The 48th meeting minutes October 2023
/Meeting minutes of the October 23rd, – 25th 2023 meeting in Beaumont, Tx
The members of the guild arrived on Monday October 23, 2023, for breakfast at 7:00am.
Mark Kropf reviewed the details of the week’s schedule along with the current officer status since the missing 2 years of no meetings due to COVID. Mark then covered the status of the Maintenance Guild and ask what the future should look like. With our industry running lean in the skilled labor sector, the ability for attendees to get to meetings has become very difficult. The new president and vice-president needs to be established. This would make Jonathan Putman the president. Jonathan has taken a new position with Nucor and will not be able to fulfill his commitment. Nate Hotson from ArcelorMittal Dofasco who volunteered to fill this void as our vice-president will check with management for approval to fill this void. Mike Osteen from CMC Texas also stepped-up and will fill an opening as an officer. Mark will be following up with them on there status. Mark is also working with Chris Long from Timken for training on meeting planning. The next meeting, we will need to have election of the next Vice-president.
The following companies were represented; Optimus steel, CMC Texas, ArcelorMittal Dofasco, Nucor Jewett, & IVACO.
Mark started the round table session at 8:15 with questions from the floor.
The group had a long discussion on the challenges the industry is facing in find and retaining skilled trades in their shop. They discussed some of the different programs and places they are using to get the skilled trades in their shop along with the economic challenges they are facing.
Took a break at 9:45
We started back at 10:00
The charge crane in the melt shop is the dirtiest crane and the maintenance group said they need to vac the crane off before they can do maintenance. What are other shops doing for they charging crane maintenance? One shop has a permanent pipe set up to minimize set up time to clean, but they clean the crane on every down day. Also, they have a maintenance crane for the down days so the charge crane can be parked for cleaning and maintenance. One shop has a second charge crane along with a maintenance crane.
What are other shops doing for charging alignment for the charging process. Arrows verses limit switch application with the pros and cons was discussed but because of the process environment the arrows were the most widely used. The Symeo RF positioning system was discussed as well and TIMKANTECH was a company mentioned.
We are having trouble with grease hardening in the line at our caster cooling bed. We currently have to change the tubing regularly; we have high temp grease and it still is getting hard and plugging off.
What are other shops using for the caster cooling bed operators. Ours have two hydraulic cylinders and they are very hard to keep synchronized. One shop used gear box drives and thought they were the best. They are cooling beds that only use one cylinder and they do not have any issues.
What are other shops using for crane movement restrictions and or poisoning and what are the pros and cons of your systems The group discussed Symeo RF systems for crane positioning versus the limit switch or laser systems. Along with the issues each shopped faced.
What are other shops doing with shutdown schedules? Weekly monthly how long?
There was a large variation from shop to shop, some are weekly 8 to 10 hours some are at 10 to 12 every 2 weeks. There was a long discussion on the different schedules from shop to shop along with the causes for missing the start-up times. The group also discussed maintenance group structures from planners, leader’s coaches and maintainers.
How many burners are other shops using in their furnace? The group discussed each of their configuration and who was being used. Carbon, Lime and burner positions, and angles were discussed. There
The group broke for Lunch at 12:00
We started back at 1:00
Central Maintenance reliability does planning but get little more from them, how do other shops utilize their time more efficiently? A conversation was held about the structure of using planners versus the maintenance guy planning his own job. But the general feeling within the group was to have planners but to have them more active in not only planning the job but closing it as well. Material, parts and time tracking for the repair jobs are critical information that needs to be retained in the system.
The group discussed the reliability of the “Terminator” for making furnace bottom and sidewall repairs. Then discussed how often they need to drain the furnace for the tap hole repairs and maintenance.
How do other shops keep the area clear from scrap around the tilt cylinders? One shop use an outside contractor that used magnets and other equipment once a month. But some do daily cleaning. The no man on the floor has had a negative impact on the ability to clean these areas, so now there needs to be innovative ideas on preventing the build up of scrap around the cylinder.
Does anyone have problems with steel splash on the contact pads? They are changing them almost a weekly event. They discussed baghouse drafting to delta port size as part of the problem. Spray ring performance also plays into the build up on the pads and heads. One shop does a clean and inspection on the vault wall secondary every month as well. The conversation moved to the “beer can” power cable connectors that enable them to do a power cable change in les than 30 min. This technology has made it very easy yo do a power cable change with minimal impact to productivity.
