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Dutch Fluid Power Conference 2016

An end users view to hydraulic design

René Cnossen

Together we make the difference

Overview;

1. Who are we?

2. What we are doing?

3. What design do we want?

4. Why should we specify and why not?

5. What do we need in the future?

Who are we?

Tata Steel IJmuiden an introduction

Yearly production 8 million tons of steel strip products.

Production process

• Iron ore reduction to steel

• High temperatures 1600°- 1800°C

• High product weight 48 tons

Drive systems

• Electrical drives up to 12 MW per motor

• Hydraulic power units up to 2250 l/min 210 bar

• Standard mineral oil systems

Production installations

• Dedicated heavy duty design

• Long service life

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• Low maintenance

• Safe to use

• High forces high loads

What are we doing?

Projects and engineering centre PTC HTD maintenance service

• Involved in projects selection and execution for asset

development and asset reliability improvement

• Large investment projects

• Revamp blast furnace 6

• Replacement down coiler 1 hot strip mill

• Continuous Caster 23, BOF 2

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What are we doing?

• Very competitive market requires continuous improvement

• New product development require new assets

• Business case is leading for the project

• Careful process from business idea up to start of commercial

production.

• PTC translates functional specifications into technical

requirements and Request for

Quotation.

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Engineering and design

Engineering based upon best practices safety, operations and

maintenance.

Dedicated team of 6 hydraulic project engineers and 8 Hydraulic

maintenance engineers.

Transfer Tatasteel requirements into RfQ for Orginal Equipment

Manufacturers

Controlling engineering products of contractors

QC/QC during manufacturing and erection

What design do we want?

Why?

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Hydraulic design specifications

Why? • 24/7 production process

• Heavy loads with high accuracy

• Harsh environment, temperature, dust, vibrations, water,

chemicals

• High safety demand

• Familiar design and components for maintenance staff

• Long service life long maintenance intervals

• High reliability and easy maintenance

• High costs of unscheduled down time.

BEST

PRACTICES

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What design do we want?

Design Signature, HP pumps

Tata Steel Ijmuiden standards and guidelines can be found on the

internet;

http://veiligheid.tatasteel.nl/en/Regulations/Technical-

requirements/Technical-Directives/Mechanical-

Engineering/Hydraulics.html

• Variable displacement pumps 1000rpm, A4VSODR

• Hose burst safety switch

• Pump block, filter, relief valve, check valve,

ball valve

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What design do we want?

Design Signature, Fluid

Power units

• HLP ISO Vg 32cSt,

• Heating with solenoid op. relief valve

What design do we want?

Design Signature, Operator Safety

Design Signature,

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filtration

Filtration system

• Very important for the service life of your system.

• Required system cleanliness in specifications

• No supplier tells you why the offered filter system is effective.

• Downsize filter flow rate

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Design Signature, Piping

• Welded cones or flanges, backing gas, 100% X rayed > PN

40bar.

• Bended pipes

• Stauff clamps on rigid supports

• Pipe hose connections with welded blocks

• Flushing with super heated oil and v> 7 m/s until cleanliness

ISO 4401 1999 17/15/12.

•

Piping

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Design Signature, manifolds Control valves

• Manifold table design, forged steel blocks, grinded Ra < 0,4

• Spool valves limit choice NG10, 25, 32, external X and Y,

reduced pilot pressure 25 bar.

• Stack height maximum 3 items.

• Cartridge valves not drilled in the main manifold blocks but in

add on block.

• Proportional valves with external amplifier card in dedicated

cabinet.

• Servo valves with Px filter 3μm, check valves to block servo

valve in case of emergency stop of power failure.

• P, A and B shut of valves

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Why should we not specify?

Apostles versus Ipad generation

Why should we not specify? Know what, but not why.

• To update a standard document is time consuming and often

neglected.

• It is written but the motivation is lost.

• New generation can not explain why it must be done like that.

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Why should we not specify? O.E.M. ‘s global players with own standards

• Why should we change something which has been sold many

times before? But doesn’t work in IJmuiden.

Tradional techniques versus early adapters When and how to apply new technology?

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Why should we not specify?

Maintenance interest versus commercial interest

• Tata Steel hydraulic standards cost money.

• The procurement officer does not want any hydraulic

standards.

• Functional specifications and

ISO are sufficient.

Maintenance interest versus commercial interest

• Final decision is made upon total lump sum / total cost of

ownership.

• Suppliers profits demand low cost countries

• The quality of the supplied goods is not always what we

assume.

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Traditional design choices versus new developments • Specifications can kill innovative solutions,

• Zincpot lifting table with 4 HPU’s VS Drive pumps

4 lifting cylinders / servo control 210 1

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4 lifting cylinders controled by VSDpump 1

What do we need in the future?

Higher forces, faster actuators with more accuracy.

Online data analysis of system behaviour

Industry 4.0

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What do we need in the future? • Skilled, quality concious suppliers

• Bright young people with passion for hydraulics.

• Ir, Ing, PhD, BSc, MSc?