Proceedings

4/SE1996 Annual Convention

X 8H $^

B/TIB

September 30,1996

Hyatt Regency Chicago

Chicago, Illinois

Contents

Coke Operations SessionChairmen: Thomas A. Berg, Director—Manufacturing, Citizens Gas & Coke UtilityRichard J. O'Hearn, Assistant Division Manager, Acme Steel Co., Chicago Plant

George Sich, Jr., Maintenance Manager—Cokemaking, AK Steel Corp., Ashland Works

Coal Properties—Measurement and Application to Cokemaking 1

Hope D. Huntington, USX Engineers & Consultants, Inc.

Electrohydraulic PID Backpressure Control System 13

Charles T. Truett, Dwight G. Fohner, Sloss Industries Corp.

Start-Up at Koppers' Monessen Plant 17

Richard James Burkhart, Koppers Industries, Inc.

A Retrofit Coking Process Using Coke Powder Coal Blending 19

Wen Yanming, Chen Changhua, Xu Xinzhou, Jinan Iron and Steel Co., Coking Plant

Shitang Tong, Wuhan Yejin University of Technology and Science

Blast Furnace General SessionChairmen: Deryl Biron, General Foreman—Iron Making Maintenance, Algoma Steel Inc.

Robert Jason, General Supervisor—Operations, LTV Steel Co. Inc., Cleveland Works—iron ProducingAndrew Kmiec, Area Manager—Operating Practices, U.S. Steel Group, USX Corp., Iron Producing Div.

Upgrade of Process Control Systemat U.S. Steel Fairfield No. 8 Blast Furnace 37

Rich Camlic, U.S. Steel Group, USX Corp.; Neil J. Goodman, Davy International

1995 Repairs to No. 8 Blast Furnace—U.S. Steel Gary Works 51

Laurence E. Scott, Jr., Thomas G. Yearsich, Gary Works, U.S. Steel Group, USX Corp.;William E. Pyne, ATSI, Inc.

No. 5 Blast Furnace 1995 Reline and Upgrade 77

Thomas F. Kakascik, Jr., Steubenville Works, Wheeling-Pittsburgh Steel Corp.

Start-Up and Optimization of SIDERAR Blast Furnace 2 81

Fernando Giandomenico, Oscar Lingiardi, SIDERAR General Savio Works;

Juan Manuel Gonzalez, Instituto Argentine) de Siderurgia;

Marteen Geerdes, Hoogovens Technical Services, Umuiden;

Electric Furnace Maintenance SessionChairmen: Jonathan Ridgeway, Manager—Melting, Casting and Teeming

Republic Engineered Steels, Inc., Melt ShopJohn A. Tacca, Maintenance General Supervisor, North Star Steel Co., Minnesota Div.

Design of the Hylsa AM DR Plant for HYTEMP®Hot DR! Transfer to the Thin Slab Casting Mill 101

Pablo Duarte, Ronald Lopez, Hylsa, SA de CV, HYL Technology Div.

Maintenance of Secondary Power and Structural

Systems for Electric Arc Furnaces 113David A. Surgeon, David G. Berg, James R. Tober, Erie Copper Works, Inc.

Electric Arc Furnace Vacuum Switch Design,Application and Maintenance 127

David W. Skeans, Joslyn Hi-Voltage Corp.

Basic Oxygen Furnace SessionChairmen: Manfred Eysn, General Manager, Voest-Alpine Industrieanlagenbau

John F. Spencer, Manager—Sales and Proposals, Reichard Industries, Inc.

Analysis of BOF Trunnion Ring System 129Charles A. Schacht, Schacht Consulting Services;Dennis H. Radford, Great Lakes Div., National Steel Corp.

Assembly and Exchange of No. 7 BOP Vessel at Weirton 165William J. McElhaney, Eric J. Bamhouse, Weirton Steel Corp.

Replacement of No. 4 and 5 Vessels

at Algoma Steel's No. 2 Basic Oxygen Steel Plant 167Helmut E. Brandstetter, Algoma Steel Inc.;Michael J. Stercho, MAN GHH Corp.;Rashed N. Nagati, Nagati, Inc.

Rehabilitation of BOP Vessel Drive at National Steel 175Dennis H. Radford, Timothy M. Machak, Great Lakes Div., National Steel Corp.;Miron Mironczuk, In-Place Machining

Pickling and Process Lines SessionChairmen: Richard Gordon, General Manager—Engineering and Maintenance Technology, Dofasco Inc.

Ganapati Sengupta, Technical Consultant, Inland Steel Co., Indiana Harbor Works

New Pickling Line at Great Lakes Division of National Steel 179Jack R. Spanitz, Jr., William King, Great Lakes Div., National Steel Corp.

