Proceedings

AISE1996 Annual Convention

October 1,1996

Hyatt Regency Chicago

Chicago, Illinois

Contents

Throughwall Repair SessionChairmen: William P. Mentzer, Manager—Process Safety, U.S. Steel Group, USX Corp., Clairton Works

Norbert G. Oligmueller, Engineering Supervisor—Coke Ovens and By-Products, Stelco, Inc., Hilton Works

Throughwall Repair Panel Discussion 793

Ralph D. DiStanislao, LTV Steel Co. Inc., Pittsburgh WorksRichard J. O'Hearn, Acme Steel Co.

Ronald M. Schoen, Sloss Industries Corp.

Alternate Ironmaking SessionChairmen: Walter Nummela, Director—Customer Technical Services,

Cleveland-Cliffs Inc., Ore Sales Department

Joseph J. Poveromo, Director—Technology, International, Quebec Cartier Mining Co.

Stanley Sowa, Superintendent—Direct Reduction Plant, Georgetown Steel Corp.

Forces Marketing Corex® 795

Reginald Wintrell, Geneva Steel

First Results from Cleansmelt Pilot Plant 807

Giansilvio Malgarini, Alessandro De Cesare, Antonello Di Donate, Paolo Granati,

Giuseppe Federico, Centre Sviluppo Material!

Proven Ausmelt Technology—Pig Iron to Add Value

to Coal and Iron Ore in South Australia 817

Neill Arthur, Meekatharra Minerals Pty Ltd.; J. Ken Hamilton, Ausmelt Ltd.

Ladle Session

Chairmen: Alan Baylis, Project Manager, Dynex Engineering Inc., Engineering Dept.

Matthew Nousak, Staff Engineer, Middough Associates Inc., Process Mechanical

Richard Rupnow, Works Civil Engineer, LTV Steel Flat Rolled Co., Indiana Harbor Works

High Intensity Burners in Ladle Operations at Dofasco 851

Larry Anderson, Mike Fenton, Aecometric Corp.

Steel Mill Structural Engineering ModelingJohn F. McDermott, Consultant

859

Caster Upgrades Session

Chairmen: Michael Cygler, Senior Sales Engineer, SMS Concast Inc.

The Future of Capital Investment Decisions an the Steel Industry 881Richard D. McLaughlin, Beddows & Company

Caster Upgrades Panel Discussion 883

Gunther 0. Behrends, Stel-Tek Engineering Co. Ltd.

Leonid Beitelman, J. Mulcahy EnterprisesMichael R. Dalby, Chaparral Steel

Donald P. Lorento, AccuMold

Wade L. Olson, Allen-Bradley Co.

Quality and Inspection SessionChairmen: David L. Chase, Manager—Hot Mill, Nucor Steel-Arkansas

Lou Donkle, Program Engineer, Bethlehem Steel Corp., Burns Harbor Div., Technology Dept.

Full Volume In-Line Detection of Inclusions and Surface Defects 885

B. Main/, J. Lueckers, P. Balthasart, IRM

Intelligent On-Line Surface Inspection on a High-Speed Skinpass Mill 893

Faustino Obeso, Juan A. Gonzalez, CSI Pianos

Martin Levoi, European Electronic Systems;

Sergio Dominguez, Pascual Campoy, Disam-University Politecnica

Javier Mochon, Cenim

Temate® 4000 On-Line Coil Volumetric Defect Detection System 909

Kenneth R. Camplin, Dennis D. Lang, Daniel T. MacLauchlan,Babcock & Wilcox Innerspec Technologies

Computer Applications II SessionChairmen: Jere Hartnett, General Manager—Process Automation, Dofasco Inc.

Robert Johns, Supervisor—Process Control, Bethlehem Steel Corp., Bums Harbor Div.

Finishing Mill Electrical Upgrade for 80-ln. Hot Strip Millat U.S. Steel Mon Valley Works

,. 917Richard M. Baker, Scott M. Dom, Daniel P. Smith, U.S. Steel Group, USX Corp.

