Project review

JACOB ELLISCO-OP 2015PROJECT REVIEW

6 May, 2015

MELT SHOP – MED. VOLTAGE VENTILATION

Objectives

• Assess and improve ventilation and cooling in transformer/reactor/rectifier space

Project goals:

• Reduce PM time spent cleaning/dusting equipment

• Reduce arc flash hazard from dust loading

• Reduce heat exhaustion risk to personnel


Airflow Study/RCA Investigation


Primary modes of failure:• Dust carry-over through evap. cooler• High moisture carry-over• Failure of secondary air circuit• Sealing of reactor vault

Airflow Study/RCA Investigation


Improvement: Replacement of AMER-KOOL equipmentBenefits:• Increased effectiveness of filtration

• Removal of secondary air circuit – increased reliability• New canister filters to reduce PM cost – change-out, time, service life

• More efficient and reliable cooling at same airflow capacity• Replace corroded galvanized sheet metal w/ stainless to increase service life• Reduced moisture carryover

Improvement: Close off access hallway to reactor roomBenefits:• Scale-laden air no longer drawn into reactor from exterior+LMS• Air will properly change out between transformer+reactor

Improvements


Replacement of AMER-KOOL equipment:• Currently awaiting decision on filtration design• Vendor lead time = 6-8 months• Contact: Mark Krajewski; AAF International

Arc flash/partial discharge monitoring of transformer equipment:• Evaluated by FLIR vendors during February visit• Project implementation TBD after testing equipment in ladle application

Future/Long-term work

MELT SHOP – BILLET WEIGHING SYSTEMObjectives

• Improve the use of the online billet scale in statistical process control• Use Level 2 data to investigate variation in cast billet weight• Overall goal of increasing yield in the rolling mill

MELT SHOP – BILLET WEIGHING SYSTEM

Conclusions● Data collection and measurement error prevents reliable use of SPC for

weight measurement/mill yield control● Cleanup of data highlights weaknesses in procedure, measurement, data

recording, and knowledge management in addition to steel casting defects● To reduce and control defects, a foundation for continuous PDCA

improvements must be put in place:Suggestions for immediate improvement: Revise process map to

communicate procedure, automate control systems using reliable SPC data, integrate knowledge management, and plan for new standards and procedures

● Future improvements: Use foundation of reliable measurement and interpretation to improve yield via PDCA cycle

ROLLING MILL – STAND HEAT EXCHANGERSObjectives

• Reduce total maintenance costs for heat exchanger filters• Minimize frequency of filter changeouts• Long-term: eliminate need for weekly PM schedule

ROLLING MILL – STAND HEAT EXCHANGERS

• 17 air-cooled DC slip ring motors• Slip ring brushes generate fine carbon dust• Need for continuous air cooling + dust containment• Makeup air intake• Carbon filters vs makeup filters

Process Overview


Airflow Study

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 170

100

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Makeup Intake Flow Volume

Pre-Down Day Post-Down Day

Stand Motor #

Airfl

ow (C

FM)

* * * * * * * *++ ++ ++ ++


Improvement:• Redesign intake plenums to take box filtersBenefit:• Consistency in design between all heat exchangers• Stops any debris from bypassing filter – increased life for box filters• Less time cutting and installing filters

Improvement:• Intake pre-filteringBenefits:• 95-99% of debris never reaches filter• Increased filter life• Very low maintenance• Very little reduction in flow

Improvement:• Connect exchanger intakes via manifoldBenefits: • Able to preclean with fewer equipment pieces – less maintenance cost

Design Considerations


Estimate for current maintenance cost:

Estimate for improvement cost:

Cost-Benefit Analysis


Example: For individual precleaner option, n=17

Break even equation:

Cost-Benefit Analysis

Estimate: if the new filters only need to be changed 2x per month, the improvements will pay for themselves within 8 months

To determine λ: Install test precleaner and monitor filter condition – awaiting delivery of precleaner

SHREDDER – INFEED CONVEYOR TRACKINGObjectives

• Design method to track the life cycle of infeed conveyor chains• Collect data for mean failure time of chains to inform PM replacement• Carry over tracking system to new infeed conveyor

SHREDDER – INFEED CONVEYOR TRACKING

Problems with current process:• No way to predict infeed chain failure• Infeed breaks are extremely costly (8hrs downtime minimum)• Unable to track PM chain replacement

• Risk of repeated work

Problem approaches:• Keep track of infeed chain life cycle

• Short-term: Monitor use since last replacement• Long-term: Construct failure distribution to determine service life

Problems to solve:• How to mark and organize chain sections for long-term tracking

• Previous attempts highlight durability as major issue• High attrition of infeed flights

• Need to construct process for tracking and replacement

Project Overview


Comparison of 2 proposed solutions:

Option 1: Manual tracking of plates welded to flightsAdvantages:• Lower initial cost• No extra equipment to maintain• Ability to track life-cycle of flights as well as chainsDisadvantages:• High flight attrition – frequent marker replacements• Training and documentation required for implementation

Option 2: RFID tracking of chains:Advantages:• Direct tracking of chain – no interference from flight attrition• No extra work needed during flight replacementDisadvantages:• Higher initial cost• Reliability of RFID reader

Solution Overview

Date Section # Motor Rev Conveyor Rev12/11/2008 2-3 98,870.50 1,267.6012/18/2008 3-4 110,000.00 1,360.00


• 100’ of chain (5 sections) being replaced during outage• Flights/chains are marked for temporary identification• Cable ties attached to chain – durability test• Mock-up of flight/chain replacement form for contractors• Marker plates TBD by LCS Metal

Future Work

SHREDDER – NFRS NO.1 COOLING FANObjectives

• Make the no. 1 cooling fan in the NFRS building easily accessible for maintenance

SHREDDER – NFRS NO.1 COOLING FAN

Cooling fans 3 – 5 PM’ed by manliftCooling fan 2 accessible from building interiorCooling fan 1 is neither accessible by manlift or platform• Inability to PM fan, primarily belt changes• No way to access for repair, even in emergency• Fan has been accessible by manlift in the past (had to get it wired

somehow), but added structures now block any way in

Need solution to minimize total cost of maintenance without sacrificing function

Overview


Drawing Synthesis


Designs + Revisions


Option 1: Reverse orientation of no.1 fan• Plan: Have PCI construct scaffold to unbolt fan, hoist out from exterior• Need to consider changes in center of mass• Possible adjustments needed to girt/purlin mounting/exhaust louvre

Option 2: Build hinged frame to allow fan to swing outside

Option 3: Make a vent!

Things to consider:• Value of fans to safety, comfort• Air circulation/displacement• Plans to add additional fans

Overview of Solutions

CSI/STOREROOM – NON-STOCK WIRE REELSObjectives

• Construct permanent outdoor storage space for non-stock electric wire reels

• Compact space to allow for additional storage

• Provide easy forklift access to wire reels

• Organize reels to allow for easy identification

CSI/STOREROOM – NON-STOCK WIRE REELS

Overview

0 10 20 30 40 50 600

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1613151314131613121012

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1011101215121112

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151210121112

78697

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7581096

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587

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85

10878

Flange (in)

Wid

th (i

n)

• Inventory+sizing of all reels in storage area• Design for efficient storage


Rack Space Design• CCC is already underway fabricating pallet

rack• Reel rack frames assembled and ready for

installation


Problem: Unlevel ground and pipe encountered upon removal of wire pallets• Unable to assemble reel racks on uneven ground

Contact: Ruben Peña• Ready to pour 30’x30’ slag base as soon as work space is clear• Current situation: Waiting on availability from CCC to finish clearing space• Reel racks are ready to assemble and load once storage area is level

Current Situation

OPERATIONS – OFFICE REMODELObjectives

• Remodel Danny + Linda’s offices in Operations building

• Ensure quality work to customer spec, timely scheduling, and cost savings

OPERATIONS – OFFICE REMODEL

Major elements:• New desks, cabinets, window sills, countertops, etc.• Relocate Linda’s doorframe• Replace ¼” wall paneling with sheetrock• Sheet over ext. door and window in Danny’s office• New ceiling tiles, window glass, repaint ceiling grid• Electrical work: Boxes/panels to be moved, need to run HDMI across Danny’s office to install TV

Work plans:• Remodel contracted to Koehler const.• Electrical work contracted to IES (formerly planned in-house)• All components for work are ordered• Need to relocate Danny+Linda and remove wall paneling to prep for demo work

• Demo temporarily postponed due to emergency onsite work by Koehler, lack of manpower to relocate offices during outage (demo originally planned to begin 5/11)

Current Situation

MISC. PROJECTS AND MAINTENANCE SUPPORT

Small scope/break-in projects include:- Design of AC unit stand for reheat furnace- Shop drawings of Habitat door frame holder- Created torch patterns for break-in work e.g. 4-strand chute, entry funnel weldment, broken storm

drain, drain cover on FM464 property

MISC. PROJECTS AND MAINTENANCE SUPPORT

CAD Samples

CO-OP OVERVIEW – MAIN TAKEAWAYS

• Plan and execute improvements based on clear objectives that quantifiably connect with objectives of the business as a whole

• Knowledge management: Process knowledge, previous work, documentations, lessons learned• Balance planning and action• Balance research and investigation• Be nice to engineering!• Be even nicer to your planners!• Be even more nicer to operations!

THANK YOU!

Project review

Documents