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Proceedings of the
Iron & Steel Technology Conference
Volume III
5-8 May 2014
Indianapolis, Indiana
U.S.A.
ASSOCIATION FOR IRON & STEEL
\^ Aii*mmi$m
Ronald E. Ashburn, Publisher
Karen D. Hickey, Managing Editor
Christopher P. Brown, Lead Graphic Designer
Krista J. McGhee, Copy Editor/Graphic Design Assistant
A Publication ofthe Association for Iron & Steel Technology
TABLE OF CONTENTS
AISTech 2014 —Volume III
ROD & BAR ROLLING
Rolling Mill Process Improvements
Heating Induction Power, New Paths for Improved Efficiency and Flexibility in the Rolling Mills
for Steel Long Products 2557
Alberto Lainati
The Importance of the Water Treatment Plant for the Performance of a Rolling Mill 2569
Silvia Cattarino, Marco Colautti, Sandro Mansutti
Enhanced Surface Inspection of Long Products With Pseudo-3D Techniques 2581
Riccardo Ferrari, Marco Appio, Valerio Moroli
Split Ends During Long Products Rolling: Billet Quality or Rolling Process? 2591
Jorge Madias
De-Oiling of Oily Mill Sludge and Scales 2603
Romain Frieden, David Rodriguez, Marc Pelletier
Rolling Mill Equipment Innovations
The Effect of STF Steel in Beam Mill Vertical Edger Bearings 2611
Paul Brda
Advanced Control Solutions for Flying Shears and Practical Application on Existing Equipment 2619
Marco Capitanio, Roberto Migliorati, Stefano Arondi, Alberto Giacomelli
Manual Bar Code Tag Identification for Steel Applications 2629
David Anderson
Vision-Guided Robotics Provide a Flexible, Automated Billet Tagging Solution 2643
Tim Dykstra, Doug Taylor, Jim Crenshaw
High-Speed Rolling —Part I
Latest Improvements in Quality and Process Control of New Bar-in-Coil Lines 2657
Claudio Fabbro, Maicol Cimolino
High-Speed Rolling —Part II
FLUR® — New Fast Lock/Unlock Ring System for Wire Rod Finishing Blocks 2669
Matteo Tomba, Nicola Tomba, Andrea Fontanini, Massimiliano Zuccato
Recent Developments in Laying Head Technology for High-Speed Rod Rolling Mills 2677
Christopher Lashua, Bruce Kiefer
PERT Tailor-Made Solutions for the Finishing Blocks: Three Different Types of Blocks for 1- or
2-Strand Rolling 2685
Matteo Tomba, Massimiliano Zuccato, Andrea Fontanini, Nicola Tomba
Stepless Reform Technology for Wire Rod Mills 2693
Bruce Kiefer, Margaret Gentile, Sudhakar Teegavarapu, Christopher Lashua
Rod Mill Finishing End Modernization at Sterling Steel 2701
Kermit Reins, Steven Spencer, Luis Pietra Santa
Rod & Bar Rolling Technology
Danieli Automation Low- and Medium-Voltage Drives: Designed for Metals Industry 2711
Raffaele Treu, Stefano Barbanti
Advanced In-Line Surface Inspection of Hot Beams, Rails and Special Profiles Full Range 2715
Eddy Libralesso, Erika Guerra
Design of No-Twist Mill Parameters for Minimized Geometric Variation in the Hot Bar Rolling
of Steels 2725
Kuldeep Agarwal, Rajiv Shivpuri, Nicolas Poulain
Thermomechanical Processing Simulation of Mill Deformation of High-Carbon Wire Rod 2735
Stephanie Miller, Emmanuel De Moor, Glenn Eavenson
Process/Quality Opportunity Improvements Through Integrated CC/Wire Rod Tracking CoupledWith Hot Eddy Current Wire Rod Data 2743
Bruno Chedal Anglay, Karen Gallardo, Juan Molinari Piqueras
Rail Steel Production at Evraz Zsmk With MSR 2753
Luigi Morsut, Marco Rinaldi, Alberto Urbano, Marco Lena
PIPE & TUBE
Pipe & Tube Advancements