New Adaptive Finishing Mill Setup Model and Gauge Control Upgradefor LTV Steel Cleveland Works 80-ln. Hot Strip Mill 925

Adam Randall, Cegelec Projects Ltd.;Julie Farabaugh Kaplan, LTV Steel Co. Inc., Cleveland Works, DHCC 80-ln." HSM;James S. Mislay, LTV Steel Co. Inc., Cleveland Works, Computer Process ControlGregory J. Oprisu, LTV Steel Co. Inc., Cleveland Works;

Application of PC and LAN for an L2 Setup Modelof a Single Stand Reversing Mill 957

Remn-Min Guo, Armco Research and Technology;Charles R. Kendell, Armco Inc., Coshocton Stainless Div.;Dave McGraw, Armco Inc.

Project Management SessionChairmen: R. F. Pascuzzi, Vice President—Project Operations, Kvaemer Davy

John Pavia, Manager—Engineering, U. S. Steel Group, USX Corp., Mon Valley WorksMatt Vizzini, Project Engineer, Voest-Alpine Industries, Inc.

Project Control and Project Management Tools 967

Lawrence R. Barkowski, Allegheny Ludlum Corp., Technical Center

James Kenneth Cravens, Raytheon Engineers and Constructors

Cold Rolling Lubrication SessionChairmen: Bernard J. Bast, Research Engineer, Bethlehem Steel Corp., Homer Research Lab

Norman F. Rodowicz, Senior Energy & Environmental Engineer, U.S. Steel Group, USX Corp.

Cold Rolling Solutions: Current Trends Panel Discussion 969

Tom Burgess, Dofasco Inc.

Harry D. Hatters, LTV Steel Co. Inc., Technology Center

Alan G. Keyser, Quaker Chemical Corp., North American Steel Div.

William Ricks, United Lubricants Corp.Charles E. Varga, D. A. Stuart Co.

Process Safety Management SessionChairmen: William P. Mentzer, Manager—Process Safety, U.S. Steel Group, USX Corp., Clairton Works

Process Safety Management Panel Discussion 971

John E. Havard, Citizens Gas and Coke Utility, Indianapolis Coke

Joseph H. Howard, LTV Steel Co. Inc., Indiana Harbor Works

William P. Mentzer, U.S. Steel Group, USX Corp., Clairton Works

Partnering SessionChairmen: Donald Krtanjek, Senior General Foreman—Maintenance,

Bethlehem Steel Corp., Sparrows Point Div., Ironmaking Dept.Walter Toot, Mechanical Engineer, WCI Steel, Inc.

John Wallace, Staff Process Engineer—Development Engineering, U.S. Steel Group, USX Corp.

Partnering and the WCI Blast Furnace Reline 973Dale W. Musolf, WCI Steel, Inc.

Basic Ingredients for a Successful Partnering Agreement 983

Mark M. Brandon, Hoogovens Technical Services USA, Inc.

Ian F. Carmichael, Davy International

Ian Joseph Cox, ATSI, Inc.

John R. Hewitt, Davy Songer Inc.

Dale W. Musolf, WCI Steel, Inc.

Gerard T. Schreiber, GrayCorLaurence E. Scott, Jr., U.S. Steel Group, USX Corp., Gary WorksGeorge R. Segedi, LTV Steel Co. Inc., Cleveland Works

Oxygen Steelmaking SessionChairmen: Daniel Meinzen, Manager—Technology and Quality, Gulf States Steel, Inc.

Stephen Palmer, Engineering Manager—Steelmaking and Casting, AK Steel Corp., Middletown Works

Total Slag Management Program:An Innovative Performance Partnership 985

Gregory L. Echols, Rouge Steel Co.;

Robert J. Koffron, Jr., Tetron, Inc.

Michael J. Mohan, ESM II Inc.;

Tetron-Based Slag Control at Rouge Steel 995

Robert J. Koffron, Jr., Ross A. Jacobs, Tetron, Inc.

Hot Metal Handling and Treatment Systems Panel Discussion 1003

Robert V. Branion, Jr., U.S. Steel Group, USX Corp., Gary Works

L. Mark Keilman, Inland Steel Company, No. 2 BOF Shop

Raymond Sarson, AK Steel Corp., Middletown Works

Mike Schadle, Bethlehem Steel Corp., Burns Harbor Div.

Richard R. Watkins, LTV Steel Co. Inc., Indiana Harbor Works

New Plants SessionChairmen: Alan Brough, General Supervisor, Algoma Steel Inc.

