The Maintenance Guild is a non profit corporation formed to bring together Maintenance personnel working specifically in the steel mill melting and rolling operations around the world. It is designed to give us a forum to openly share views and ideas on improving our respective maintenance organizations and operations within the Melt Shop and Rolling Mill.
This web site will be the main communication point to convey information on meetings, new ideas, and answers to questions or solutions to problems that you maybe experiencing in your shop. If you are involved in the maintenance operations in a melt shop or rolling mill please feel free to fill out a membership form, there is no cost to be a member. This way we can get information to you as needed on meetings and seminars as they are scheduled. If you want to become a voting member we now have a $25.00 annual fee which can be paid for on our web site.
The Maintenance Guild will hold their Twenty Ninth meeting on Sept. 29, 30, and Oct. 1, 2010.
The twenty ninth meeting of the Maintenance Guild will be held in Harrisburg, Pennsylvania with our host Plant being ArcelorMittal Steelton. This meeting will have a different format to attempt to accommodate better attendance and participation in the round table session. All attendees should plan to be in an all day round table session on Wednesday with an evening hospitality mixer. The technical presentations and tour will be on Thursday and our Golf Outing Friday morning. Transportation for the Plant tour will be provided for the group. We will be staying at the Holiday Inn East located at 4751 Lindle Road, Harrisburg, PA 17111. You can fly into Harrisburg International Airport which is approximately 6 miles from the airport to the Holiday Inn East. You will need to provide your own transportation from the airport to the hotel. They do have a complimentary Airport shuttle service. The room rate for the Guild members will be $105.00 dollars per night. To make your reservations click on this link http://ichotelsgroup.com/redirect?path=rates&brandCode=HI®ionCode=1&localeCode=en&GPC=MIX&hotelCode=MDTEA&_PMID=99801505 or call 1-(717) 939-7841for reservations and ask for the ‘Maintenance Guild’ rate. 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) and can 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 cut off date for the block of room we have on hold is Sept. 20, 2010 and we only have 40 rooms in the block 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
Posted by Mark G Kropf on Tuesday 25 May 2010 - 19:28:31
Meeting minutes of the April 14th – 16th meeting in Fort Wayne, In
The members of the guild arrived on Wednesday November 14th for breakfast at 7:00am and the Round table sessions began at 8:00. Dave Giancola introduced the executive board and reviewed the details of the next meeting September 29, 30, and October 1 in Harrisburg, PA with ArcelorMittal – Steelton hosting. Bob Fabian covered the topics for the technical presentations which could be copper casting maintenance and repair along with panel maintenance. Dave opened the floor for nominations of vice-president. He reminded the attendees that membership dues are paid to be classified as a voting member and the member must have an active role in the maintenance departments in a management or professional level. Members need to make sure they have approval of the potential candidate before submitting them for nomination. Next Dave Giancola had everybody introduce themselves and the company they work for. The following company’s were represented; CMC, Nucor Timken, SDI Butler, SDI Columbia City, Alta, V&M Star Evraz Rocky Mountain Steel and ArcelorMittal.
The round table session began with questions from the floor at 8:30. Dave had everyone go around and state their main issues and concerns in their shops then moved to detailed questions and discussions.
Dave stated out asking about Whiting cranes and their experiences. Short conversation was held on this topic.
DC furnace bottom anode issues, Life currently 250 heats and have a large amount of lead in their anode.
What pm’s are being performed on the Concast hydraulic oscillators and what measurements do you get to determine when to change them. Most shops look at them annually or on a heat count basis. More discussions were held on the maintenance planning and measurement technologies.
What fluids are other shops using in there oscillators, water-based fluids like glycol were used but from various different suppliers.
A question about Degasser ejector cleaning, how often and how do others clean them? Weekly, bi weekly and monthly were standard time frames along with high pressure blasting
Furnace automation technologies and implementation issues were discussed from RTD designs and life to proximity switches.
Carbon injection Burner placement and angle in the furnace issues were discussed to find out what the key indicators would be to determine placement and the number of burners needed.
Non contact water cleanliness issues were discussed and what other shops are doing in to control this issue.