Cutting-Edge Technologies for Meeting the Growing Demand ofPremium Connections
Stefano Carfagno, F. Boccioni, S. Solda
2761
Innovative Solutions for Improvements in Seamless Tube Production 2767
Thomas Wagner, Manfred Topiith, Fabio Lacapruccia, Martin Sauerland
Seamless Pipes Hardening Line Revamping: Furnace Production Increase and Energy Consumption
Optimization 2775
Gabriele Morando, Lis Soares, R. Junquiera, Alessandro Donetti
ROLLS
Factors Affecting Roll Performance
Microstructural and Precipitation Analysis of Commercial Roughing Stand Work Rolls Using
Thermodynamic Simulations and Advanced Characterization Techniques 2783
Konstantin Redkin, Christopher Hrizo, Isaac Garcia, Raymond Schleiden
Reduction of Wear on Backup Rolls in Skinpass Mills 2797
Klaus Habitzki
Work RoU Behavior Through the Stands of Hot Strip Mills 2809
Alberto Tremea
New High-Performance Roll Materials for Hot Rolling of Steel 2819
Christian Zybill, Vyacheslav Goryany, Erich Schubrikoff, Reinhard Schwens, Johannes Buch
Development of Roughing Mill Work Rolls at ArcelorMittal Tubarao 2829
Bruno Bastos da Silva Murad, Denilson de Aquino Souza, Roberto de Oliveira Costa,
Valker Macedo do Nascimento, Michael Brandner, Tommy Nylen
Interval-Based Chock Maintenance Programs 2837
Leonard Vallone
Developments in Roll Shops & Roll Shop Equipment
The Next Generation of Roll Profile Measurement Systems —The Ambit Laser-Mic 2847
Arthur Pilkington, Alec Gillis
Innovation in EDT (Electrical Discharge Texturing) for Rolls 2849
Christoph Hauck
The Latest Available Technologies in Designing Modern Roll Shops 2859
Giovanni Bavestrelli, Davide Quaglia, Giovanni Boselli, Rick McWhirter, Paolo Gaboardi, Claudio Trevisan
Herkules MACHtechnology — Superior Grinding 2867
Jared Joergens, Joerg Willi Naumann
METALLURGY — STEELMAKING AND CASTING
Caster Modeling — Heat Transfer
The Effect of Steel Composition on the Interfacial Heat Transfer Coefficients for the Secondary
Cooling Zones in a Continuous Caster 2873
Kenneth Blazek, Rudolf Moravec, Jaroslav Horsky, Michal Guzej
Correlation for Mold Heat Flux Measured in a Thin-Slab Casting Mold 2881
Prathiba Duvvuri, Bryan Petrus, Brian Thomas
Water Distribution Assessment Applied to Mathematical Model of Continuous Casting of Steel 2895
Charles Sostenes Assuncao, Roberto Parreiras Tavares, Guilherme Dias Oliveira
Transient Model of Preheating a Submerged Entry Nozzle 2907
Yonghui Li, Brian Thomas
Slab Surface & Internal Quality
The Improvement of Transverse Crack on Slab for Plate Products 2923
Hsing-Yu Sun, Yen-Hao Su, Chun-Hung Wu, Bing-Yuan Chen
Identification and Reduction of Unsteady Bulging in Continuous Casting 2931
Naveen Gupta, Thinium Natarajan, Thomas Piccone, Douglas Ashley
Improving Surface Quality of Hot and Cold Rolled Strips — A Case Study 2945
Sunil Kumar, Victor Hernandez
On the Mechanism of Mechanical Soft Reduction and Macrosegregation Quality Criteria of
Continuous Casting of Steel 2959
Mostafa El-Bealy
TMCP— Temperature and Microstructure for Cast Products 2969
Michael Hoenig, Markus Reifferscheid, Uwe Plociennik, Ulrich Kerp, Markus Nuellmann
Precipitation and Effects of Carbonizing Inclusion During Solidification for Low-Carbon,Al-Killed Steel 2979
Jing Guo, Shusen Cheng, Tianxu Zhang, Junliang Ge, Yingwei Zhang
METALLURGY — PROCESSING, PRODUCTS & APPLICATIONS
High-Strength Steel
