Document Xg9mwXzOXwZeOK8D61Lr638K
PLAINTIFFS
I I EXHIBIT ,,,
ENGINEERING REPORT RELINE & REBUILD OF STOVES #1> //2, #3 and #4 AND NATURAL GAS MAIN
#1 BLAST FURNACE - HAMILTON PLANT JUIX 30, 1965
REVISED MARCH 1?, 1966
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WORKS ENGINEERING ARMCO STEEL CORP. MIDDLETOWN WORKS
Prepared by: H. L, Osborne F. D. Rentschler H. C. Erbacher
Supervising Engineer
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TABLE OF CONTENTS
SECTION
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DESCRIPTION Introduction and Summary General Description Equipment Description Sequence of Construction Schedule Chart of Accounts (Project Sections) Chart of Accounts (Details) Estimate (Summary) Estimate (Details) Arrangement Drawings
PAGE NO. 1&2 3 4-7 8 9 & 10 11 12-32 33 & 34 35 - 39 40-42
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I INTRODUCTION AND SUMMARY; The Hot Metal requirement for the
] Middletown Expansion Program (Phase I) is 6,000 net tons of molten
iron per day. This is predicated on the anticipated production
. goals. Hot metal production is to be obtained, for this phase, by
modifications of the existing facilities. The subsequent report
defines the modification of the stoves associated with the #1 Blast
Furnace at the Hamilton Plant. This proposed rennovation is a
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portion of the overall Blast Furnace Project 7121, and is reported l*
as a singular identification.
The objectives of hot metal production from Furnace #1 will, in part,
be attained by increasing the Blast temperature to 2000 F. straight
line. Included with these modifications is the installation of
natural gas fuel injection to the furnace.
To achieve the anticipated effect, the following individual facilities are required.
1. New burners, fans, valves, and piping, 2. Increase height of three of the four stoves. 3. New support valves, i.e. hot blast, cold blast, chimney,
etc., to sustain projected temperatures and flows. 4. New ceramic checkers and brickwork in stoves to sustain
elevated temperatures and flows. 5. Structural .supports and modifications necessary for
instanation and service. 6. Natural gas/main.
Proposed stove modifications are to be performed in conjunction with the Furnace Reline and the installation of Semi-automatic
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Stove Controls. Appropriations for the Reline and Control'" Conversion are requested against the Middletown Works Normal Budget, and are referred to in this report only in terms of scheduling. Individual components are required for installation during the Reline tenure.
In this report, the economical advantages of improved blast heat and stove operations are considered secondary to production and conservation of coke. However, the results of similar conversions at the Middletown Blast Furnace indicated a substantial economical savings.
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AKE-003062
II GENERAL DESCRIPTION: The existing burner arrangements aYe insufficient /; J to attain a straight line blast temperature of 2000 F. Consequently,
new burners and associated fans, valves, and electrics are proposed. The proposed units are to be of such capacities to eliminate marginal operational fallacies often encountered.
Design investigations indicate the required heat storage capacity and . heat transfer abilities can be achieved by increasing the height of
Stoves #1, H2, and #3 to that of #4. This, in conjunction with new domes and miscellaneous repairs to steelwork, platforms,'and openings, will render the existing shells useable..
The linings of the combustion chamber, dome, walls, and checkers of each Stove are to be compatible with the projected temperatures and flows. Likewise, the required operational gas and air valves are to be in line with these physical requirements.
Natural gas is presently unavailable in the Hamilton Plant. The proposal includes correlation with the Cincinnati Gas and Electric Co. to extend their main across the Great Miami River onto the plant site. Armco would then route the main inside the plant.
Due to the extreme congestion in the immediate area of the Stoves and Furnace, several items relating to compactness of valving, piping, fan arrangements, etc, have been taken into consideration.