Maintenance planning is being implemented and how are other organizations set up? Discussions were held on training, planning and staffing of a maintenance planning system. There were various configurations from shop to shop and all members shared their pros and cons to the systems they were using. Communication to the maintenance personnel on the floor was noted as critical to the success of the planning process. As well as listening to what they are seeing in regards to frequency of PMs and other maintenance functions.
We took a break at 9:40 and resumed the round table discussions.
Rolling mill water filtration and cleaning systems; what are other shops using and how do they perform?
Finding maintenance personnel was a topic of discussion. Most mills have experienced a large amount of skilled labor retiring and the new younger work force is not interested in the hot, dirty, rotating shift type of work environment. This makes finding new skilled labor difficult. Discussions on state and federal funding for training has helped but the problem comes in that the other industries are paying a little more for skilled labor and then they leave.
The question was asked about the LED lighting in an industrial setting. Also what are other shops installing High pressure sodium, metal halide were the two most talked about.
Run out roll lock up prevention was brought up and lubricant issues were discussed and which types are working.
Injection carbon conveying system components was discussed from transfer hoses to piping applications, and then discussed the feed mechanisms and the different types of manufactures.
Furnace ground issues were discussed and the discussion focused around reference grounding along with the plant ground grids. This was all to find a way to control induction currents on and around the EAF.
Safety programs and all the different ways we can improve the safety records in our respective shops. Programs from pre work stretching and tool box conversations to near miss reviews and interaction with the workers. Over the long term it has to become a cultural thing that everyone develops into and participates in. Sprains and strains is the top recorded injury. A monetary reward system was also discussed. Pop sickle and fresh fruit programs are implemented in some of the hotter climates by the shop nurse that brings personnel contact to the workers. Letters to families that makes them aware of safety incidents at work is another thing that promotes safety in their lives. PM program for clamp pressure? Some are using the Hammers system. They also have upgrade kits for the clamp systems.
Runway inspection system in the high production shops, how do you do it or schedule these inspections. Most utilize annual outages.
Who is using Water-cooled deltas those shops that use them has had good results.
What information are other shops measuring to develop a maintenance performance matrix? Different measures were brought up for discussion and each shop looked a different items. Planned vs. unplanned, downtime and $ per ton to name a few.
How are delays tracked in other shops?
At 11:55 nominations for vice president were closed and voting will take place after lunch. We broke for lunch at 12:00
After lunch ballots were passed out to all members in good standing and collected and tallied. Andy McFarlane of Nucor Seattle and Ian Reid of ArcelorMittal were the 2 nominations with Andy McFarlane winning with the majority vote and will assume his responsibilities After the Thursday evening dinner.
After the voting we resumed the round table discussions at 1:15.
Sealing the gaps arounf the EAF Panels does anyone have any good refractory recommendations? Graphite, emrald ram, electrical fire stop patch were all used in different shops.
A discussion was held on CMMS systems and manpower scheduling, planning and different software used for planning along with pre-outage meetings.
Who is monitoring off take gas and what companies are used Turnova was discussed.
What are other shops using as hydraulic cylinder rod material around the furnace to reduce the water induced wear on the chrome rod ends? Most shop used stainless rods and the second option was a double chrome process on a hardened rod material. Dover Hydraulics was one supplier discussed.
Static Var generators who is using them and what companies do upgrade and repairs to them GE and Alstom
Are there any Panel flashback detection systems in use anywhere?
Looking for a cleaning tool to use with co-jet burner ports to assure the proper contact for heat transfer from the burner to the block.
What types of hydraulic fluids do other shops use that is environmentally friendly a Castrol product was mentioned.
When you have a water leak in the furnace what is the procedures in the different shops? Do you kill all the water to the furnace or just the affected panel? Some shops have the total water “E stops” and others shop used various procedures from panel isolation and a combination of “E Stop” and isolation. There is a safety concern if you shut off all water to the EAF that you would create a potential larger safety problem.
Does anyone using any type of optic sensors for slag discoloration?
Slag door cleaning mechanisms, who uses what type? Mobile Ram, “unigate” Concast door gate and the Demag tail gate style were the types discussed.