The Effect of Coiling Temperature on the Mechanical Properties ofUltrahigh-Strength 700 MPA
Grade Processed via Thin-Slab CastingVenkata Sai Challa, Devesh Misra, Ron O'Malley, Steven Jansto
2987
Tempering Response ofTRIP-Aided Low-Carbon Steel 2999
Bimal Jha, Anjana Deva, Shashi Shekhar Mohanty
Developing a Third-Generation Advanced High-Strength Steel With Two-Stage TRIP Behavior 3013
Scott Pisarik, David Van Aken, Krista Limmer, Julia Medvedeva
Metallurgy of Plate Rolling
Effect of Roller EMS on Slab Quality and Linepipe Plate Properties 3025
Hang He, Yong-Long Liu, Hwan-Tang Tsai
Toward Interrelationship of Microstructural Evolution and Yield Strength Anisotropy in
High-Strength Line Pipe Steels 3033
Pavan Venkatsurya, Devesh Misra, Murali Mulholland, Michael Manohar, Jack Hartmann
Investigations on Internal Crack Propagation in High-Niobium Steel Slabs During Cooling and
Reheating at ArcelorMittal Dofasco 3043
Chongzhi Chang, Joydeep Sengupta
Development of Plate Roller Quench Unit and Uniform Cooling Technology 3053
Chao Wang, Zhaodong Wang, Guodong Wang
Isothermal Transformation and Precipitation Behaviors of a Microalloyed High-Strength Steel Under
Ultrafast Cooling Condition 3061
Chao Wang, Y. Y. Li, Zhaodong Wang, Guodong Wang, Devesh Misra
Research of Advanced Cooling System for High-Performance Steel Plates 3073
Bingxing Wang, Zhaodong Wang, Guodong Wang
METALLURGY— PROCESSING, PRODUCTS & APPLICATIONS/
WIRE ASSOCIATION INTERNATIONAL
Metallurgy of Wire Rod I
Recent Applications of a Heater Cover in a Stelmor Cooling System 3081
Siwon Yoon, Gwansik Min, Seongkyu See, Sanghyun Oh
Influence of Drafting Schedule in High-Speed Drawing of Carbon Steel Wires on Their Structure and
Mechanical Properties 3089
Stanislav Sosna, Jan Krnac, Jana Kavulokowa, Jan W. Pilarczyk
Effect of Cryogenic Uniform Deformation on Strengthening of High-Carbon Steel Wire 3107
Tadakuni Hori, Motohiro Nakano, Atsushi Sasaki, Hiroshi Utsunomiya
The Influence of Oxygen-Enriched Burner Systems on the Scale Formation of Steel Alloys During
Heating Processes 3115
Christina Viktoria Sobotka, Helmut Antrekowitsch, Holger Schnideritsch
Metallurgy of Wire Rod II
MicroNiobium® Steelmaking Alloy Approach in 1080 Wire Rod 3133
Steven Jansto
Interplay Between Grain Size and Austenite Stability on the Deformation Behavior of High-Strength,
High-Combination Austenitic Stainless Steels 3143
Venkata Sai Challa, Devesh Misra, Mahesh Somani, Pentti Karjalainen
Complementary Use of Thermo-Electric Power, Internal Friction and Calorimetry for the Study of the
Microstructural Evolution of a Pearlitic Steel During Cold Drawing and Static Strain Aging 3151
Aude Lamontagne, Xavier Kleber, Veronique Massardier, Daniele Mart
ENERGY & UTILITIES
Future Trends
The ISO 50001 and Potential Impacts on the Steel and Metals Industries 3159
Michael Crowley, Wade Williatt
Drastic Reductions in Energy and Water Consumption in Large Iron and Steel Metallurgical
Complexes 3167
Osvaldo Bascur, Rene Arroqui
Next-Generation Reheat Furnace Control: ZoloSCAN Laser Combustion Diagnostics 3177
Ken Grieshaber, David Giltner, James Phillips, Terence Choncoff, Rajlco Vukobrat
Impact of the Natural Gas Revolution on the North American Steel Industry
New Technologies That Will Maximize Natural Gas Benefits for Iron and Steel Processing 3191
Carlo Raggio, Jared Kaufman