Chemical Pickling Process at Allegheny Ludlum's

No. 91 Anneal and Pickle Line 187Anthony A. Pengidore, Mannesmann Demag Corp.;Gustav Cserr, Jr., Vandergrift Plant, Allegheny Ludlum Corp.

Temate® 2000 Weld Quality Inspection System 199Dennis D. Lang, Daniel P. Geier, Babcock & Wilcox Innerspec Technologies;Anton J. Rovito, LTV Steel Co. Inc.

Submerged Combustion: Lower Costs, Higher Qualityand Faster Throughput in Acid Pickling 211

Ron Walker, Robert Williams, Walker Engineering

Bar and Shape Rolling I SessionChairmen: Edward Fell, Superintendent—12 In. Mill, CSC, Ltd.

William Kerns, General Manager—Operations, J&L Structural, Inc.

The REFLEX Laser Profile Gage 225

Geoffrey Sagar, Integrated Photomatrix Ltd.

Optimizing the Performance of Bar Mill Shear Knives 237

John T. Jasko, Grinding Engineering Services Co.

Size-Free Rolling Technology for Bar and Wire Rod Using 4-Roll Mill 255

Yukihiro Hoashi, Hiroyuki Ohira, Toshiyuki Hoshino, Mizushima Works, Kawasaki Steel Corp.

Georgetown Steel Abrasion-Free Coil HandlingJoseph R. Ford, Georgetown Steel Corp.

257

Energy and Combustion SessionChairmen: Edward Duke, Area Engineer, Wheeling-Pittsburgh Steel Corp., Steubenville Works

Frederick Guyor, Superintendent Plant Services, J&L Specialty Steel, Inc., Detroit Plant

Robert Kane, Combustion Engineer—Utilities, WCI Steel, Inc.

Topping Turbine Generator in Blast Furnace Power House 267Robert E. Mooney, REM Engineering, Inc.;

Raymond C. Ganga, The McBurney Corp.;Pittman Owen, Fairfield Works, U.S. Steel Group, USX Corp.

Thermal Imaging Applications at Carpenter 287Glenn H. Rohrbach, Carpenter Technology Corp.

Danarc Technology—Latest Applications 291Peter Samuelsson, Danieli;

Kjell Bergman, Centro-Met AB

Reheat Furnace Upgrade Results in Significant Production Increase 297Andy H. Burns, Thermix Ontario Inc.

Fred L. Fuhrman, Hauck Manufacturing Co.

Environmental Engineering I

Water Treatment Issues SessionChairmen: Richard Dugan, Design Engineer—Environmental, AK Steel Corp., Middletown Works

Dennis Poulsen, Manager—Environmental Services, California Steel Industries, Inc.

Novel Techniques for Reclamation of Waterand Scale Products in Steel Mill Operations 309

Mikael Wallin, Bill Schlittler, Svedala Pumps and Process AB

Grease Skimmer Essential for Successful Operation of

Circulating Water System at North Star Steel 323Dave Giancola, North Star Steel Co., Ohio Div.;Dennis Weaver, Abanaki Corp.

Technical Aspects of Brownfield Development—A Steel Mill Case History ... 335Geoffrey A. Glanders, August Mack Environmental, Inc.

Nonchemical Approach to Hard Water Scale, Corrosionand White Rust Control 341

C. Jack Quinn, Purdue University;T. Craig Molden, Molden Associates, Inc.Charles H. Sanderson, Superior Manufacturing Div., Magnatech Corp.

Maintenance Technology IChairmen: Howard Ralyea, Senior General Foreman—Maintenance

Bethlehem Steel Corp., Sparrows Point Div.

Douglas Velegol, SeniorTechnical Engineer and Predictive Maintenance Planner, Weirton Steel Corp.

Gear Spindle Management and Reconditioning 361

Thomas M. Ryan, Xtek, Inc.;Albert P. Westra, Jose deJesus, Jr., Sparrows Point Div., Bethlehem Steel Corp.

Improving Mechanical Reliability and TroubleshootingEffectiveness with Lubricant Condition Monitoring 377

Drew D. Troyer, Diagnetics, Inc.

Mold Oscillation Performance Monitoring with

Predictive Maintenance Tools at National Steel, Great Lakes Div 391

Timothy M. Machak, Great Lakes Div., National Steel Corp.; Hank Herber, I.S.I.

Plating Line Efficiency Enhanced through Proactive Maintenance 397

Joseph Dominick, Computational Systems Inc.