Structural inspections who is doing it and do you do it internally or contact it out? Some shops do it annually internally and contracting out through the local iron workers with a structural engineer. Globex and structural preservation systems were two companies discussed.
Cell phone policies and newspapers in the shops, which is doing what? Most shops restrict usage and or having them on the floor.
We finished the round table discussion at 2:30 and loaded the bus for our tour of SDI Columbia City.
This meeting the members will be on their own for dinner and returned to the hotel for the Hospitality room activities from 6 till 11.
Thursday morning Dave opened the meeting with introductions and when to the first presentation. The first presentation was by Ian Reid from ArcelorMittal Dofasco presented a paper on “latest hot metal charging practice at the EAF”
The next presenter was Cecil Wristen from Vacuum Electric Switch Co. presented a paper on “Life Testing Remanufacturing VBT* Switches”
The next presenter was Loren Schultz from Hypro is presenting a paper on “Particle Counting Technologies for Water Glycol”
Our last paper for the day was presented by John R. Rolison, ASP from SDI Butler presented a paper On “plant safety and the achievements at Butler”
All presentations will be available on the website under the Technical papers section.
After the technical papers were complete, the group broke for lunch at 12:00 left the hotel at 1:00 for their tour of the SDI Butler Steel facility. After returning from our tour we joined in the Hospitality room at 6:00 for a social hour. Dinner was served at 7:00 and we were able to listen to Glenn Pushis V.P. General Manager - Flat Roll Division – SDI -Butler talk about his plant and the economic conditions in the steel industry. We finished the night with conversation and hospitality.
Friday morning we went to the Shoaff Park for our golf outing.
Posted by Mark G Kropf on Tuesday 25 May 2010 - 18:41:04
Meeting fee: $350.00 if not already paid, will need to be collected to cover meals and meeting incidentals. Questions: Call Mark Kropf (330) 479-5060, Dave Giancola (330) 742-6326 Dress: Business Casual attire
8:00 - 8:30 IN THE St. JOE ROOM INTRODUCTION BY DAVE GIANCOLA, FLOOR OPENS FOR NOMINATIONS FOR VICE PRESIDENT, GENERAL BUISNESS, & NEXT MEETING DISCUSSION.
8:30 - 9:30 ROUND TABLE DISCUSSIONS
9:30 - 10:00 BREAK
10:00 - 11:50 ROUND TABLE DISCUSSIONS
11:50 –12:00 ELECTION OF VICE-PRESIDENT
12:00 - 1:00 LUNCH BUFFET
1:00 - 2:30 ROUND TABLE DISCUSSIONS
2:30 - 2:45 BOARD BUS OUTSIDE HOTEL PROMPTLY FOR THE TOUR OF THE SDI COLUMBIA CITY PLANT.
3:30 - 5:00 SDI COLUMBIA CITY TOUR
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)
Thursday, April. 15, 2010
7:00 – 7:45 BREAKFAST BUFFET
7:45 – 8:00 MEETING ROOM: SIGN IN WITH YOUR BUISNESS CARD
8:00 – 8:10 INTRODUCTION: DAVE GIANCOLA
8:10 - 8:50 PRESENTATION: IAN REID FROM ARCELORMITTAL DOFASCO IS PRESENTING A PAPER ON “LATEST HOT METAL CHARGING PRACTICE AT THE EAF”
8:50 QUESTIONS
9:00 BREAK
9:10 - 9:50 PRESENTATION: CECIL WRISTEN FROM VACUUM ELECTRIC SWITCH CO. IS PRESENTING PAPER ON “LIFE TESTING REMANUFACTURING VBT* SWITCHES”
9:50 QUESTIONS
10:00 BREAK
10:10 – 10-50 PRESENTATION: LOREN SCHULTZ FROM HYPRO IS PRESENTING A PAPER ABOUT “PARTICLE COUNTING TECHNOLOGIES FOR WATER GLYCOL”
10:50 QUESTIONS
11:00 BREAK
11:10 - 11:50 PRESENTATION: JOHN R. ROLISON, ASP FROM SDI BUTLER IS PRESENTING A PAPER ON “PLANT SAFETY AND THE ACHIEVMENTS AT BUTLER”
12:00 QUESTIONS
12:10 LUNCHEON BUFFET
1:00 – 4:30 BOARD BUS OUTSIDE HOTEL PROMPTLY FOR THE TOUR OF THE SDI BUTLER STEEL PLANT
5:00 RETURN TO THE HOTEL
6:00 -6:30 GATHER IN THE BALLROOM FOR HOSPITALITY
6:30 - 8:30 DINNER – BALLROOM INTRODUCTION OF THE NEW VICE PRESIDENT AND PRESIDENT OF THE MAINTENANCE GUILD.
