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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?