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2011 December Issue
Full Table of Contents
Maintenance & Reliability Technologies |
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About the Cover
Steel mills require mechanical components that provide increased reliability in an environment of ever-increasing production demands. Gear designers and manufacturers focus on improving the quality and technology of their products through advancements in materials, heat treating and manufacturing. With facilities in Cincinnati, Ohio; Hammond, Ind.; and Plzen, Czech Republic, Xtek employs state-of-the-art gear design analysis, gear tooth grinding and gear certification.
Photo courtesy of Xtek.
Full magazine available in the Members Only Area - NEW UPGRADED FORMAT! |
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Technical Features Table of Contents
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| 41 |
Spares Consolidation at USS-POSCO Industries
This project won the AIST Maintenance & Reliability Technology Committee’s 2010 Bronze Reliability Achievement Award, which recognizes iron and steel producing companies for reliability improvements and achievements.
Timothy D. Kuzmicky (left), division manager — reliability, and Mikal T. Brevig (right), department manager — MRO materials, USS-POSCO Industries, Pittsburg, Calif., USA (tkuzmicky@ussposco.com, mbrevig@ussposco.com)
In 2006, UPI saw the need to identify and control all spares to reduce cost, aid maintenance planning and limit the variability of assets. Part of the solution to eliminating safety issues was good housekeeping. This work details the three-year project to identify, purge and consolidate spares at UPI. |
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| 48 |
ArcelorMittal Burns Harbor Hot Strip Mill Achieves Nearly $2.3 Million in Savings Through the World-Class Equipment Reliability Program
This project won the AIST Maintenance & Reliability Technology Committee’s 2010 Silver Reliability Achievement Award, which recognizes iron and steel producing companies for reliability improvements and achievements.
Scott Piech, manager — proactive maintenance, ArcelorMittal, Burns Harbor, Ind., USA (scott.piech@arcelormittal.com)
This work provides an overview of the ArcelorMittal Burns Harbor world-class equipment reliability program, an effort to make equipment assets more reliable. The program yielded millions of dollars in savings, increased safety and ultimately changed the culture at the plant’s hot strip mill. |
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Reliability-Based Approach to the Combustion Process
This project won the AIST Maintenance & Reliability Technology Committee’s 2010 Gold Reliability Achievement Award, which recognizes iron and steel producing companies for reliability improvements and achievements.
David DaSilva (left) and Fernando Blanco (right), reliability technicians — applied reliability group, USS-POSCO Industries, Pittsburg, Calif., USA (ddasilva@ussposco.com, fblanco@ussposco.com)
USS-POSCO Industries developed and implemented a formal combustion program within the framework of an established reliability-based improvement cycle. This resulted in stabilization of UPI’s combustion processes and ultimately improved efficiency, throughput and operational costs. |
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Tuyere Failures: Cause and Effect
Charles Copeland (left), senior process technologist, and Stuart Street (right), manager — technology, ironmaking department, Severstal Dearborn, Dearborn, Mich., USA (ccopelan@severstalna.com, sstreet@severstalna.com)
Tuyere failures at Severstal Dearborn were investigated using concentration failure mapping, computer modeling, tuyere dissection and process review. This paper reviews the investigations and subsequent changes to operating practice and tuyere design. |
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81 |
Results of the Co-Injection of PCI and Synthetic Titanium Dioxide Products for Protection of the Hearth of ROGESA No. 5 BF After Stop for Relining
Walter Hartig (left), AG der Dillinger Hüttenwerke (ROGESA-Ironmaking Plant), Dillingen, Saar, Germany (walter.hartig@dillinger.de); Djamschid Amirzadeh-Asl (center), Sachtleben Chemie GmbH/Rockwood Specialties Group Inc., Duisburg, Germany (d.amirzadeh-asl@sachtleben.de); and Dieter Fünders (right), GSR, Moers, Germany (synthetische.rohstoffe@web.de)
A new technique of injecting a mixture of pulverized coal and small amounts of synthetic titanium dioxide achieves a reduction of the temperatures in the hearth area and thus a quick and cost-effective wear protection of the hearth refractory. This paper examines the benefits of this technique. |
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Challenges in Reliable Electrical Testing of Rotating Machines
Howard W. Penrose, vice president — engineering and reliability services, Dreisilker Electric Motors Inc., Glen Ellyn, Ill., USA (hpenrose@dreisilker.com)
The importance of understanding the capabilities and limitations of the technologies for testing electric machines cannot be understated. This paper reviews several examples of the capabilities and limitations of both PD Surge and a Motor Circuit Analyzer. |
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