Document jBG7b0GzqjgZrOOXpgzO2qEkN

FILE NAME Corning OC DATE 1967-1968 DOC OC208 DOCUMENT DESCRIPTION Kaylo & Reports 4 7 VS ~ Mr. R. Grant Toled R. F. Shannon Granville KAYLO RESEARCH AND DEVELOPMENT MONTHLY REPORT FOR JANUARY 1958 February 5 1968 . . :+ ve ' Mr. Mr. . Mr. Mr. Mr. M. Hardwick Berlin J. Helser Berlin A. J. Pearson Toledo J. Rhoads Berlin V. V. Smith Toledo This report summarizes major Process Development activities carried out in January by the Kaylo Research and Development Laboratory in cooperation with Berlin plant personnel in support of plant operations It also briefly summarizes the status of Marketing supported Keylo Product Development programs Process Development 1. Process Audit Continuing audits of the Berlin operation by R & D indicates a substantial upsurge in product quality workmanship plant appearance and equipment and mold maintenance This was evidenced by higher job efficiencies and higher throughputs in December and January A quality control product audit conducted on February 1 by Marketing and Toledo and plant Quality Control personnel gave further evidence of the recent upsurge in product quality Included in this audit i were many of the pipe sizes which are considered the toughest to 7 pour 1.e. those sizes which normally have the highest incidence of visual defects and low job officiencies The general concensus of . those present at the audit was quality of Kaylo pipe had improved in recent months with fewer air holes and broken corners Kaylo block was of very high quality probably the best on the market today ee . . a | . 2 Batch A. Carbon Modified 10 Batch Approval was received from Marketing to carry out an extended trial of carbon block modified 10 batch This study will . determine whether elimination of mold oiling is possible provided an internal lubricant is added to the batch One block train is currently being cycled without oiling As of February 1 the train had been cycled ten times and still looked good Final results from this study should be available in late February - . U Use imported diy Oat ^' es ybah di ie Tn -e_ ts Wt ge eee ~ toe -- a . He ett . re oe er ae . tes too - . fee ad . . . : - os Swe Cr ee wet se et FROPRIETARY . This document document or any parts parts of of it divulged should not to others divulged to copii mir without permission without permission permission permission of . so - . Awann Anus. ~ - N {hoe I " ery er ae ee ee 308 Loner ~ een - Mr. K. Os Vi ied B. 700 Pound Dust Batch C Process Control summarized and issued J. Helser of Berlin dust batoh formula- form all of the data from 700 pound in report in recent months These data coupled tions poured at Berlin all indicate the so called data from Granville trials dust and 300 C with &dust batch 400 pounds of Berlin process 700 pound hammermilled offware will produce a high pounds of Jeffrey meets the CAS quality product which fully se ff the of preparing a 901 to cover the purchase The plant is in process dust bandling equipment of a Jeffrey hammermill and suhpapvoertbinegen made to have substantial In the meanotfimoeffawrarraengpermoecnetsssed through a Jeffrey hammermill quantities 8 and 16 hour trials of the 700 pound will permit extensive to verify process This dust batch to be conducted at Berlin so as ' ~ and product quality under plant conditions performance . Prohardenable Prohardenable 17 Core research has been directed toward i prehardenable Extensive modified batch was developed which fully 17 batch A cement and the CAS except for coppressive moets UL product requirements confirm the fact compressive strength A search of UL records A monary strength is not a part of17 thebactuorbrenwtilUlLbeproiscseudeudreby February 15 report on prebardonable Manufacturing Toledo Quality by D. A meeting of Marketing Product Testing personnal Control and Process Control R & D and Bust follow for future action on this program La oe & wes.. ag arte? 6 tapben ere + D. 10 Block Batch fact for years that batch formulations It has boon a known not always yield good Kaylo block designed for Kaylo pipe did flexibility now avail- and vice versa With the greater process of batch formulations specifically able at Berlin development is now possible A modified designed for block or for pipe for block was 10L batch designed especially version of the This batch is lower in cost placed iinmpprroovdeudctviiosnuailnapJpaenauraarnyce and fields a prodpruoducctt ofssuup pe erriioo rr has an RL -- la 43 Vass, - ert ak wk ese kr os ied quality ep. ~~ OC. * oF - ofp ste soos . os . terse ar) 3. Proces1s4 3.7 o- * oe . <r id . sf econ A. Process Mosting and quality review meeting was A comprehensive monthly process 18 1968. The next meeting is tentatively held at Berlin on January coincide with the next plant trip scheduled for February m2e1ettiongs will provide for regular review as by the writer These & D programs programs jand follow of all plant and plant process process programs responsibility ito status fining and responsibility responsibility & ee ara bere bere and c Tics ek se This content es should not be copied now dirigy to others without permission of Corning