Operation control will be exercised from the pyrometer, control center, proposed in the Semi-automatic valve operators project. (Normal Budget)
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III EQUIPMENT DESCRIPTION:
a) Stove domes and shell extensions Stoves #1, #2 and //g:
Welded, l/2" plate, ASTM A-285 Grade C Firebox. Top platform
and access are to be raised compatible with the Stove extensions.
b) Linings:
Combustion chamber, domes, checkers, wall insulation and
supports are to be designed for 2,500 F. dome temperature, and
1,000F. chimney temperature to maintain 2,000 F. straight
line blast temperature with 60,000 cfm flow. Checkers are to be
multihole, interlocked, affording a total heating surface of approximately 160,000 ft. ^
The Combustion Chamber will be approximately 25 ft. ^ area
which will afford a gas area ratio of 900 ft. 3 gas/ft.
The
quality of ceramic will be as specified by Research Center. .
The prpposal includes mullite in dome and combustion chamber and
twenty feet of checkers, next ten feet of lesser mullite and the
lower fifty-two feet of high quality. This proposal has been
reviewed with Research personnel. Plant Management, Operational
Supervision, Division Engineering, and Works Engineering. The
review and discussions were made collectively and everyone was in
accord with this economical zoning effect.
c) lining Support-:
Metallic checkers are of cast iron ASTM A-48-56 Class 35* The
columns, girders and grids are of steel 1$ Cr., 5% Mo. similar
to ASTM A-182 Grade F-12.
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AKE-003064
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d) Platforms:
Platforms, access stairs, maintenance levels, and service
decks -win "be provided for all valves, drives and mechanisms.
e) Cold Blast Main and Valves:
The proposed modifications of the cold blast main include
new regulating valves, shut-off valves, and associated piping
and fittings to each Stove, Connections will be welded, using
3/8" plate of ASTM A-283 Grade C steel. Regulation of air will
be by 30" disc butterfly valves. The valves will be powered
by drive units, proposed in the Semi-automatic stove control
project (Normal-Budget). They will also have manual hand wheels
in case of power failure. The isolation shut-off valves will be
30" gate type, also power and manually operated as noted above.
f) Hot Blast Valves:
The 42" hot blast valves are of the improved mushroom design with
II water cooled flanges. They are welded construction of
ASTM A-387 Grade C Firebox steel. Hie opening or closing
time is approximately 15 seconds, obtained by an electric
power operator.
g) Stove Burners and Valves
Each Stove is to be equipped with a proposed burner rated at
22,500 SCFK of enriched blast furnace gas with a heating value
of approximately 90 BTU/ft.
The burners are fabricated steel
i with appropriate supports, inspection ports, drains, etc. The
mixer arrangement is to be of suitable design, commensurate with
the gas and air characteristics to afford proper flame propogation.
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Combustion fans are to be single inlet type, inlet vane control, direct driven air foil. Their rating is 22,500 scfm at 1?50 rpn at 40" W.C. static pressure. Drives required are 180 bbp maximum. An outlet damper to control system pressure will be installed, as well as an inlet stack to afford clean combustion air. ' Burner isolation valves will be water cooled, gate type, 48" diameter. Operators will be approximately 5 HP and will open or close valve in about ten seconds.
Coke gas, up to 1.3 nsillion ft. 3 per day, will be used for fuel enrichment. This additional gas therefore, will not be available for Middletown Works. Regulating will be by butterfly valves operated and controlled by the facilities installed in the Control Project (Normal Budget).
Blast Furnace gas will be the primary fuel. New 36" connections will be made due to the new burners. Valves will include plate goggle, butterfly regulating, and safety shutoffs. The regulating units will be electric operated and controlled by the facilities included in the Control Project (Normal Budget).
h) Chimney Valve; Combination chimney - blowoff valves are proposed for each Stove. These units are motor operated, cast steel, water cooled seat, elbow type. The operators will be installed under the Control Project. Manual operations will be afforded in case of a power failure. Operating time for the electric drive will be approximately ten seconds.