Donald Gerstner, Chief Development Engineer~Flat Rolling,U. S. Steel Group, USX Corp., Development Engineering

India's Newest and Widest Hot Strip Mill 1005

Roger Brown, SMS Engineering;S. Srinivasan, Essar Steel Co.;

Ted Urban, General Electric Drive Systems;

Endless Hot Strip Rolling at Kawasaki Steel Chiba Works 1025

Takeshi Takano, Kawasaki Steel Corp., Chiba Works, Hot Rolling Dept.;

Keiji Matsuda, Kawasaki Steel Corp., Chiba Works, Equipment Technology Dept.;

Shoichi Moriya, Kawasaki Steel Corp.. Chiba Works, Plant Control Technology Dept.;

Nobuhiro Shibatomi, Yoshiki Mito, Kanji Hayashi, Hiroshima Machinery Works,

Mitsubishi Heavy Industries Ltd., Steel Manufacturing Machinery Designing Dept.;

Technology and Performance of Modern Steckel Mills 1057

Stephan Kramer, SMS Schloemann-Siemag AG, Engineering Research-Plant Engineering;

Gunter Kneppe, SMS Schloemann-Siemag AG;

Dieter Rosenthal, SMS Schloemann-Siemag AG, Hot Rolling Mills Div.

Flexible Thin Slab Rolling: Matching the Requirements

of Major integrated Plants .

1097

Estore A. Donini, Roberto Borsi, Andrea Carboni, Danieli & C. SpA

Production Planning and Scheduling Session

Chairmen: Don Harris, Manager—Process Improvement, The Timken Co., Faircrest Plant

Ray Woodcock, Manager—Process Systems Control, Allegheny Ludlum Corp., Brackenridge Works

Production Planning, Scheduling and Monitoringin a CSP Plant—What Are the Benefits? 1119

Serge Delisle, Steve Winner, Software Professionals Corp.

Execution Strategies for Mill Capacity and Small/UniqueOrder Scheduling for Continuous Production Facilities 1135

James MacAdam, Randy Mlinarcik, Dale Rabeneck, Computer Task Group—Metals Center

Dynamic Scheduling for Continuous Castingin an Integrated Production System 1153

Steven D. Duket, Pritsker Corp.

Asynchronous Teams for Steel Industry Mini-Mills 1163

Pedro Sergio de Souza, IBM Applied Manufacturing Technologies;Jose Roberto Favilla, Jr., IBM Corp.

Electrical Engineering SessionChairmen: Ruben DelValle, Sr., Plant Engineer, U.S. Steel Group, USX Corp., Gary Works

Thomas W. Szkut, Control Systems Specialist, Dofasco Inc., Engineering and Maintenance Technology

Finishing Mill and Coiler Automation Upgrade at Armco, Butler Works...

1169

Donald G. Rugh, David L. Kramer, Armco Advanced Materials Co., Butler Works;Luther J. Holton, Luther Holton Associates;Kenneth J. Panko, Patrick F. McDonough, Davy International

A-C Motor and Drive Technology for Wire Rod

and Bar Mills—North Star Steel 1181

Robert Aust, Siemens Energy & Automation, Inc.;

Michael Roether, Siemens AG Industrial Building and Systems Group

Finishing Mill! Modernization at LTV Steel 80-ln. Hot Strip Mill:

Success of Phased-ln Startup in Minimizing Impact on Production 1191

Patrick F. McDonough, Davy International;Steve R. Kuczek, LTV Steel Co. Inc., Technical Center;

Gregory J. Oprisu, LTV Steel Co. Inc., Cleveland Works;

Julie Farabaugh Kaplan, LTV Steel Co. Inc., Cleveland Works, DHCC 80-ln." HSM

Mill Buildings SessionChairmen: James Rowland, Consultant, Bethlehem Steel Corp.

Jack Spanitz, Engineer, National Steel Corp., Great Lakes Div., Engineering Dept.

Fatigue Life Analyses of Crane Runway Girders 1213

Raymond S. Milman, Middough Associates Inc.

Load and Resistance Factor Design of

Stepped Crane Columns in Industrial Buildings 1219

Robert A. MacCrimmon, Acres International Ltd.;

D. J. Laurie Kennedy, University of Alberta;

Charles Albert, Canadian Institute of Steel Construction

Hydraulic Bumpers For Protecting Buildings,Cranes and Operators from Impact Damage 1243

Paul G. Kit, Gantrex Corp.