Fiberglas Corporation 309 waa ea 2. cux cux cu=x . an a UL _ SMe Ue WLMIIL -3- February 5 1968 i, AN G 8 Bulk Storaro ("> y NA In December 1967 the plant went full time on the 8 bag 752 pound cement batch identified as 10L This batch formulation contains plans a substantially higher percentage of Portland cement than quicklime Plans are to switch in early February one of the bulk aysters from quickline to Portland cement with a possible daily savings of over 40 Installation of a third bulk system in our for near future to handle quickline will bring daily savings over 70 Note Plant Engineering informs me a third syster can be added to the present bulk system at minimum oost fourth system to handle diatomaceous earth would be quite expensive) C. Water Control - Batch e For years the Berlin process has been plagued with density control The main cause for this problem has been water measurement measurement Recently the problem has been compounded by the practice of adding coment to the asbestos tank causing build up in the tank which affects the accuracy of the present water measuring system Purchase of a water meter is under consideration Locating a meter which will yield the accuracy needed to control water solids of Kaylo batoh is ourrently underway An alternate method of measuring water even more accurately than commercially available meters can is being studied by Plant Engineering Plant Process Control a| nd D. Results of this study will be reported in February soy Mee 1 Waste Slurry - _ . a ~ . . cere . : TB oe i bee . 0 oe - Ses, Plant audits conducted by R & D last summer and fall Indicated ' one of the major causes for variability of batch properties processing and product properties was use of waste slurry Substantial improvements have been made recently at the plant in the handling and holding now under constant agitation of waste slurry A study will be undertaken shortly to gain even - better control over waste water composition and solids A piece of equipment commercially available and now in use by the water treating and process industry for separating solids from vatar ~~ will be investigated From an economia standpoinwte must continus. to use waste alurry At the same time reduction of its effect is on batch consistency processing and product quality of utmost importance to the plant operation are on y . _ ace Ly ow ao aE ". ee be BS the Vacuum Stripping . = -- : ee Vs lp oa 74 . 7 " * " the wate tee -- ect .oo ... the diam diam 39 39 presnt presentpresent A major Kaylo procesa problem which has existed From day one has been stripping of flatuores A concept known ad vacuum we was stripping suggested years ago as a means for overcoming this problem In January Berlin plant maintenance and engineering personnel on their own initiative built and successfully testoi neo ide a prototype vacuum stripping device for flatware oore and block PROPRIETARY _ This document or any parts of it should not to others be copied nor divulged without permission of 310 o E. You Stripping Cont) Once it is installed on the in block and oore offware the false bottom plates and line we can expect a reduction NEW caused by chips remaining under chipped and broken corners should te reduced substantially Pouring rates should also increase since stripping continues to be one of our current throughput F. Prehardening ae . ~~: ry Meetings were held with Toledo General Engineering personnel ~~ to review process problems relating to prehardening of Kaylo General Engineering will conduct studies at Berlin directed toward collecting data as to rates of pretardening temperatures required and alternate methods for beating the molds and batch to reduce prehardening time During these meetings Kaylo R & D passed on to General Engineering a number of suggestions relating to modifications modifications which could be made to the existing prohardeners to make them even more effective These modifications could also be incorporated into the design of the new prohardeners to be installed on pouring line 3 a so - G. Graphite Treated Holds oO so Dr. C. L. McKinnis of the Kaylo R & D Lab has evolved a new concept for eliminating the need for oiling of molds It involves the application of a molecular layer of graphite to the metal surface of the mold The current thinking is to apply this costing in the mold shop at the time the train is being cleaned Initial lab data shows promise Arrangements have been made with M. Hardwick to evaluate this concept at Berlin under plant _conditions possibly in late February 7 wt . f we . . H. 4 Back in the 1950 it was believed long up and down cycles were necessary to prevent ware blow In fact for years a multiple stop operation was used to bring the SID cylinder up to pressure The same in reverse was used to lower the ' pressure In the early 1960's experiments were conducted at Granville which indicated up and down cycles oould be reduced substantially without adversely affecting product properties J. Helser ; Berlin Process Control reduced the up and down cycle to one The half hour and one hour respectively in recent years In January the down The The further reduced