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i) Maintenance and Service Lighting:
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Suitable area lighting is proposed for night-time inspection,
operations and maintenance.
j) Natural Gas
A 12" gas main is proposed to terminate in the Blast Furnace
area. This line will be extended from a Meter Station to
j which the Cincinnati Gas & Electric Co. will provide a suitable
utility feed. The 12" Armco line will be approximately
2,300 lineal feet with suitable valves, fittings, and supports.
Number 1 Blast Furnace, with a blast temperature in the 2000 - 2200 F. range could use up to 5.2 million ft. ^ of Natural Gas per day. This is based on gas requirements of 5% at 50 lbs./in. 2. k) Electrical Equipment A 750 KVA Substation is proposed to furnish power for the fan drives. Conduit, wire and switchgear suitable in capacity will be installed in conjunction with the Substation. l) Cold Blast-Mixer Connections The existing 20" mixer line will be relocated and modified to include one butterfly regulating valve in the cross connection from the cold blast main. The individual Stove connections will include motor driven 20" gate valves to isolate the mixer air when it is not required.
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I V SCHEDULE: Work covered by this report is tentatively proposed as
] per the following gross schedule. The prime qualification of this alignment is the expedient approval of appropriations.
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AKE-003068
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AKE-003069
VI CHART OF ACCOUNTS: The project sections indicated below
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scope the modifications to the Stoves of #1 Blast Furnace.
?121-1*01 Raise Stoves #1, #2 and #3? Reline Stoves #1, #2, #3 and ffh 7121-1*02 Chimney Valves and Flues 7121-1*03 Gas Piping to Burners 7121-1*01* Gas Burners 7121-1*03 Blowers 7121-1*06 Mixer Piping 7121-1*07 Cold Blast Main 7121-1*08 Coke Oven Gas 7121-1*09 Hot Blast Valves 7121-1*11 Mechanical Replacement Parts 7121-710 12" Natural Gas Main 7121-820 Electrical Equipment 7121-830 Conduit and Wiring 7121-81*1 Electrical Replacement Parts 7121-910 Job Supervision 7121-920 Temporary Construction 7121-91*0 Engineering 7121-970 Contingency 7121-980 Fees 7121-995 Small Tools and Consumables
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AKE-003070
7121-iiOl
RAISE STOVES ffl, f}2 AND #3: RELINE STOVES #1? #2, #3 AND
This Project Section shall include all cosf'f-or labor,
materials, and equipment to increase the height and to
reline the Stoves.
020 Remove
This account shall include all costs for removal of the
lining and checker supports of Stoves #1, f/2, #3 and ffh,
also the relocation of support facilities such as small
piping, misc. accesses, platforms, and piping openings.
This account shall also include relocating the domes on
Stoves #1, #2, and #3.
027 Patch Plates at Cleanout Manholes
This account shall include all costs for patching shell
plates at the location of existing cleanout manholes.
033 Excavation
This account shall include all costs for the excavation
of platform support foundations.
03$ Backfill
This account shall include all costs for backfill adjacent
to support foundations.
177 Concrete Footings
This account shall include all costs for platform
foundations.
220 Miscellaneous Steel and Iron "l
This detail account shall include all costs for platform
J supports, accesses, decking, and the like. 221 Checker Supports
:! This account shall include all costs for purchase and *
installation of heat resistant alloy castings to support
.the checkers.
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222 New Shell Plate for Stoves ffl, 2 and #3
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This account shall include all costs for the" extension
to Stoves #1, #2, and #3 (approx. 11'-0") to attain
required checker volume.
366 Painting
This account shall include all costs for painting
Stove shells, domes, platforms, and unprotected steel
work.
L38 False Bottoms for Stoves
This account shall include all costs for labor and
material to erect false bottoms in U Stoves to insure
proper gas seal.
$90 Lighting
This.account shall include all costs for lighting of
. platforms, maintenance areas, and facilities used for
continuous operations.
