machine design, Vol.5(2013) No.

1, ISSN 1821-1259

pp. 17-22
Original scientific paper

STUDIES AND EXPERIMENTAL RESEARCH ON THE BEHAVIOR IN EXPLOITATION OF THE BEAM ENSEMBLE OF THE INGOT HANDLING CRANES IN SIDERURGICAL METALLIC WORKSHOP
Cristina Carmen MIKLOS 1, * - Imre Zsolt MIKLOS1 - Carmen Inge ALIC 1
1

POLITEHNICA University of Timisoara, Faculty of Engineering Hunedoara, Dept. Engineering and Management, Romania

Received (05.05.2012); Revised (01.06.2012); Accepted (05.06.2012) Abstract: The paper includes in first part the experimental investigations proper, carried out according to the steps of the research program given in the final part of the precedent paper. The research has been done on the geometry of the beam ensemble of the ingot-handling crane from the Pit Furnace Workshop under analysis, and the results have been interpreted both qualitatively and quantitatively, with respect to the influence of the specific exploitation conditions in siderurgy upon the safety of these structures. The critical analysis and the interpretation of the results of the measurements was further extended over the investigation of the causes and factors that made for the evolution of geometrical imperfections and deviations that have been noticed. In the final part of the paper we suggested possibilities of turning into account the data and information obtained as a result of the investigation and experimental research programs. Key words: experimental investigation, geometrical imperfections, structural imperfections, deviations.

1. INTRODUCTION
The results of the studies and experimental investigations, [1], meat to analyze the behavior in time of the beam ensemble of the ingot-handling cranes in siderurgical metal workshop proved the existence of certain factors that generate both geometrical and structural imperfections, due to which the resistance structures in exploitation are different from the theoretical ones, as to their behavior when charged. An estimate on the safety in exploitation of the beam ensemble of the ingot-handling cranes in such a workshop implies therefore the approach of the imperfections, deviations and flaws that can appear during manufacturing, mounting or exploitation, respectively those that arise in the course of time, due to the specific actions determined by the technological process.

Table 1. The Plan of Topographical Operation and Adjacent Measurements Means/ Fundamental procedures THE STEP magnitudes used and the and the of the necessary Target objective calculations A. ALTIMETRIC MEASUREMENTS - The method Level The height of of the mean differences A1. The the detail geometric with respect level points leveling to the level determinati situated on - The guide marks on of detail level 2t and calculation and RNE1 and points 2s compensation RNE2 of level B. DIRECT MEASUREMENTS OF THE ENSEMBLE OF THE INGOT HANDLING CRANE GEOMETRY The distance B1. The between the Direct measurements of the effective axes of the respective distances, setting rolling tracks followed by an analytical apart of the lying on and graphical processing of rolling different the results tracks lines Horizontal B2. distances Views and direct readings of Horizontal between the the horizontal deviations deviations theoretic with respect to the end points from the view axis of the rolling tracks. straight of and the line the lines of track. Measurements carried out on site

2. EXPERIMENTAL RESEARCHES CARRIED OUT. THE OBTAINED RESULTS

The experimental investigations proper were carried out according to the steps in the Research Program given in the final part of the preceding paper. The estimation of the magnitude of deformations and movement that appeared in the course of over 30 years of exploitation has been done according to the measurements made inside and outside the workshop. The succession of the operations can be seen in the Plan of Topographical Operation and Adjacent Measurements given in Table 1, where, according to each step, we mentioned the topographical method we used and the measurements that we have been done on site.

*Correspondence Authors Address: Politehnica University of Timisoara, Faculty of Engineering Hunedoara, 5 Revolutiei Str, 331128 Hunedoara, Romania, cristina.miklos@fih.upt.ro

Cristina Carmen Miklos, Imre Zsolt Miklos, Carmen Inge Alic: Studies and Experimental Research on the Behavior in Exploitation of the Beam Ensemble of the Ingot Handling Cranes in Siderurgical Metallic Workshop; Machine Design, Vol.5(2013) No.1, ISSN 1821-1259; pp. 17-22

Means/ proceTHE STEP Fundamental dures used and magnitudes and the the necessary of objective Target calculations B3. The geometry of supporting areas and clamping the rolling beams to the pillars of crossframes.