the up cycle to 15 minutes and cycle to 30 minutos What does this mean Capacity of the present o SID's has been increased the equivalent of two or more trains per day Also we any have gained a foothold on extending the patent protectioonn the SID process OCF SID patent has expired *, The special process tricks needed to make such short up and down oyales work without blowing up the ware are probably patentable PROPRIETARY This document or any parts of it should not be copied nor divulged to others without e ee 211 Mr. R. S. Grant -5- February 5 1968 4. Raw Materials A. Glass Technology ~~ ew ome fe we A meeting was held at Berlin with Glass Technology personnal to determine how and where they could help A comprehensivs review of batch materials used sources of raw materials and methods of mixing were provided Glass Technology Areas where Glass Technology could provide immediate help were defined They include Locate alternate vendors of lime and silica ohemical analysis of all batch materials as a prelude for writing tighter purchase specifications and analysis of Kaylo batch + - and product on a regular basis to determine chemical variation for future upgrading and process control B. - ee ad . ro cre . & ves The ourrent 10L batch requires substantially less diatomaceous earth than previous batch formulations an so diatomaceous eartihs an expensive raw material We need an alternate source for obvious reasons Also indications are a second source will create the competition needed to obtain lower prices Active programs are underway with both Dicalite and United Sierra Plant trials of a Dicalite material is tentatively scheduled . for Zebruary | Aposite Asbestos ae ..Y L. . : ^ meeting was beld with Mr. Cryor President of North American - Asbestos Corporation concerning fiber length of amosite asbestos | The problem is purchase specs for amosite asbestos are so loose - it is difficult to have any basis for rejection This meetin<-g: was prompted by the fact it was the combined belief of plant and R & D personnal K asbestos shipped to Berlin last fall ce as the equivalent of W asbestos was actually shorter and could . have been a possible cause for lower product strength A basis for evaluating amosite asbestos fiber length and for complianos 1 with a specification also to be worked out is under active -, negotiation : : | = z oy - Oe se oe te r: d ee ws. . tee ary 1. + ae well e . ~ . . ole 2X," [ rr Ca a Mr. Cryor is also arranging to have amosite asbestos dry milled milled milled In either Africa or England for us All other manufacturers of calcium silicates dry mill their asbestos we wet grind ^' trials will be made with the dry milled asbestos as soon wute improved product properties .06 ; ve it arrives to determine determine - whether whether , product LA - . e : e ,t ets ets ; prpr t pr ttare possible pospossiblie blepossible 1 a pr t . as BSA WRC! WL G oom c Chrypotile Asbestos .D Chrypotile Chrypotile Chrypotile Asbestos Asbestos Asbestos menal m do ' - ~ * Roe * &. rr re do LCDE le . - ae - 4T te, 2 xs,7 riceung riceung riceung riceung o: - ece cctaed asbestoC s O Mallett at to Bauer tc i Bauer cit , baing used tests were fun Granville on 4T and 70 asbestos at Berlin Both were found to be meeting our Puroba Specification as to fiber length PROPRIETARY. This document or any parts of it Ehould not be copied nor divulged i ay a, ee+) x 212 Kr K. Grant . 050 . February 5 1968 5. Alternate High Temperature Insulation Processes oF A. Process - New Facility . comprehensive being A report is prepared for Management various processes which must be considered for the concerning and possibly later at Berlin Various new facility filter press bonded aggregate verticalprcoacsetsisnegs Cirnocslfuideilndg and pan pouring are being reviewed in depth as to advantages and disadvantages of each capital capital expenditures needed throughputs and economics The R & D report will issue on or about February 15 B Crosfield Autoclaved Process Process Arrangements were made with the Crosfield people to obtain samples of their product for physical property study and verification _ and a quantity of their calcium calcium silicate raw material for sample preparation at Granville As of the date of this report neither has been received at Granville . .. . : : Product Development 1. Stress Corrosion The second 3,000 pound grind of 2379 2379 glass from Philadelphia Quartz was released to Berlin for plant trials trials A series of was made in January directed toward toward plant trials evaluating the batch formulations developed last summer and fall at Granville These formulations - expected to produce harder stronger ware and lower batch costs are being shipped to Granville Product are Samples and stress corrosion testing Testing Lab for physical thermal for The 10L batch poured on December 28 passed the 6 day stress corrosion test but was marginal on on the 10 day test 3 out of 10 te ,*- samples cracked This batch was identical to the approved last February of Philadelphia Quarts 1967 by duPont duPont except for 2377 glass for Granville one the poured and substitution The cause this melted 2399 glass variation in results results is ourrently under investigation 2. 