OhO Start-up
This account shall include necessary services to
start-up and test Stoves before placing Stoves in
operation.
650 Repairs
This account shall include all costs for labor and
material for repairs to existing facilities including
lummite floor, platforms, domes on #1, #2, #3 and tih
Stoves, and miscellaneous units that are to remain
in operation.
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AKE-003072
660 Reline and Dryout Stoves
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This account shall include all costs of labor and
material for the relining of Stoves #1, #2, #3 and
#b* Lining and drying-out costs shall also be
included in this account.
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7121-L02
CHIMNEY FLUES
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This project section shall include all costs for labor,
materials and equipment used to install new combination
chimney and blow-down valves conforming with Stove-
requirements.
020 Removal
This account shall include all costs for the removal
of existing valves, the relocation of chimney valve
connections on the Stove shells and the temporary
reinstallation of the existing chimney valves.
L6l Water Piping
; This account shall include all costs of materials only
?. for cooling water piping. '
\ U62 Chimney Valves
i; This account shall include all costs of material only
*. for four combination chimney valves conforming with
" proposed Stove requirements.
U6U Pipe Installation
This account shall include the labor and services to
install the proposed valves, flues, and piping.
6g0 Repair Flue Lining
This account shall include all costs for labor and
materials to repair the flues and valve sand seals
n of the four stoves. !
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7121-1*03
GAS PIPING TO BURNERS
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This project section shall include labor, material,
and services required to connect Blast Furnace gas
piping to the stove burners.
026 Relocate
This account shall include all coste of labor, field
materials and services necessary to relocate the
burner take-off lines to the gas main, install
temporary leg from main to existing burner and
permanent leg to new burner.
033 Excavation
This account shall include all costs for excavation
of piping and valve support foundations.
035 Backfill
This account shall include all costs for backfill as
required adjacent to the valve and pipe support
foundations.
177 Concrete
This account shall include all costs of- concrete
required for the foundations for the valves and
piping supports,
220 Miscellaneous Steel and Iron
This account shall include all costs of steel work
as required for supports and service platforms in
conjunction with the gas valves.
l*6l Piping
This account shall include all costs of materials
for safety seal water piping to the burners on four
stoves.
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AKE-003075
I162 Valves
1 This account shall include all costs for goggle and
regulating valves for the Blast Furnace gas to the four stove burners. It6Ii Pipe Installation This account shall include all costs for the installation of piping and valves associated with the water seal piping to the burners. 6j>0 Repair This account shall include all costs for repairs to the existing gas main, supports and associated units of the gas piping system that will remain in service.
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AKE-003076
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7121-liOit
GAS BURNERS
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This project section shall include the replacement
of existing burners with units capable of attaining the requirements of the proposed operations. 020 Removal of Existing Burners & Blowers
This account shall include all costs for the removal of the existing burners and blowers of Stoves ffl, #2, #3 and #U. 033 Excavation This account shall include all costs for the excavation of burner foundations.
035 Backfill This account shall include all costs for labor and materials suitable for backfill adjacent to the burner foundations.
177 Concrete This account shall include all costs for concrete and placement of the burner foundations.
220 Miscellaneous Steel and Iron
This account shall include all costs of steel work for maintenance platforms supports and stairs associated with the proposed burners. h6l Piping
This account shall include all costs for piping and connections (material cost only) between the burners and stoves.
L62 Valves
This account shall include all costs for the burner
isolation valve (material cost only) between the burner and
stove.
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AKE-003077
Lt<Sh P.ipe and Valve Installation This account shall include all costs of labor, and services necessary to install piping and valves.
610 Burners This account shall include all costs for the purchase of the burner equipment for four stoves.
620 Burner Installation This account shall include all costs for labor and services to install the burner equipment on four stoves.
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AKE-003078
7121-LOS
BLCWERS
This project section shall include the fansV motors,
piping, etc. associated with the stove-burner.
U6l Air Intake Piping
This account shall.'include all costs for purchase of
inlet piping to the four fans in order to obtain clean
combustion air.
