Electrical Engineering Intern Steel Finishing Maintenance

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Electrical Engineering InternSteel Finishing
Maintenance

• By Nick Lockard

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Projects

• Variable Frequency Drive (VFD)
• Troubleshooting and Repair Procedures Manual
  (TRP)
• Soft Start
• Root Cause Analysis

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Variable Frequency Drive (VFD)
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VFD Introduction

• What is it?
• System for controlling the rotational speed of an
  AC electric motor by controlling the frequency of
  the electrical power supplied to the motor.

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Problem
Old System
On/Off
Motor
Fan
Dampers
Baghouse

• Not energy efficient
• Causes excessive wear and tear on motor
• Can not vary speed of motor

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Solution
New System
VFD
Motor
Fan
100 Open Dampers
Baghouse

• Much more energy efficient
• Causes less wear and tear on motor
• Ability to control speed of motor, thus
  controlling air flow

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VFD Project Details

• Research
• What is a VFD
• Wiring
• Coordinate various aspects if installation
• Created simplified steps for future use

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VFD Benefit to Company

• Save money
• Save maintenance
• Ability to control air flow without wasting
  energy

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Personal Benefits

• Learned how to conduct research
• Learned how to coordinate plans and scheduling
  with various organizations
• Learned what a VFD was

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Root Cause Analysis (RCA)

• Helps identify trends with maintenance issues
• Ability to plan according to past problems

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Soft Start Galvanize Fume Exhaust

• Supervised the installation and start up
  procedures
• Write start up procedures for switching from
  across the line starter to soft start and
  vise versa

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Troubleshooting Repair Procedures Manual (TRP)

• To provide a clear and informative way of
  performing various electrical maintenance tasks
  in the steel finishing department

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Problem

• No standardized way of communicating
  troubleshooting procedures to the MTEs when the
  supervisor is not available

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Solution

• Develop a standardized manual that can be used to
  perform electrical maintenance procedures
• Quick reference guide for the MTEs
• Help identify safety issues

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Details

• Research
• Internet research for troubleshooting AC/DC
  motors and starters
• Sorted through old tech manuals to find theory of
  operation
• Had to find illustrations/schematics
• System specifics
• Cranes
• Galvanizing Heating Towers
• Galvanizing How To

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Sections

• Seven sections
• DC motors
• AC motors/starters
• Galvanize heating tower furnaces
• Cranes
• Galvanize How To
• Series 6 PLC
• Glossary

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Construction

• Manual is in a table form, for easy understanding
• Dont have to sort through hundreds of pages just
  to find one particular problem
• Living document

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Benefits to Company

• The TRP will provide a resource for any MTE with
  the ability to perform electrical work in the
  steel finishing department
• The TRP is also a quick reference guide for any
  MTE who is unsure on how identify an associated
  malfunction
• 30 Copies have been made available for
  disbursement

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Personal Benefits

• Learned how to incorporate troubleshooting
  procedures into an easy to follow guide
• Learned a great deal about electric motors,
  starters, and PLCs

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In Conclusion

• I feel that I have learned a lot at WCI Steel and
  I hope my work will help to benefit the company
  in the future

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A Special Thanks to

• Bill Beinecke
• Duane Lanham
• Mark Pawcio
• Scott Rummel
• Nancy Mackey