Measurements carried out on site

Table 2. Measurements of the effective distance between the rolling tracks Axis No. Opening I - II Opening II - III

- The distances from the face of the pillars to the axis of the upper foot of the rolling beams; - The dimensions of the upper idem to foot of the rolling beams; point B1 - The dimensions of the crosssections of the pillars

Effec. Nom. Devia- Effect. Nom. DeviaCross opening opening tion opening opening tion frame [m] [m] [mm] [m] [m] [mm]

1 2 3 4

30,003 30,005 30,009 30,025 30,032 30,044 30,000 30,026 30,038 30,025 29,998 29,991 30,004 30,001

+3 +5 +9 +25 +32 +44 +26 +38 +25 -2 -9 +4 +1

11,001 11,000 10,997 11,004 10,999 11,002 11,000 11,004 11,004 11,010 10,998 11,001 11,000 11,001

+1 0 -3 +4 -1 +2 +4 +4 +10 -2 +1 0 0

For the altimetric leveling, taking into account the provisions of [2], we used as a topographic instrument the Ni007 Automatic Level, recommended for precision measurements, for which, in the case of using the invar leveling rod, leads to square error of 0.5 ... 0.8 mm/km of double leveling. After the measurements on site have been done, the provisional elevation calculated and the leveling traversing compensated, we obtained the final elevation marks of the detail points positioned on the resistance structure. As a result of direct measuring of the elements of the beam ensemble of the rolling tracks, we determined: a. The actual distance between the rolling tracks, respectively the distance between the rolling lines whose axes had been marked on this purpose, on the upper surface of the rails, in the area of the axis of each cross frame. The results of the measurements after having carried out the necessary corrections, as well as the deviations calculated with respect to the nominal distance are given in Table 2. b. Deviation from the straightness of the rolling tracks, given in Fig.1, and estimated according to [3], by direct reading (on a horizontal ruler, attached to a vertical rod) of the rail deviation with respect to the axis of the viewpoint from station S toward point V (also marked in Fig.5 of the preceding paper), both points being placed at the end bay of the workshop.

5 6 7 8 9 10 11 12 13

c. The geometry of the areas where the rolling beam are clamped to the pillars The direct measuring of the dimensions and distances exemplified in Fig.2 for the 1st row of pillars have been carried out during the repairs on the Pit Furnace Workshop, after the rolling rails were removed in order to be replaced and the system of their clamping to the upper foot of the beams be modified.

Fig.2. Dimensions and distances characteristic to the geometry of the rolling beams Fig.1. Leveling of horizontal deviation from the straightness of the rolling track 18 The values, Table 3, were obtained after having measured the dimensions marked b2 and a, with a steel ruler and the dimension b1 with a sliding calipers.

Cristina Carmen Miklos, Imre Zsolt Miklos, Carmen Inge Alic: Studies and Experimental Research on the Behavior in Exploitation of the Beam Ensemble of the Ingot Handling Cranes in Siderurgical Metallic Workshop; Machine Design, Vol.5(2013) No.1, ISSN 1821-1259; pp. 17-22

Table 3. Measurements of characteristics to the geometry of the rolling beams Pillars of: Zone Axis 1 opening 1_2 Pillars of: Zone Axis Axis Axis Axis Axis Axis Axis Axis Axis Axis Axis Axis 2 3 4 5 6 7 8 9 10 11 12 13 opening 2_3 opening 3_4 opening 4_5 opening 5_6 opening 6_7 opening 7_8 opening 8_9 opening 9_10 opening 10_11 opening 11_12 opening 12_13 row I II [mm] a a b1 511 b1 505 495 610 610 625 610 615 615 615 511 530 b2 b2 d d row II I [mm] a a b1 503 b1 490 511 500 507 505 505 510 505 500 508 506 b2 991 b2 991 991 993 985 -

influence on the work conditions when the resistance elements or the entire structure are charged.