L6L Piping Installation
This account shall include all costs for labor and
] service to install the intake piping.
$60 Motors
I This account shall include all costs to purchase and
1 install four- (approx. 180 HP each) blower electric motors.
3 610 Blowers
This account shall include all costs to purchase four
3 blower Tans and appurtanenses.
i 620 Installation
This account shall include labor and service to install
the blower equipment scope of work same as on #610.
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AKE-003079
712I-h06
MIXER PIPING
This project section shall include the relocation and
alterations to the cold blast mixer line.
026 Temporary Connections
This account shall include all costs for all temporary
and relocated mixer line connections to the Cold Blast
Main and the Rot Blast ?7alve from the new mixer main.
L6l Piping
This account shall include purchase cost only for the
20" pipe necessary to alter the mixer lines.
U62 Valves
This account shall include purchase cost only for the
regulating valves and shut-off valves in the mixer line
and in the connections to the hot blast mixing valves.
h6h Installation
This account shall include all costs of labor and services
to erect the piping, valves, and supports associated with
the cold blast mixer piping.
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AKE-003080
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7121-hO7
COLD BUST MAIN
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I This project section shall include the connections of
'! the cold main to the stoves, relocations, and valves associated with these connections.
026 Relocate and Repair Cold Blast Line
This account shall include all costs of labor and
material charges to -repair and relocate existing cold
blast main piping and connections.
h6l Piping
This account shall include purchase cost only for pipe
necessary to rework the cold blast stove connections.
h62 Valves
This account shall include purchase cost only for
regulating and isolating valves to achieve the proposed
stove operations.
h6h Installation
This account shall include all costs of labor and services
to install piping for cold blast stove connections and
valves.
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AKE-003081
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1 7121-L08
COKE GAS
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This project section shall include the coke enriching
! gas arrangement to the burners of the four stoves.
026 Relocate and Repair Gas Line
i This account shall include all costs of labor and
materials toaelocate the coke gas header.
L6l Piping
This account shall include purchase cost only of 8"
- main and runouts of V pipe.
I}62 Valves
l This account shall include purchase cost only of the manual shut-off valves, regulating valves and orifice
i metering equipment for the V connections to each burner.
U6U Pipe Installation
This account shall include all costs of labor and
services to install the piping and valves associated
with the 8" main and four runouts for coke gas to
the stove burners.
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AKE-003082
7121-bO?
HOT BUST VALVES
This preoject section shall include the replacement
of hot blast valves and related connections.
020 Removal
This account shall include all costs for the removal
of the existing hot blast valves, flanges, drives and
connections.
026 Temporary Lower Valve Section
This account shall include all costs of labor and
material required for the temporary connection of
the .hot blast valve to existing lower section of
the existing valve and provide refractory timing
for all temporary connections.
033 Excavation
This account shall include all costs for excavation
necessary for foundation to support valves.
035 Backfill
This account shall include all costs for backfilling
the blast valve support foundations.
177 Concrete
This account shall include all costs for concrete
and placement for the hot blast valve foundations.
Ii62 Valves
This account shall include purchase costs of the h2"
mushroom valve, equipment for all four Stoves.
b6b Installation
This account shall include all costs of labor and
services for the installation of the proposed hot
blast valves.
2b
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AKE-003083
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660 Refractories for Lining Valves
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This account shall include all costs of materials
and installation for the lining of the four hot
blast valves.
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AKE-003084
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MECHANICAL REPLACEMENT PARTS
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This project section shall include the mechanical
replacement parts required.
6h3 Replacement Parts
This account shall include all costs for the purchase
of the valve seats, valves, gears, coupling, etc.
considered as replacement parts.