GUEST SPEAKER: GLENN PUSHIS V.P. GENERAL MANAGER - FLAT ROLL DIVISION – STEEL DYNAMICS
8:30 - 11:00 HOSPITALITY SUITE WITH BEVERAGES
Friday April, 16, 2010
9:00 - 1:30 GOLF OUTING AT “SHOAFF PARK GOLF COURSE”
Posted by Mark G Kropf on Friday 02 April 2010 - 09:57:03
Remeber your $25.00 annual membership fees are due. This meeting we will be electing a new vice president. The member dues need to be current to be considered a voting member per our corporate charter. You can make your payments on line or by check. Payments should be made out to:
Maintenance Guild PO Box 80461 Canton, Ohio 44708-0461
Posted by Mark G Kropf on Wednesday 17 February 2010 - 18:44:56
The annual meeting is set for April 14, 15 & 16th in Fort Wayne, Indiana
SDI Butler will be our host for the April meeting and we will be staying in Fort Wayne. Please look for registration details next week. Please note in making your travel arrangements, our golf outing will be on Friday and our round table will be either Wednesday or Thursday so please make sure you are available for an all day Wednesday meeting. Also please be thinking about nominees for Vice President as we will be voting at this meeting as Dave finishes his term as president and Ange steps up to assume his new role. Send your nomination to Mark as soon as you confirm them with the nominee. Membership fees are now due and can be made on line.
Posted by Mark G Kropf on Friday 12 February 2010 - 08:41:51
Meeting minutes of the November 4th – 6th meeting in Youngstown, Ohio
The members of the guild arrived on Wednesday November 4th for the Golf outing at Reserve Run Golf Club. That evening we all joined for hospitality at the Hampton Inn, Canfield. On November 5th Dave Giancola opened the meeting with the introduction of the officers and general business and then began with the introduction of the technical papers. The first presentation was by Mark Kropf from AE Resources is presenting a paper on “Opportunities to utilize waste heat for power generation and a reduced carbon footprint” The next presenter was Bob Ehrlich from Power Electronics International is presenting a paper On “VF drives for mill EOT cranes, benefits and considerations.”
The next presenter was Richard Szeg & Lou Lazzaretti from SMS Millcraft is presenting a Paper On “Measure and Maintain Caster Alignment”
Our last paper for the day was presented by Nick Klipa from CONCAST presenting a paper on “V&M star Caster Upgrade Project”
All presentations will be available on the website under the Technical papers section.
After the technical papers were complete, the group broke for lunch at 12:00 left the hotel at 1:00 for their tour of the V&M Star Steel facility. After returning from our tour we joined in the Hospitality room at 6:00 for a social hour. Dinner was served at 7:00 and we were able to listen to Eric Shuster - Manager Rolling Mill V&M Star talk about his plant and the economic conditions in the steel industry. We finished the night with conversation and hospitality.
Friday morning we had a short Business meeting to determine the location of the next meeting and to remind the membership that the spring annual meeting will be an election meeting for a vice president. Members need to make sure they have approval of the potential candidate before submitting them for nomination. Next Dave Giancola had everybody introduce themselves and the company they work for. The following company’s were represented; CMC, Nucor Timken, Republic, Alta, V&M Star and ArcelorMittal.
The round table session began with questions from the floor at 8:30. Dave had everyone go around and state their main issues and concerns in their shops then moved to detailed questions and discussions. Bob Fabian ask that as they come up for questions also be thinking about what type of papers they would like to hear at the next meeting.