3.1. Aspects of the quantitative analysis

According to the aspects mentioned above, the analysis and interpretation of the results of the study program as well as the technical and topographic measuring of rolling track ensemble looks as follows: a. The level marks of the rolling beams from the Pit Furnace Workshop according to the longitudinal section drawn in Fig.3 shows obvious differences both along the line and cross - sectionally. The highest level difference between the maximum elevation mark and the minimum one, measured at the face of the upper foot was 62 mm for the rolling beams on the row II I and 27 mm for those on the row I II, values which do not rank within the maximum 20 mm difference admitted by norm [4] along the same line.

593 514 995 1090,5 599 505 row I II [mm]

row II I [mm]

584 522 1004 1086,0 605 515 1011 571 501 1001 1072 586 496 1000 616 496 1002 1117,0 601 494 1000 586 609 995 1083,5 636 505 1008 634 616 992 1130,0 604 505

594 616 1000 1094,0 610 503 1005 637 634 993 1133,5 606 508 1007 639 626 1005 1141,5 634 500 594 610 995 1091,5 656 506 627 611 1000 1127,0 629 510

582 531 1001 1082,5 605 505 1000 579 531 1000 1079,0 576 505 1004 Fig.3.The longitudinal execution shape of the rolling beams; Length scale 1:100 ; Height scale 1:1 It has also been noticed that the difference of level have also been surpassed cross-sectionally (norm [4] admits a maximum of 10 mm) starting with axis 5 along the entire workshop, with a maximum value of 47 mm at axis 9. The value of these deviations as well as the important slope variations shown by the rolling tracks have caused problems in the good functioning of the ingot handling crane, wearing the rails and causing extra strains both for their own resistance structure and for the one of rolling beams. That is why, on the occasion of repair of the workshop, after about ten years of exploitation, the solution envisaged was to weld on the upper foot, in the area marked Z* in figure 4, some intermittent fixing plates of variable thickness. But this solution solved the problems mentioned only partially, as one can notice from the situation resulting from the measurements and given in Fig.3. 19

3. THE CRITICAL ANALYSIS AND INTERPRETATION OF THE RESULTS OF THE EXPERIMENTAL PROGRAM
The values obtained through the measurement program give the possibility of analyzing the geometrical behavior of the beam ensemble of the rolling tracks in the workshop under consideration, which has been in exploitation for the last 30 years. This analysis has been further carried on with respect to the following aspects: quantitatively, by a comparison of the values of the experimentally determined deviation with the admissible ones, according to the actual designing norms and provisions; qualitatively, by an estimation of the causes and factors that lead to the respective geometrical imperfections, as well as considerations upon their

Cristina Carmen Miklos, Imre Zsolt Miklos, Carmen Inge Alic: Studies and Experimental Research on the Behavior in Exploitation of the Beam Ensemble of the Ingot Handling Cranes in Siderurgical Metallic Workshop; Machine Design, Vol.5(2013) No.1, ISSN 1821-1259; pp. 17-22

b. The results of the measurements pointed out to the fact that the actual deviation from the distance between the beams is above the limit value of the deviation, (which, according to norm [5] is in the case of the workshop under consideration 6.75 mm), all along the zone between axes 4 and 9 of the cross frames in the Pit Furnace Workshop; a maximum deviation of 44 mm has been noticed at axis 6. c. Horizontal straightness deviations of the rolling track lines, gives above in Fig.1, surpass the limit deviation accepted according to [5], at axes 4 and 10 on line I II and along the zone between axes 5 and 11 on the line II I in the Pit Furnace Workshop. d. The level differences between the upper sides of the rolling tracks, calculated according to the values pf the elevation marks, have been given in Fig.4, by drawing the longitudinal shape of each line of the rolling track. One can notice that the maximum value of the admissible difference, i.e. 20 mm, according to [5] between the maximum elevation mark and the minimum one on the same line of the rolling track are exceeded on both lines on row II of pillars, the deviations having a 31 mm maximum value on line II I and 52 mm on line II III of the rolling tracks; one can also notice an excess in the 1/1500 maximum value of the admissible slope.

At the same time, in the Regenerative Chamber Workshop the level differences at axes 4, 7, 8, 9, 10, 11 and 12 of the cross section frames fail to rank within the same admissible deviation values.