ELECTRICAL APPLICATIONS
Process Upgrades/Drive Systems
SDI Butler Cold Mill— Modernizing a High-Production Mill on the Fly 3203
Mike Morris, Thomas Richards, Richard Ward
Modern DC Drive Retrofits Improve Efficiency and Availability in the Iron and Steel Industry* 3211
Alexander Lenz, James Clark, Thomas Junger, Joe Felten, Matti Paaso
Proposed ffiC Standard for AC Adjustable Speed Motors for Rolling Mills 3217
Ronald Tessendorf, Sumiyasa Kodama, Morita Noboru, Prabhuraj Bhooplapur
HiSection Plus: New Intelligence in Rolling Process 3231
Riccardo Ferarri, Luciano del Pin, Giuseppe Buzzi
A Large Capacity 3-Level EEGT Inverter for Rolling Mill Application 3237
Kenji Oda, Mostafa Mamum, Katsuhiko Fukuma, Hiromi Hosoda, Marcelo Lara
Industrial & Commercial Power Systems Considerations I
Enhanced Arc Flash Mitigation Solutions — New Approaches for Switchgear and Motor Control
Centers 3247
Terry Schiazza, Fabio Mielli
First SPLC to Stabilize Active Power for a 3-Electrode 90-MW Arc Furnace 3253
Bradley Lueger, Thomas Ma, Dong Shen, Jason Cheung
Best Practices for Electrical System Reliability 3267
Alan Ross
Furnace Transformer Protection Against High-Frequency Switching Transients 3273
Stefan Kornhuber, Dirk Niehus, Oleg Kouzmine, Wojciech Piasecki, Fabio Fracaroli
Industrial & Commercial Power Systems Considerations II
Modernization of Mill Power Systems for Better Control and Visualization 3281
Brian Clark, Tim Burttram
Advancements in Vibration Monitoring 3289
David Mazur, John Kay, Kenneth Mazur
Introducing Power System Event Report Data Into Plant Historian Systems 3299
Michael Rourke, Mahti Daliparthi, David Mazur, Rob Entzminger
Maintenance of Your Electrical System for Maximum Reliability 3309
Alan Holt
Review of Sensor Technology in Steel Production
EM Inspection of Microstructure During Hot Processing: The Journey From First Principles to Plant 3317
Anthony Peyton, Claire Davis, F. van der Berg, Brian Smith
An Integrated Approach to Radioactive Source Detection at Steel Mills and Scrap Yards 3327
William Richardson, David Barnes, Zachariah Kashif, Richard Seymour, Steve Tymoszuk
Real-Time Water Detection Technology at ArcelorMittal Coatesville 3339
Doug Zuliani, Hamzah Alshawarghi, Vittorio Scipolo, Marshall Khan, Walter Bilski
New Opportunities for Process Control and Quality Assurance Using Laser Profile Gauges for
Thickness and Width 3351
Achim Sonntag
Topographic Surface Inspection System for Slabs and Heavy Plate 3361
Rainer Fackert, Andreas Weinert, John Buckman
COMPUTER APPLICATIONS
Modeling I
Tuyere Failure Analysis and Improvement Through CFD Simulation 3373
Yan Chen, Bin Wu, Anfani Okosun, Dong Fu, Thomas Hensler, Donald Zuke, Sergey Trenkinshu, Chenn Zhou,
Xingjian Chen
CFD Simulations for Water Flow in Lance to BOF 3385
Breno Totti Maia, Bruno Orlando de Almeida Santos, Fabricio Silveira Garajau,Marcelode de Souza Lima Guerra
Zone Modeling Coupled With Dynamic Flow Pattern for the Prediction of Transient Performance
of Metal Reheating 3395
Yukun Hu, John Niska, Jonathan Broughton, Edward McGee, Chee-Keong Tan, AlexanderMatthew, Paul Roach
Information Technology
Cybersecurity for Industrial Plants: Threats and Defense Approach 3409
David Hreha, Fabio Mielli
Considerations in Software Application Development for Adaptability and Maintainability 3415