The group had a discussion on tilt platform rocker bases and pier life and most OEM would say 10 to 15 years and most shops have seen life in the 20-year range but have had issues with wear.
Turret bearing and hydraulic cylinder storage was also discussed from shop to shop.
What kind of schedule to other shop have for hydraulic cylinder change outs, are they on a calendar or wear type schedule. Most shops use a calendar schedule from an annual to 2-year schedule depending on cycle life.
Who uses EMF systems on the casters. Some did and they discussed the maintenance and upkeep of these systems.
Took a break at 2:50
We started back at 3:10
Does anybody know any companies for used motors or obsolete motors? The group had a couple of names they shared. Eerlet was mentioned for control box repairs.
What companies are out there that provides crane services and possible parts supply. Simmers was one and a couple of others were discussed.
What methods do other shops use to make sure hoses are connected correctly. There were a couple ideas discussed and lettering on the hose for directional identification was discussed.
Do other shops have issues with scrap magnet over heating? Yes, one shop built installed a current draw meter so the operator would know the magnets were getting hot. So they built a water tank that they can set the magnets in and use a spare set to keep loading
What type of baghouse bags are other shops using? Gore was the primary bag supplier mentioned and their low drag bag was discussed. The Fiberglass and Kevlar both are good performers.
What brand of crane brakes are other shops using? Cutler Hammer was the one discussed in detail for their reliability.
How do other shops handle the material in the bag house? Screws, pneumatic, air slides were discussed.
What type of swing cylinder mounts are used in other shop. Most are ridged mounts but do not have issues with off center loading.
Drop box design conversation was held in regard to the size, temperature drop and the need for peak shavers.
What are other shops using to flush the electrode arms? Some chemical flush was discussed but caution when doing it on aluminum arms.
How do other shops measure temperature on the ladle preheater? Pyrometers, thermal couples and infrared sensors were mentioned.
How do other shops remove the breakout skulls from a cast break out? Most will pull them out from above the mold, and sometimes you will put it from the bottom past the straightener and from the mold area.
How do other shops handle being “on call” for maintenance breakdowns, is there compensation? Some shops do not compensate for on call duty and others will provide 3 hours of pay for on call, but if they are called in then overtime pays is made.
Different shift schedules were discussed from the 10 hour days to the Depont schedules.
How do other shops manage outside contractor jobs on down days? Company maintenance personnel and or supervisors will monitor those assigned jobs.
Do any shops use “cool vests” when in hot environments? Some have but they need refilled often so it isn’t the most convenient. When the environment is over 100F then you work a 45 min in 15 min cool. So on the same topic what it the maximum hours that an employee can work? The range was 13, 14 and 16 was the max.
The round table finished at 5:15 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. Mark 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.
Mark made the introduction for our first presentation at 8:05.
PRESENTATION:
DAVID BROUSSARD OF AMERICAN HOFMANN PRESENTING A PAPER TITLED “AB9000 ACTIVE BALANCING SYSTEM”
David finished the presentation at 8:35 and took questions from the floor.
After a short break Mark introduced our second paper at 9:00.
ALDO LONGO OF A. LONGO CONSULTING PRESENTING A PAPER “EAF HEALTH AND SAFETY WITH NO MAN ON THE FLOOR”
Aldo finished the presentation at 10:20 and took questions from the floor.
Mark made the introduction for our fourth presentation at 10:40
BRIAN HILK OF KALINBORN ABRISIST PRESENTING A PAPER TITLED “WEAR SOLUTIONS FOR THE STEEL INDUSTRY”
Brian finished the presentation at 11:10 and took questions from the floor.
After a short Break Mark introduced our fifth paper at 11:20
ROB STRAIN OF NU-CORE PRESENTING A PAPER TITLED “ELECTRODE ARM REFURBISHMENT PRACTICES”
Rob finished the presentation at 11:50 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 OPTIMUS STEEL facility.
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 8:00 we were able to hear our guest speaker.
SCOTT ANDREWS, MILL GENERAL MANAGER OPTIMUS STEEL
From 8:30 - 11:00 the group finished with a mixer to discuss the day’s events and information.
WEDNESDAY OCTOBER 25, 2023
MEMBERS WILL ENJOY A GOLF OUTING AT BRENTWOOD ENTERTAINMENT COMPLEX
TEE OFF 8:04AM
MEMBERS ARE ON THERE OUR FOR THE REST OF THE WEEK