3.2. Aspects of the quantitative analysis

Qualitatively, the causes and factors that made for the geometrical imperfections we pointed out to, have been considered as follows. 3.2.1. The overall conception of building the resistance of the workshop The solution of inserting some incomplete cross sectional frames within the resistance structure, the rolling beams seated on the upper part of the pillars, as well as the constructive structure of these supporting points (given in Fig.2 and Fig.4 of the preceding paper) can be considered as potential factors in the modification of the geometrical structure under exploitation charges. We came to this conclusion after having analyzed the degree of freedom in the above-mentioned joints, which, although rigid to anything but the movements of positioning marks, when the resistance elements in the joint, may yet allow both horizontal and vertical movements. We can thus explain the longitudinal and cross sectional slides, which, at axes 5, 8 and 10, where the three incomplete frames are placed, acquire significant values. The similar deviations, ranging within the same order of magnitude or, in some cases, even above, which were noticed with the resistance of elements from the bays next to the incomplete frames, may be caused by the transmission of the unfavorable behavior from the cross sectional frames to the neighboring ones, which would represent an experimental confirmation of the fact that the phenomenon of spatial interaction of the resistance structures, specific to workshops with traveling cranes, appears as an interaction in movement. The favorable effects of the phenomenon of spatial interaction, considered in terms of a redistribution of the charge from the more loaded frames to the less loaded ones, or to those not loaded at all with the charges deriving from the action of the traveling cranes, may also be accompanied by unfavorable effects, i.e. deformations, which, aggravated resistance structure. 3.2.2. Imperfections and appearing in the stage of mounting the resistance structure The high values of the deviations noticed with the elements of the rolling beam ensemble, both horizontally and vertically, may be caused either by deviations from the pillar positioning marks, when mounting them, or a later sinking of the foundations, accompanied by twisting. The second hypothesis would be partially justified by the movements noticed on the 2nd level of the measurements, i.e. on the pillars of the cross-sectional frames in the area of supporting the rolling beams. This sinking, which according to the elevation marks obtained by topographic measurements, should have had maximum values in the central pillar area, between axes 1 5, would have modified similarly the elevation mark RNE1, placed in the moment of construction. The checking of this hypothesis was done by measuring the elevation mark mentioned on RNE1, with respect to

Fig.4. The execution longitudinal shape of the rolling tracks Length scale 1:100 ; Height scale 1:1 As to the cross-sectional level differences on the upper surface of the tracks, the admissible value according to [5], is 10 mm on the support and 15 mm on the field, but they are exceeded in the workshop from axis 5. 20

Cristina Carmen Miklos, Imre Zsolt Miklos, Carmen Inge Alic: Studies and Experimental Research on the Behavior in Exploitation of the Beam Ensemble of the Ingot Handling Cranes in Siderurgical Metallic Workshop; Machine Design, Vol.5(2013) No.1, ISSN 1821-1259; pp. 17-22

the known elevation of a topographic mark in the area. The elevation mark we obtained in this way, i.e. +251.037m, compared to that of +251.035m, found on the mark, proves that the foundations did not sink. That is why, we considered as valid the first hypothesis i.e. that of incorrect positioning of the pillars for resistance structure, the deviations being not only longitudinal or cross sectional, but also with respect to the positioning of their setting upon the foundation. 3.2.3. Imperfections due to exploitation The intense exploitation of the three travelling cranes with rigid support, operative in the Pit Furnace Workshop has caused in time a loosing of the screws that fix the rails, which caused both deviations from the straightness of the rolling tracks, and premature wear of the rails. The supplementary strains upon the resistance structure of the travelling cranes due to the existence of important uneven areas, and of deviations from the admissible tolerance with respect to the nominal distance between the rolling tracks, had unfavorable effects upon the geometry of both the crane and the ensemble of rolling beams. Moreover, the systematic use of the travelling cranes in supplementary technological operations such as the cleaning of the pit furnace hearth, made for the accentuation of the geometrical imperfections and deviations that mentioned. At the same time, we mention modifications in time of the technological process in the Pit Furnace Workshop, which imposed changes in the configuration of the train of travelling cranes. Thus, contrary to the provisions in the project, which implied three travelling cranes, two 50 kN ones and a 50/300 kN one, placed at one end of the train, the workshop is furnished with two 50/300 kN travelling cranes, plus a third one, in between, with a capacity of 100/400 kN. Taking into account the important contribution of the charges upon the travelling cranes as compared to that of other categories of actions, one can consider that is a similar manifestation of the negative influence of intensity modifications and of the alternation of the configuration of charge trains. This influence, completing the effects of the other deviations and geometrical inexactitudes analyzed in this paper, lead to the alteration of the initial geometry of the ensemble of rolling tracks and, at the same time, to an increase in the strains that generated these supplementary deformations and movements of the resistance structure of the workshop in exploitation.