Noah Wolf-Johnston, John Frochio
Applying New Technologies: Virtual Reality and Augmented Reality Applied to the Iron and
Steel Industry From Training to Commissioning, SCADA and Plant Simulation 3429
Fabian Barreiro, Aldo Barreiro, Leonardo Aguirre, Miguel Simiand
Leveraging Cloud, Mobility and Wireless in Steel Plant Operation 3439
Mahesh Subrmaniam
High-Availability Wireless Networks for Industrial Applications 3447
Steve Carender, Mariano Zecchi, Edgardo La Bruna
Quality Management System MEVInet-Q 3453
Horst Krauthauser, Jens Hausner, Blanch Smith
Automation, Monitoring & Robotics
New Developments in Automatic Defect Detection for Slabs and Billets for Total Quality Control 3465
Robert Smith, Sandro Orlando, Riccardo Ferrari
Robot-Aided Automation for Powder Feeding in Continuous Casting 3475
Zhi Zheng, Tianyou Liu, Taotao He
Robotic System for a "Zero Operator" Continuous Casting Floor 3481
Riccardo Ferrari, P. Demetlika, Luigi Martino Galasso, Fulvio Romano
Control & Modeling
High-Precision Numerical Simulation for Effect of Casting Speed on Solidification of 40 Cr During
Continuous Billet Casting 3487
Ya-nan Chen, Yan-ping Bao, Zun Peng, Li-hua Zhao, Min Wang
A Unified Spatial Curvature Framework for Coordinated Pass Scheduling, Shape Targeting and
Mill Setup 3495
Mark Zipf
3D Hearth Wear Model—Theory and Operational Practice* 3511
Alois Altendorfer, Elisabeth Frank, Thomas Kronberger, Martin Schaler
Rolling Simulation Using Finite Element Analysis 3521
Rajeev Baskiyar, R. Topno, Partha Pratim Sengupta, Shashi Shekhar Mohanty
An Experience of Plant Control in RIVA Group Using Operator-Independent Technology 3527
Riccardo Ferrari, Nicola Veneri, A. Pezzoni, Marco Ometto, Luigi Martino Galasso, Fulvio Romano
PROJECT & CONSTRUCTION MANAGEMENT
Project Scope Development — Case Study & Construction Safety Best Practices
Safety Practices for Capital Projects 3539
JeffAdams
Project Excellence & Execution
ArcelorMittal USA Blast Furnace Gas Flare Capture Project 3545
John Seaman
CSP Plant Expansion Projects in the United States 3551
Wolfgang Spies, Detlef Ehlert, Gregor Schneider
MAINTENANCE & RELIABILITY
Asset Improvement Through Culture Change
Predikto Analytics Case Study: Predicting Delays and Production Yield in a Steel Manufacturing
Plant 3561
Robert Morris, Mario Montag
Life Prediction in Industrial Equipment 3569
Nicholas Walla, George Cingle, Bin Wu, Chenn Zhou
Maintenance Improvement, Change and People's Mindsets 3581
Richard Johnson, Lyle Bufogle
Application of Proactive Maintenance Technologies
Integrative Condition Monitoring System for Metals Industry 3585
Arno Haschke
Effective Use of Condition Monitoring in Tracking Large Gearbox Bearings 3593
Kenneth Foster
Maintenance Basics in Conjunction With Integrated Condition Monitoring Is the Simplest Way of
Enhancing Machine Reliability and Availability 3605
Sanjay Bhansali, Pradeep Agrawal, Shivnath Ram, Neeraj Tripathi, Arindam Gangopadhyay
Integrated Equipment Maintenance Technology at China Steel Corp 3619
Yi Yuan Tseng
Electrical Reliability Best Practices
Preventive Maintenance Strategies for Power Distribution Systems 3633
Charles Alvis
Integrated Condition Monitoring Can Play a Significant Role in Reduction of Electrical Power
Consumption of Plant Machinery 3639
Sanjay Bhansali, Pradeep Agrawal, Shivnath Ram, Neeraj Tripathi, Dhananjoy Mahata
