Main Caster Hydraulic System Retrofit

An electric arc furnace steel processor wanted to upgrade their operations and profitability:  

• Reduce the time of the charging / tapping cycle  
• Provide for emergency power during an outage
• Increase the system pressure capabilities
• Improve component duty cycle

The equipment was observed in operation and production and maintenance personnel were consulted as correct operation sequence functions were determined.

A course of action was determined which included:  

• Increased flow capacities of the main hydraulic system.  Control allowances made for:  
  • Mass acceleration and deceleration  
  • Electrode engagement
  • Structural design limits 
• Design of a dedicated high-pressure standby accumulator system  
• Upgrade of filtration
  • Improved particulate ingression control  
  • Lowered cost / gram of filtered contaminant
  • Synchronization of a multiple pump configuration to allow all pumps to respond simultaneously to system pressure and flow demands.  

Results: 

• More than 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 from 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 by 20%