Lock out Tag out? One shop designated the Electricians to perform Lock out tag out. The group discussed how they qualify there people on Lock out Tag out. Most shops do not qualify outside contractors to do Lock out Tag out. There was a long conversation on this topic including tryout after the Lock out is completed.
Broke for Lunch at 12:10
We started back at 1:10
Does anyone have any ideas on how to install a grease shield on a 20’ slew bearing in a standard downturn? The group did a little brainstorming to come up with ideas.
Does anyone use in place vibration sensors on cranes? Some have wired and some had wireless. The paper from 2012 September meeting was sent to him for reference.
What are other shops doing to control slag splatter from the billet burner? Sprays to the majority move it down the flume but other splatter have to remove manually every down turn.
Does anyone use monolithic roofs there was a couple of shops that use them.
Does anyone have problems with the electrode clamp hydraulic hose? Ours are melting at the fittings on the arm side of the hose. There was a long conversation on the potential causes but everyone pointed to carbon fittings rather than the stainless steel they should be.
Took a break at 2:15
We started back at 2:30
What type of tunnel panels are other shop using? Some used cast iron, water with cast iron were some used.
How do other shop update drawings after job or project. Some shops have internal engineers or co-op students do them. Then other contracted the task with an outside engineering firm.
What type of pm’s are other shops doing on mast roll boxes. There were only a couple of shops with any type of pm’s mostly a grease and visual inspections were done.
What are other shops using for water back up in the event of a power outage? Most shops have a backup pump systems. Some have electrical generators
Does anyone use Melter for water cooled roofs? Some do but shipping cost is high and makes them less competitive.
Has anyone done redesign on there “B” phase loop. Any one used the BSE loop study? One shop has had it done and they did provide an improvement in the power efficiency.
Is anyone using solo gas analyzer? No one was at the time some had ESOP systems but accuracy has been questionable.
What companies are other shops using for their electrode lead repair and what type of wear protection is being used? Watteredge and Nucore were 2 discussed. Swivel clamps were also discussed with some shops using them on their leads.
Is anyone injecting lime in a burner panel? no
Anyone have any experience with the Siemens PLC. We have them on our retort furnace and the PLS panels are running real hot? Everyone who has them, did not have heating issues.
What are other shops doing for tie off point when working on mast arms? Some shops have tie off points for arm inspection and the covered how they were designed and installed.
What type of filters are other shops using for caster water? Sand, Centrifugal force type filtering. We want to improve the quality water before it gets to the sand filter. The group discussed multiple ideas for them.
Took a break at 3:55
We started back at 4:05
Is anyone using graphite wheels? Most of those present used them in high temp application like on rotary furnaces. Others thought about using them in a caster application.
What types of cable carriers are other shop using on their caster transfer car? The group discussed what they use as well as different types of carriers system.
Are other shop using an alternative material for run out rolls like aluminum bronze or other materials? The group share the differ things that have been tried and used.
Does anyone use air drive motors? Most used electric motor and seemed to be very reliable.
What do other shops use to clean around the LMF? Grant or Gradall. Grant was the most widely used.
What are other shops doing to keep the door clear? One shop actually has a burner right over the door and it works very well.
Does anyone use BSE to evaluate baghouse performance? Bender was used and Hatch.
Who is making the tap hole sander? Longo/More/Tenove were a few.
The round table finished at 4:45 pm.
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 provided by the supplier sponsors.
The group started off Tuesday with breakfast from 7:00 to 8:00. Bill opened the Technical session with updates for the day and reminded everyone that was in attendance to provide their business cards for the attendee list. This will be emailed to the attendees later in the week.
Bill made the introduction for our first presentation at 8:05.
LEE MONTGOMERY & STEVE HORNYAK OF CASTROL INDUSTRIAL PRESENTING A PAPER TITLED “LUBRICATION CHALLENGES”
Lee finished the presentation at 8:35 and took questions from the floor.
After a short break Jonathon introduced our second paper at 9:00.
ROSS KOVANDA/TOM MILLS OF AMERICAN CHEMICAL TECHNOLOGIES & ROBERT MCKIMM FORM PROFESSIONAL LUBRICANT SOLUTIONS PRESENTING A PAPER TITLED, "US STEEL GARY WORKS CASTER CASE STUDY”.
Ross & Tom finished the presentation at 9:30 and took questions from the floor.
After a short break Jonathon introduced our third paper at 9:55
DAVE ROBERTS OF AIRSTREAM PRESENTING A PAPER TITLED "ADVANCED SERVICES SOLUTIONS TO DRIVE OPERATIONAL EXCELLENCE AT NUCOR JEWETT EAF EMISSION SYSTEM FANS UPGRADE”.
Dave finished the presentation at 10:30 and took questions from the floor.
Bill made the introduction for our fourth presentation at 11:00
ROBERT STRAIN OF PRIMETALS PRESENTING A PAPER TITLED, "LADLE STIRING TECHNOLOGY”
Robert finished the presentation at 11:30 and took questions from the floor.
12:00 Members went to lunch
1:00 Members boarded bus and departed at 1:15 for the tour of the Ellwood Quality Steel plant
4:30 RETURN TO THE HOTEL
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 BJORN GABRIELSSON EGI VICE PRESIDENT STEELMAKING TECHNOLOGY ELLWOOD GROUP INC.
From 9:00 - 11:00 the group finished with a mixer to discuss the day’s events and information.
WEDNESDAY OCTOBER 10, 2018
9:00 - 2:00 MEMBERS WILL ENJOY A GOLF OUTING AT THE MILL CREEK GOLF COURSE LOCATED AT 1 WEST GOLF DR., BOARDMAN, OH 44512. TEE OFF 9:00AM
MEMBERS ARE ON THERE OUR FOR THE REST OF THE WEEK