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December
2006
Vol. 3, No. 12
Maintenance and Reliability Technology
About the Cover
To minimize the use of overhead crane time, RG Kelly Inc. designed an innovative concept to replace the ladle turret slewing bearing on the Gallatin Steel thin slab caster. A runway system and transfer car were constructed under the turret to lift and move the 300-ton upper section to provide access to the bearing. In the photo, the turret is being moved back into position over the new bearing and mounting bolts. Read more about the project on page 29. Photo courtesy of Gallatin Steel.
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Implementing Reliability Excellence
Mark Keneipp (left), Alcoa Warrick Primary Metals, Newburgh, Ind. (mark.keneipp@alcoa.com), and Randy Heisler (right), Life Cycle Engineering, Charleston, S.C. (rheisler@LCE.com)
This article explains how reliability excellence can be achieved through the assessment of current conditions, the development of a master plan, a change in
organizational structure and culture, and the
measurement of key performance indicators.
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40
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Eleven Basic Rules to Follow to Attain R&M Excellence
Jack R. Nicholas Jr., chief executive officer and minority owner, Maintenance Quality Systems LLC, Millersville, Md. (jdnicholas@supernet.com)
This article presents 11 rules and associated corollaries that lead to successful implementation of reliability and maintenance programs. Real-world examples of successes and failures are provided.
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53
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Shutdown Delivery Management System
John Craig, hot mill technology project coordinator, Dofasco Inc., Hamilton, Ont., Canada (john_craig@dofasco.ca)
A shutdown requires clearly defined roles, clear lines of communication and an efficient flow from one phase to the next. This article describes the five phases of a shutdown management system that results in improved safety, throughput, quality and cost.
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64
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A Diagnostic Method for Predicting Maintenance Requirements in Rotating Equipment
Kevin Hunt (pictured), James Stulen and Bill Lindsay, Dofasco Inc., Hamilton, Ont., Canada (kevin_hunt@dofasco.ca, james_stulen@dofasco.ca, william_lindsay@dofasco.ca)
This article presents a simple, cost-effective, on-line diagnostic method for predicting maintenance
requirements in rotating equipment. It is shown that spindle maintenance can successfully move from time-based maintenance to condition-based maintenance with this system.
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77
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The Process of Upgrading the Mold Oscillation System at Nucor Steel–Decatur
Matthew Smith, electrical supervisor — casting, and Philip Fonner, lead mechanic — hot mill, Nucor Steel–Decatur, Decatur, Ala. (msmith@nucortusk.com, pfonner@nsdecatur.com)
Through off-site testing, Nucor Steel–Decatur was able to design a new mold oscillation system and avoid costly downtime. This article describes the project and how the design led to greater reliability of the system, even after an emergency commissioning.
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82
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Elimination of Contamination During Repairs or Modification to an Existing Hydraulic Piping System
Scott Adams (left), technical sales — steel, and Chris Peitchinis (right), operations manager, Tube-Mac Industries Ltd., Stoney Creek, Ont., Canada (scott.adams@tube-mac.com, chrisp@tube-mac.com)
This article describes an attempt to replace or modify an existing operating piping system without introducing contamination during a normal maintenance outage. The solution was a mechanically attached, nonwelded piping system.
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89
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Purification of Morgoil® Bearing Lubrication System
Carlos Robles and Melvin Batchelor, Mittal Steel USA West Div., East Chicago, Ind. (carlos.robles@mittalsteel.com); Kal Farooq, senior staff engineer — scientific and laboratory services, and Andy Messerschmitt, Pall Corp, Port Washington, N.Y.; and Tom Wood (pictured), primary metals sales manager, Pall Corp, Avon, Ohio (kal_farooq@pall.com, tom_wood@pall.com)
The lubrication system for a 5-stand cold rolling mill was experiencing elevated levels of contamination. This article discusses the installation of a Pall purifier and the marked improvement in the condition of the fluid.
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136
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Experimental Designs Toward an Understanding of Process Phenomena in Steelmaking
Ragnhild E. Aune, senior researcher, and Seshadri Seetharaman, professor, Division of Materials Process Science, Royal Institute of Technology (KTH), Stockholm, Sweden (aune@kth.se, raman@kth.se)
With the increasing demands on product quality due to highly technological applications, metallurgical processes — above all, with respect to steel production — need a sound understanding and optimization based on process phenomena. Many of the processes occur under dynamic conditions, with the properties of the system undergoing continuous changes. The depletion of reactants due to ongoing reactions or the retardation of the transport of the products causes changes in local physical properties, which, in turn, can lead to further complications. Since these changes and their consequences cannot be estimated by suitable models with existing knowledge, experimental studies and visualization have become very important. Appropriate experimental design, at the laboratory scale, in order to understand process phenomena is thus an important area in high-temperature steel research. Unfortunately, due to funding constraints, the importance of experimentation has been set aside, and today there are very few laboratories in the world that are suitably equipped for these kinds of studies. This paper highlights some of the experimental studies carried out in the laboratory of Materials Process Science, Royal Institute of Technology, Stockholm, Sweden. Studies in cokemaking, ironmaking, steelmaking and continuous casting are discussed.
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