Bearing Reliability & Maintenance Technologies
Toroidal Roller Bearings in Continuous Casters Improve Reliability 3651
Warren Doerner, Wade Dudik
Why Are My Continuous Caster Bearings Failing? 3657
Majkol Spirovski
Ceramic Bearings for Electric Motors
James Oliver, Robert Glutting
3667
New Seal Design Improves Vertical Edger Roll Bearing Performance 3677
Wade Dudik, John Delia Villa
Creative Maintenance Strategy: Applying Low-Cost and Innovative Ideas to Improve the Performance
of a Steel Rolling Mill 3685
Ahmed Emam Noureldin
Innovative Maintenance & Reliability Technologies
Earliest Leak Detection (ELD): A New Concept of Security in Water Leak Detection in Electric
Arc Furnaces 3695
Paulo Hopperdizel, Breno Totti Maia, Thiago Wandekoken
Understanding Torque Amplification Factors (TAFs) and Their Effect on Drivetrain Maintenance
and Reliability 3703
Daniel Phillips, Dennis Craig
A New Generation and a New Process — An Application That Can Do for Technicians What CAD
Does for Engineering 3717
Brad Jensen, Mark Alligood
Improving the Reliability of Blast Blowpipes 3729
Chuck Copeland, Stuart Street
LUBRICATION & HYDRAULICS
Lubrication & Hydraulics
Novel Laboratory Lubrication Tests for Cold Rolling Emulsions 3747
Bas Smeulders
Improvement of Rolling Oil of Cold Rolling Mill at JFE Fukuyama Works 3757
Makoto Yamawaki, Naoki Ikeuchi, Yuya Ikehara, Noriki Fujita, Junichi Tateno
Understanding the Fire-Resistant Hydraulic Fluid Selection Puzzle 3767
John Schlobohm
How Efficient Is Your Hydraulic System? How Can You Tell? 3775
Daniel Helgerson
REFRACTORY SYSTEMS
Refractory Linings
Improved Concave Lining Design for the Bottom of RH Degasser 3783
Alain St-Jacques, Michael Heiligenbrummer
Electric Arc Furnace Process Improvement and EAF Lining Concept 3789
AshrafHanna, Karl Zettl
MATERIAL HANDLING/TRANSPORTATION & LOGISTICS
Material Handling & Transportation Innovations
Increasing Productivity and Safety in Railroad Operations at Steel Plants by Implementing Railroad
Management System (RMS) 3799
Mariano Zecchi, Edgardo La Bruna
Component Improvements on Lifting Equipment 3809
John Novak
How Lift Truck Innovation Can Improve Your Bottom Line 3829
Herman Klaus, Jan Willem Van den Brand
Improved Quality and Safety in Coil Yard Operations Through Accurate Coil Tracking 3837
Tim Case, Chris Hoitenga, Edgardo La Bruna, Fernando Marsonet
CRANES
Cranes
Predictive Maintenance for Automated and Manual Overhead Bridge Cranes: Leveraging New
Technology to Predict Crane Maintenance 3847
Karl-Heinz Foerderer, Tom Anderson, Bastian Zimmermann
Affirmative Abrasion: Innovation and Advancement in Industrial Braking Systems 3859
Christopher Koralik
Radio-Based Distance and Position Measurement for Cranes and Mobile Equipment Operating in Harsh
Environments 3869
Dirk Brunnengrdber, Edgardo La Bruna
Everything You Wanted to Know About Crane Hoist Brakes* 3881
Mike James
Author Index 3893
* The following papers in Volume HI of the AISTech 2014 Proceedings appear courtesy of the companies
listed alongside them:
Modern DC Drive Retrofits Improve Efficiency and Availability in the Iron and Steel Industry — ABB Inc. and
ABB Automation Products GmbH
3D Hearth Wear Model - Theory and Operational Practice— Siemens VAI Metals Technologies GmbH
Everything You Wanted to Know About Crane Hoist Brakes — Konecranes