Lubrication SessionChairmen: Bruce W. Nale, Predictive Maintenance Engineer, Allegheny Ludlum Corp., Brackenridge Works

Richard C. Schrama, Senior Specialist, Roll Services Technology, Dofasco Inc.

Grinding Fluid Technology and Selection Criteria 403

Dennis C. Zintak, Castrol Industrial North America Inc.

Biocides Use Strategies for Lubricant Rancidityand Biofouling Prevention 413

Frederick J. Passman, Biodeterioration Control Associates, Inc.

Gear Oil Classification and Selection 429

Dennis A. Lauer, Kluber Lubrication N.A.L.P.

Current Methods of Lubricating Heavy-Duty Open Gear Drives 441

Charles D. Barrett, Castrol Industrial North America Inc., Performance Lubrication Div.

Environmental Issues for Coke Producers SessionChairmen: Ronald M. Schoen, Manager—Coke Plant, Sloss Industries Corp.

Joel L Sundholm, Senior Development Engineer—Coke, LTV Steel Co. Inc., Technology Center

Jack A. Withrow, Staff Process Engineer, U.S. Steel Group, USX Corp.

Clairton Works, Coke Development Engineering

Meeting Mercury Effluent Limitations at the Warren Coke Plant 447

James Fittipaldo, Bill Mills, Warren Coke Plant, LTV Steel Co. Inc.;

George M. Wong-Chong, ICF Kaiser Engineers

Acme Steel Cyanide Precipitation Process 457

Larry W. West, Acme Steel Co.

Using Waste from Coking Plants to Produce Metallurgical Coke 459

Vitaly Gulyaev, Dnieprodzerzhinsk State Technical University, Scientific Dept.

Blast Furnace Reline SessionChairmen: David Kristo, APEX Manager—Coke and Iron Div., U.S. Steel Group, USX Corp., Gary Works

Keki Nanavati, Senior Engineer—Development Engineering, LTV Steel Co. Inc., Technology Center

Mark Rosi, Vice President—Operations, Paul Wurth Inc.

Reline Philosophy: Mini vs Conventional Panel Discussion 461

Deryl H. Biron, Algoma Steel Inc.

Richard R. Schat, Dofasco Inc.

David H. Wakelin, LTV Steel Co. Inc.

John P. Wallace, U.S. Steel Group, USX Corp.

Water Cooling in Electric Furnace Panels SessionChairmen: Steve C. Roeber, Project Manager, Inland Steel Bar Co.

Robert Siddall, Manager-Primary Operations, Pennsylvania Steel Technologies Inc.

Water Cooling in the Electric Furnace—Current State of the Business,A Panel Discussion 463

Dick Arthur, UCAR Carbon Co. Inc.

Jesus F. Carlos, Melter SA de CV

Manfred Haissig, Fuchs Systems, Inc.

Wayne F. Walker, Superior Machine Co. of South Carolina, Inc.

Basic Oxygen Furnace Hoods SessionChairmen: Hawley Garvin, Senior Engineer, Bethlehem Steel Corp., Sparrows Point Div.

Kegham Markarian, Senior Development Engineer, LTV Steel Co. Inc., Technology Center

Basic Oxygen Furnace Hoods Panel Discussion 465

James L. Barkan, Babcock & Wilcox Co., Engineering—U & EPD

Neil J. Goodman, Davy International

Robert Eugene Hargrave, Betz Laboratories

Rashed N. Nagati, Nagati, Inc.

Modernization SessionChairmen: Richard Corbett, Assistant Superintendent—Cold Sheet Mill

Bethlehem Steel Corp., Burns Harbor Div.

Alan Reed, Chief Engineer—Rolling and Finishing, Geneva Steel

Modernization of Three Hot Strip Mills

in the Peoples' Republic of China (P.R.C.)Liu Jie, Anshan Iron and Steel ComplexLiu Binnan, Wuhan Iron and Steel Co.

Dai Ping, Wuhan Iron and Steel Co.

Sun Yi Kang, University of Science and TechnologyXu Hai Hong, Congqing Iron and Steel Design Institute

James McMahon, Cegelec Automation, Inc.

Aloys F. Seeger, Cegelec Automation, Inc.

Lin Qi Zeng, Taiyuan Iron And Steel Co.

Wang Qifeng, Taiyuan Iron and Steel Co.

Han Jinsheng, Taiyuan Iron and Steel Co.

James D. Robertson, Cegelec Automation, Inc.

Li Liang Zhen, Shanghai Meishan Corp.