First question was about utilizing outside sources for maintenance training. The members in attendance discussed the usage of outside training facilities as well as internal training. They also discussed the possibility of removing someone that may not have preformed as well as they thought. Ramsey Test Assessment was also discussed as a measure of what training is needed. CMC introduced their program called “21st Century Steelmaking”. It was mentioned that a dedicated training coordinator is helpful to a successful program.
It was pointed out that the maintenance Guild is a very important organization and we need to make sure that it remains viable and available for the future members.
Does anyone have problems with bag house dust sticking in the hoppers? Some did and have utilized a slippery surface coating in the duct and fluidizers for the hoppers. Sonic horns were discussed as well as reviewing the chemical makeup of the dust. Also mentioned were air slides, fluidizer beds, silent horns, and the BHA sonic tubes. It was mentioned that Alta Steel uses air horns.
Is anyone having problems with delta arcing? Yes some items to look at would be evacuation, carbon injection operations, grounding, arc bars, coating the bottom pipe with a ceramic coating and foamy slag performance based on arc stability.
How often do you align your caster and what are the tolerances allowed? About every 5 years the slab caster plants will laser align their machine? We are looking a 3 different radiuses and are always out of alignment Radius gauges are used and can assist when blending a particular roll with other rolls in the machine.
What experience does anyone have between pulse air vs. reverse air with shakers? There was a general discussion held about geographical locations and deciding what type of maintenance you want to do. Each design has its pros and cons and you would have to decide which one would work best with the given parameters that you are dealing with.
Is anyone using the replaceable hot face system on their carbon injection burners? No one here was using them but has heard about them.
How many shops us automatic sample lance systems and whose are you using. Variable shops were using them from different manufactures. Different designs and locations were also discussed.
Is anyone using the PTI quad jet burner system? No one had any experience with them. Some are trialing the Nucor jet box design copper blocks.
Is anyone using coating hydraulic cylinder rods? No one in this group had information on this, but one mill trialed a coating with no luck.
Is anyone using Concast burners? No one here Beaumont maybe using them.
Is anyone using blow back thermocouple detection systems and what is the temperature range. Dofasco has been using them with good results. Ange S to send Bob F some literature
Has any shop developed a Panel change procedure for safety? Nothing formal has been utilized, some shop have procedures dealing with position in relation to the panel during the change. Some shops utilize a bleed off type system to prevent pressure.
Can the Maintenance guild possibly start sharing different safety procedures during the round table session to expand our experiences? Yes. Mark will set up a safety page on the website for members to share. There was also a discussion held on updating safety procedures after new or upgraded equipment has been installed. What process do other shops use to assure consistency in lockout tag out procedures between different departments and areas in the shops? Different shops have established plans to assure the proper lock out tag out procedures that cover multiple areas. Others are in the process of developing and training to assure safe lockouts. Group lockout procedures were discussed and how they apply to operators, outside contractors, and maintenance. Tool box talks and other means of communicating and monitoring the various procedures to assure consistent and accurate safety procedures were discussed along with “cardinal rules” and how they are handled.
Is any using ceramic coatings on delta rings and or panels? Yes there were some shop trialing different types of coatings. Mark will send contact information on the companies that have this type of product.
Are any shops dealing with employees leaving for higher paying jobs? Some were and trying to develop different ways to attract and retain people. We know that we will lose good people and there are some industries you cannot compete with.
What is the status of the Arc flash rating compliance in the other mills? Most have been through the process and have included the mechanical group as well. There were a couple of mills that are in process of becoming compliant. Maybe we could get a shop that has done all the training to do a paper on the process for the guild.
How many shops run a reactor on their furnaces that use it to control arc stability? The ones that use reactors report good reliability.
Are there any shops adjusting their pm program based on operating data points to generate work orders?
What are the other scrap bucket suppliers? Signal, Gerard, Ewing were a few named.
Does anyone have information on cameras that can look into the caster molds to monitor mold powder applications? There was some that have this and the information will be emailed to him.