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AKE-003085
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7121-710
12" NATURAL GAS MAIN
This project section shall include the natural gas main from meter station to the Blast Furnace area. This proposed system is required for gas injection in the
furnace. 03ii Ditching and Backfill
This account shall include all costs for trenching
and backfill for the proposed 12" Natural Gas Main. 037 Track Crossing
This account shall include all costs for materials, labor and services to make eight track crossings for the proposed natural gas line. 038 Roadway Crossings This account shall include all costs of materials, labor and services to construct two roadway crossings for the 12" natural gas main. L6l Pipe and Fittings
This account shall include purchase costs for pipe and fitting materials only for the proposed 12" Natural Gas Main. U62 Valves
This account shall include purchase costs only for valves
as required for truck lines and main on the proposed Natural Gas Line. Ii6h Installation
This account shall include all costs of labor and services
to install the 12" natural gas transmission facilities. This account shall not include crossing protection or excavations.
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AKE-003086
It66 Hangers and Supports
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This account shall include all costs of labor and
materials for supports, bents and trusses as required
for the Natural Gas line.
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AKE-003087
7121-820
ELECTRICAL EQUIPMENT
This project section shall include electrical power
requirements for the proposed stove rennovation.
026 Temporary Connections
This account shall include all costs of labor and materials
required to provide temporary operation of motor controls.
?0 Substation and Kotor Controls
This account shall include all costs to purchase a 1000 KVA
;j Substation package and motor control equipment for the burner combustion fans.
80 Installation
This account shall include all costs of labor and services
to install the 1000 KVA Substation and motor controls.
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AKE-003088
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7121-830
(CONDUIT AND WIRE
This project section shall include the electric
power transmission facilities for the proposed stove
facilities. This project section does not include
any arrangement associated with the Semi-automatic
stove control project. (Normal Budget)
026 Temporary Conduit and Wire and Relocation
This account shall include all costs of labor and
material for conduit and wire for temporary valve
operator, starter, etc.
$11 Feeder
This detail account shall include all cost for materials,
labor and services for L.16 KV Feeder for the proposed
power requirements.
-$13 Wiring
This account shall include all cost of labor, materials,
and services for 600 V. class wiring in conjunction
with the stove electrical requirements. Terminal
connection to equipment shall also be included with
this account.
$21 Conduit
This account shall include all cost of labor, material,
and services for the installation of conduit, and
fittings for the proposed stove improvements.
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AKE-003089
7121-Blfl,
ELECTRICAL REPLACEMENT PARTS
This project section shall include the electrical
replacement parts required.
6U3 Replacement Parts
This account shall include purchase cost of relays,
limit switches, indicator lights, etc. considered
as replacement parts for the project.
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AKE-003090
****** V:
VIII ESTIMATE;
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In the following detail, estimate expenditures necessary for
the subsequent outlined facilities are analysed based on
preliminary engineering drawings, and major equipment vendors
quotes.
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AKE-003091
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AKE-003093
BLUE, SMALL RED, YELLOW (W-A), SMALL YELLOW, ORANGE, PURPLE
AKE-003094
BLUE, SMALL RED, YELLOW (W-A), SMALL YELLOW, ORANGE, PURPLE
AKE-003095
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AKE-003096
BLUE, SMALL RED, YELLOW (W-A), SMALL YELLOW, ORANGE, PURPLE
AKE-003097
BLUE, SMALL RED, YELLOW (W-A), SMALL YELLOW, ORANGE, PURPLE
AKE-003098
BLUE, SMALL RED, YELLOW (W-A), SMALL YELLOW, ORANGE, PURPLE
AKE-003099
X ARRANGEMENT DRAWINGS The following drawings which outline the scope of this project are attached: 1. 013464 2. 013465
BLUE, SMALL RED, YELLOW (W-A), SMALL YELLOW, ORANGE, PURPLE
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AKE-003100
BLUE, SMALL RED, YELLOW (W-A), SMALL YELLOW, ORANGE, PURPLE
013464
AKE-003101
BLUE, SMALL RED, YELLOW (W-A), SMALL YELLOW, ORANGE, PURPLE
AKE-003102