the 1st row, respectively bays 34, 45, 56, 10-11, 11-12 and 12-13 on the 2nd row (Fig. 5a, b) and of fissures in the core of the rolling beams on the 1st row of pillars (Fig.5b).

a. Mapping of longitudinal fissures and sectional fissures in the upper foot of the rolling track beams

b. Details of the fissures from the feet and core foot of the rolling track beams Fig.5. Results of the visual analysis of the rolling beams from the Pit Furnace Workshop The appearance and development of such fissure-type flaws, as the ones noticed particularly in the smaller rolling beams could also be caused by the mechanical aging of the steel, a behavior that can be associated to the phenomenon of flowing, where the resistance of the material increases, but its tenacity and deformability characteristics decrease.

4. SUPPLEMENTARY INVESTIGATIONS UPON THE EXPLOITATION BEHAVIOR

The visual analysis of the rolling beams lead to the observance of other flaws, which may be the result of the inadequate physical and mechanical characteristics of the material, as follows: the existence of longitudinal fissures in the upper foot of the 11m wide rolling beam from bays 23 and 10 11 of the 2nd row of pillars, whose position is given in Fig.5a and b. the existence of cross sectional fissures in the upper foot of the 11m wide rolling beams from bays 23 on

5. CONCLUSIONS
The studies and experimental research envisaged by the steps of the project conceived with this aim prove the possibility of estimating the real geometry of the resistance structures in exploitation. The investigation of the causes and factors which made for the evolution of geometrical imperfections and deviations up to values which go way beyond the admissible ones, as established by the norms in force, pointed out to the important role of the general conception and the detail approach in the design of resistance 21

Cristina Carmen Miklos, Imre Zsolt Miklos, Carmen Inge Alic: Studies and Experimental Research on the Behavior in Exploitation of the Beam Ensemble of the Ingot Handling Cranes in Siderurgical Metallic Workshop; Machine Design, Vol.5(2013) No.1, ISSN 1821-1259; pp. 17-22

structures, elements that can influence in a significant way the later behavior of the construction in exploitation. The research carried out has been done the geometry of the beam ensemble of the ingot-handling crane from the Pit Furnace Workshop under analysis, and the results have been interpreted both qualitatively and quantitatively, with respect to the influence of the specific exploitation conditions in siderurgy upon the safety of these structures. The critical analysis and the interpretation of the results of the measurements was further extended over the investigation of the causes and factors that made for the evolution of geometrical imperfections and deviations that have been noticed. The valorization of these results can be done by their being taken as a basis for the monitoring programs of the constructions, both in order to obtain a closer physical modeling of the real resistance structures in view of evaluating their safety in exploitation.

REFERENCES
[1] Alic, C. (1998). Contributii la evaluarea gradului de siguranta al halelor metalice din siderurgie, tinand seama de conditiile reale de exploatare Teza de doctorat, Universitatea Politehnica din Timisoara. [2] Oprescu, N. (1973). Manualul inginerului geodez, vol. I, II, III. Editura Tehnica, Bucuresti,. [3] Cristescu, N. (1978). Topografie inginereasca, Editura Didactica si Pedagogica, Bucuresti. [4] *** STAS 8018-80. Constructii pentru sustinerea cailor de rulare ale macaralelor si podurilor rulante. Prescriptii generale. [5] *** STAS 6911-80. Cai de rulare si opritoare pentru poduri rulante si macarale. Prescriptii generale. [6] Coarc, C. (2003). Topografie inginereasca, Editura Matrix Rom, ISBN 973-685-560-0, Bucureti.

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