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An end users view to hydraulic design

Tata steel IJmuiden specific choice in hydraulic design

René Cnossen

Dutch Fluid Power Conference 2016

Tata Steel in IJmuiden

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Tata Steel in IJmuiden• Overview;

1. Who are we?

2. What we are doing?

3. What design do we want?

4. Why should we specify and why not?

5. What do we need in the future?

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Tata steel IJmuiden an introduction

Yearly production 8 million tons of steel strip products.

Production process

•Iron ore reduction to steel

•High temperatures 1500°C

•High product weight 40 tons

Drive systems

•Electrical drives up to 12 MW per motor

•Hydraulic power units up to 2250 l/min 210 bar

•Standard mineral oil systems

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Projects and engineering centre PTC HTD maintenance service

• Involved in projects selection and execution for asset development and asset

reliability improvement

• Large investment projects

• Revamp blast furnace 6

• Replacement down coiler 1 hot strip mill

• Protact laminating line

• Continuous Caster 23, BOF 2

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• Very competitive market requires continuous improvement

• New product development require new assets

• Business case is leading for the project

• Careful process from business idea up to start of commercial production.

• PTC department translates functional specifications into technical requirements

and a Request for Quotation.

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Engineering and design

• Engineering based upon best practices safety, operations and maintenance.

• Dedicated team of 6 hydraulic project engineers and 25 Hydraulic maintenance

engineers.

• Transfer Tatasteel requirements into RfQ for Orginal Equipment Manufacturers

• Controlling engineering products of contractors

• QC/QC during manufacturing and erection

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Hydraulic design specifications

Why?

• 24/7 production process

• Harsh environment, temperature, dust, vibrations, water, chemicals

• High safety demand

• Familiar design and components for maintenance staff

• Long service life long maintenance intervals

• High costs of unscheduled down time.

BEST

PRACTICES

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Tata steel IJmuiden design signature

Power units

• Variable displacement pumps 1000rpm

• Hose burst safety switch

• Pump block, filter, relief valve, check valve, ball valve

• Fluid heating with pressure relief valve, no immersion heaters

• http://veiligheid.tatasteel.nl/en/Regulations/Technical-requirements/Technical-Directives/Mechanical-Engineering/Hydraulics.html

What design do we want?

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Tata steel IJmuiden design signature

What design do we want?

Power units

•HLP ISO Vg 32cSt,

•Heating with solenoid op. relief valve

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design signature, Operator Safety

What design do we want?

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What design do we want?

Tatasteel IJmuiden design signature, filtration

Filtration system

•Very important for the service life of your system.

•We specify the required cleanliness. ISO 4406 17/15/12

•Downsize filter flow rate

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What do we specifiy?

Tata steel IJmuiden design signature, piping

• Welded cones or flanges, backing gas, 100%

X rayed > PN 40bar.

• Bended pipes

• Stauff clamps on rigid supports

• Pipe hose connections with welded blocks

• Flushing with super heated oil and v> 7 m/s

until cleanliness ISO 4401 1999 17/15/12.

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What do we specify?

Tata steel IJmuiden design signature, manifolds

Control valves

•Manifold table design, forged steel blocks, grinded Ra < 0,4

•Spool valves limit choice NG10, 25, 32, external X and Y, reduced pilot pressure 25 bar.

•Stack height maximum 3 items.

•Cartridge valves not drilled in the main manifold blocks but in add on block.

•Proportional valves with external amplifier card in dedicated cabinet.

•Servo valves with Px filter 3μm, check valves to block servo valve in case of emergency stop of

power failure.

•P, A and B shut of valves

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What do we specify?

Tata steel IJmuiden design signature, manifolds

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Why should we not specify?

Apostles versus Ipad generation

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Why should we not specify?

Know what, but not why.

• To update a standard document is time consuming and often negleted.

• It is written but the motivation is lost.

• New generation can not explain why it must be done like that.

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Why should we not specify?

O.E.M. ‘s global players with own standards

• Why should we change something which has been sold many times before?

• But doesn’t work in IJmuiden.

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Why should we not specify?

Tradional techniques versus early adapters

• When and how to apply new technology?

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Why should we not specify?

Maintenance interest versus commercial interest

• Hydraulic standards and guide lines cost money.

• The procurement officer does not want any standards and

guide lines in the contract.

• Why are ISO and EN standards not sufficient?

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Maintenance interest versus commercial interest

• Final decision is made upon total lump sum / total cost of ownership.

• Suppliers profits demand low cost countries

• The quality of the supplied goods is not always what we assume.

22

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Traditional design choices versus new developments

• Specifications can kill innovative solutions,

• Zincpot lifting table with 4 HPU’s VSDrive pumps

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What do we need in the future?

• Higher forces and more accuracy.

• Online data analysis of system behaviour

• Industry 4.0

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What do we need in the future?

• Skilled, quality concious suppliers

• Bright young people with passion for hydraulics.

• Ir, Ing, PhD, BSc, MSc?

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Thank you very much for your attention