Does anyone have experience with peak shaver system in your duct? There were a couple of shops that shared their experience with this technology. The conversation moved into bag house bag maintenance and the effects the peak shavers can have if not maintained. Then the conversation started to cover duct maintenance particularly during the cold months.
Is anyone using the XO electrode adding robot and how does it perform in the cold? There will be troubles and it will need to be kept warm and clean.
Who using what type of high voltage disconnects? Siemens, Joslyn, Pac all were mentioned.
Anyone have experience with quick disconnect connections on the electrode leads? None of the shops here had any but they did know shops that were. The next meeting we will move the round table to Thursday to avoid the conflicts with travel home. Mark will communicate the revised schedule to the membership for the next meeting.
A discussion was held on the establishment of the 5s set up process and planning.
Does anyone have spindle monitoring? Vibration monitoring was discussed and understanding the readings to determine if it is a bearing, gear or spindle issues.
Meeting adjourned at 2:00.
Posted by Mark G Kropf on Monday 09 November 2009 - 10:37:15
Meeting fee: $350.00 if not already paid, will need to be collected to cover meals and meeting incidentals. Questions: Call Mark Kropf (330) 479-5060, Dave Giancola (330) 742-6326 Dress: Business Casual attire
Wednesday, November 4, 2009
10:00 – 3:00 GOLF OUTING AT RESERVE RUN GOLF COURSE. (MAPS AT HOTEL FRONT DESK)
7:00 – 11:00 HOSPITALITY SUITE WITH HOURSDORVES PROVIDED BY SUPPLIER GROUP (At Hotel)
Thursday, November 5, 2009
:00 – 7:45 BREAKFAST BUFFET
7:45 – 8:00 MEETING ROOM: SIGN IN WITH YOUR BUISNESS CARD
8:00 – 8:10 INTRODUCTION: DAVE GIANCOLA
8:10 - 8:40 PRESENTATION: MARK KROPF FROM AE RESOURCES IS PRESENTING A PAPER ON “OPPORTUNITIES TO UTILIZE WASTE HEAT FOR POWER GENERATION AND A REDUCED CARBON FOOTPRINT”
8:40 QUESTIONS
8:50 BREAK
9:00 - 9:30 PRESENTATION: BOB EHRLICH FROM POWER ELECTRONICS INTERNATIONAL IS PRESENTING A PAPER ON “VF DRIVES FOR MILL EOT CRANES, BENEFITS AND CONSIDERATIONS.”
9:30 QUESTIONS
9:40 BREAK
9:50 – 10:20 PRESENTATION: RICHARD SZEG & LOU LAZZARETTI FROM SMS MILLCRAFT IS PRESENTING A PAPER ON “MEASURE AND MAINTAIN CASTER ALIGNMENT”
11:00 QUESTIONS
11:15 - 11:50 PRESENTATION: NICK KLIPA FROM CONCAST IS PRESENTING A PAPER ON “V&M STAR CASTER UPGRADE PROJECT”
11:50 QUESTIONS
12:00 LUNCHEON BUFFET
1:00 – 5:30 BOARD BUSSES OUTSIDE HOTEL PROMPTLY FOR THE TOUR OF THE V&M STAR STEEL PLANT
5:30 RETURN TO THE HOTEL
6:00 -7:00 GATHER IN THE HOTEL CONFRENCE ROOM
7:00 - 8:30 DINNER BUFFET CONFRENCE ROOM GUEST SPEAKER: ERIC SHUSTER ROLLING MILL SUPERINTENDANT - V&M STAR—YOUNGSTOWN
8:30 - 10:30 HOSPITALITY WITH BEVERAGES
Friday November, 6, 2009 (CLOSED SESSION FOR MILL PERSONNEL ONLY)
7:00 BREAKFAST BUFFET
8:00 - 8:30 GENERAL BUISNESS, NEXT 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
1:15 - 2:45 ROUND TABLE DISCUSSIONS
2:45 - 3:15 BREAK
3:15 - 5:00 ROUND TABLE DISCUSSIONS
Posted by Mark G Kropf on Tuesday 27 October 2009 - 11:28:23