Main Caster Hydraulic System Retrofit
Problem:
An electric arc furnace steel processor wanted to:
- Reduce the time of the charging / tapping cycle.
- Provide for emergency power during an outage.
- Increase the system pressure capabilities.
- Improve component duty cycle.
Process:
- An exhaustive study of the application was done. Including all component specifications.
- The equipment was observed in operation and production and maintenance personnel were consulted as correct operation sequence functions were determined.
- A course of action which included:
- Increased flow capacities of main hydraulic system.
- Control allowances made for:
- Mass acceleration and deceleration.
- Electrode engagement.
- Structural design limits
- Design dedicated high pressure standby accumulator system.
- Upgrade filtration.
- Improved particulate ingression control
- Lowered cost / gram of filtered contaminant
- Synchronized a multiple pump configuration to allow all pumps to respond simultaneously to system pressure and flow demands.
Results:
- In excess of 30 seconds were removed from the existing charge / tapping cycle.
- The entire cost of the retrofit ($780,000) will be recaptured within one year by profits generated by increased production.
- Improved component duty cycle.
- Emergency standby power allows for full system cycle in the event of power loss.
- System pressure capabilities were raised 20%