He Wei Ming, Meishan HSM

AHMSA Hot Strip Mill Modernization

Samuel Vargas Valdez, Roberto Marin Vidal, Homero Perez Ramon,

Altos Hornos de Mexico, SA de CV

Rebuilt Reversing Mill Performance

Kevin J. Young, Brian K. Cooper, James C. Ellingwood, Nucor Steel-Indiana

Inland Steel's 80-ln. 5-Stand Tandem Cold Mill

Hydraulic AGC Modernization

James M. Hennes, Lewis R. Kimberly, Patrick E. Bernard,

Indiana Harbor Works, Inland Steel Co.;

Jean-Marc Zanni, Davy International

501

513

515

Bar and Shape Rolling II SessionChairmen: Nicholas Currie, Project Manager, Charter Steel

Richard Maguire, Production Manager—Hot Rolled Products, Laclede Steel Co., Alton Works

Development of a Production Control and Reporting System 541

Joseph Kennedy, Quad Infotech; Terry Donovan, North Star Steel Co., Kentucky Div.

Mill Controls: Highlights of Current Systems and

Future Directions — Panel Discussion 555Alex Nicoloso, Danieli CEDA

William Hastings Rowe, Reliance Electric Co., Drive Systems DivisionVeli Matti Vekkeli, Siemens Energy & Automation, Inc.

Computer Applications I SessionChairmen: Michael Dudzic, Manager—Process Automation Technology, Dofasco Inc.Herman Henn, Senior Staff Engineer—Computer Systems Group, LTV Steel Co. Inc.

Technology Center, Process Development

Coating Weight Control for No. 1 Continuous Galvanizing Lineat Mizushima Works 557

Yoshinori Anabuki, Takayuki Yoshioka, Akio Shinohara,Kawasaki Steel Corp., Mizushima Works

Conversion of Dofasco's Galvanize Line Supervisory Control

Systems to Object-Oriented Technology 569Blair D. Gerrish, Norman S. Forrester, Dofasco Inc.

Installation and Utilisation of DAK® at IMSA's No. 2 Continuous

Galvanizing Line 597Roberto Garza, Fernando Gonzalez, Industrias Monterrey, SA de CV;Jean-Jaques Hardy, Francois Savaete, Kvaerner Clecim SA

Automatic Mold Level Control—Present Day System 609Thomas E. Hodgson, Mannesmann Demag Corp.

Environmental Engineering II

Electric Furnace Dust Treatment SessionChairmen: Eric Howland, Manager—Maintenance, Power and Utilities

Republic Engineered Steels, Inc., Central Alloy District

Edward Morganti, Manager-—Chemical and Environmental Engineering, Dofasco Inc.

EAF Dust Management: Where Are We Now?

Where Are We Going? 611Alan D. Zunkel, A. D. Zunkel Consultants, Inc.

Benefits for Steelmakers in Recycling EAF Dust 623

James Saville, David J. Sosinsky, R. Drake Green,

Horsehead Resource Development Co., Inc.

MRT Process: Value-Added Recovery of Electric Arc Furnace Dust 629

Allan S. Myerson, Metals Recycling Technologies Corp.

Maintenance Technology II SessionChairmen: Patrick Mulvey, Manager—Maintenance Strategies, LTV Steel Flat Rolled Co., Cleveland Works

Joseph Wonsettler, Manager—Reliability Improvement Team GNW-06

The Timken Co., Steel and Tube Div.

A-C Technology for Run-Out Tables 631

Robert M. Green, Lincoln Electric Co.

How to Calculate Return on Investments

for Maintenance Improvement Projects 653

Terry Wireman, TSW International

Maintenance Excellence

Lyle B. McCormick, Jr., Glenn Eisen, Omega Consultants, Inc.

675

Hydraulic SessionChairmen: Yuqin Dong, Manager—Tribology and Gearing, Tech. & Training, Operations Svc

U.S. Steel Group, USX Corp., Gary Works

Daniel D. McCoy, Product Manager, Lubrizol Business Development Co.

Flushing of Large Hydraulic Systems—Considerations for Oil Cleanliness.. 719

John Michael Sullivan, Hydro-Chem Industrial Services, Inc.

Non-Weld Hydraulic Piping System: Republic Cast-Roll Process 727

Amy L. Woy, Republic Engineered Steels, Inc.;

Angus R. Mackay, Tube Mac Industries Ltd.

Attempted Bench Test Correlation of Hydraulic Fluids

with the ASTM D-2882 Vicker's Vane Pump Test 735

George E. Totten, Roland J. Bishop, Jr., Union Carbide Corp.

Hydraulic Fluid — A Time for Change? 761Gerald J. Cochrac, Lubrizol Corp.