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