34 Inch Pipe salvaging A substantial percentage of our offware at Berlin is defined ware A as short request was made last fall fall to Marketing to change pipe specifications from 35-7 inch to 35-3 inch and to market a 34 inch product which could be salvagod from from ware with broken corners Substantial increases in packed ware would be approved these requests possible if Marketing Marketing rejected the tion change from 35-7 inch to 35-3 35-3 inch pipe length specificaThey did to the marketing of out downs out downs was started in late 34 inch agree however This program of January ane PROPRIETARY cee ~ a . S This document or document not should or any parts of it to as capled nor divulged others without divulged Fiberglas permission Corning Fiberglas Corning permission of Fiberglas Cornamate Cornamate 214 ' PF oe c 3. Asbestos , ' te < The experimental program on replacement of resumed in January under the direction asbestos by glazes was | Difficulty was encountered in dispersing of Dr. C. L. Mckinnis ... | fibers without attrition to dispersing fiber chemically treated glass this difficulty are length . Ways of circumventing now being investigated In the interim mental glass fiber Kaylo batches mixed with experi- are being run to check the resistance of conventional equipment these chemically treated fibers against the corrosive action of the Kaylo batch Multi Pipe Fittings Fittings ee ewe, R. F. Shannon and A. S. Kevlin of and Coustics on January 17 for Marketing met with Insul- of producing Multi purposes pipe of reviewing the technical aspects . prepared by Kaylo & fittings A detailed report will be plans call for covering Coustics the Multi process Tentative ~ _ to buy basic wool from OCF mold to * asnhdappeacskaatguerateThewith the OCF developed inorganic saturant dry trim fittings will be marketed by OCF - dry CareyterD CareCareyy terD t Careye terDrD A report of D findings as to asbestos prepared and released to content of Careytemp was contains almost as much Marketing It is surprising to note Careytemp asbestos as Kaylo yet their boxes do not carry any warning label and no mention of asbestos appearisn their Riese oot wie mt som 6 ris 6 6 . 4 . an oe wee ste sof . we TIT Lt, i. meet Doe Losin. - 2u2an- erine ts Te +. ONAL RS ~ etre PIN grag TEK TEK TEK : . Le x doll - doll . This doll ee should should doll but doll ddoollll crosoffits crosoffits havehave a crosoffits crosoffits pi crosoffits crosoffits crosoffits crosofits | shouslhoduld now now Corning mission to to otothheerrss led crosoffits crosoffits led led led led led wwiithtohuotut without without LL no dituged no dituged mission of Nitergius Nitergius wre eae Tse ewer wees TP rs eee ew rere ie. Ue eee lt itw Kee 00575 Nr R. & Grant Tolod 1. F. Summ Granville ATLO RS3ZURCH AND DEVE 9733791K INTELAZNI INTELAZNI 9733791K November 1 1767 Mr. M. Bardia Berlia - Mr. J. Halser Berlin Kr J. Yargeta Berlin Mr. J. Martano Bour ' J. Mr. R. . J. Mary Mary Granville Khoads Berlin Mr. B. V. Sulth Toledo Central Flos This report resuries for process development activities carried out in Gctober by the wayle Beserch and Development Laboratory in cooperatioco penration with Borlin plant personnel in support of plant oporations It also briefly rites the status of Harvsting exported mayla product devalspacnt : programs programs DeDel la za at 1 Fresess bucdt Per a 4703sont betyson 4Entries and the writer suliting of the plant process and operation by xylo & D porsonnal is being continued continued Each tixe & ; D persoonal are in the plant for pr coss meetings or to and saqu ement experistals experistals entiting of all or various process facturing arses are being carried out as as time parits basis Audits were carried out during the woms of October 16. 23 and 30 Conditions or procedures which are affecting productivity quality ^r ^ befficiencies ware called to the attention of the plant Quality Control and Process Control fanager for follow As part of the followmap of the ingest andit Berlin requestal Renting Renting Renting their platting of plant production data including physical and thermal properties offware and job officiencies Fronds over a five year period were plotted and suberitted to Farlin management personnal for study and follow It is hoped these data will parait better process ofatrol as well as inselage of gradual changes as they sctur in the process or product When siverse tronds beyin to show up edjastaunts in the betod or process can be made innolistaly Ex Attended a process reeting at Berlin oc Otober 26 at the request ot N. Rindo The purpose of this meeting was to set up a tas foros of ploat Toledo Enginsoring OF Methods Inginering and Laylo 5 D personal who will wor towned the objective of inking plant through through put at least 20 percant The incressed throughout to be achieved on pouring lines with capital expenditures limited to two additional eylinders and costs of modifying the existing lines to handle the greater throughout PROPRIETARY . fi"ee fi Se . wn, - cos oo . . 74 . ee os ~ :> 186 .. K. 5. Grect wl Rovember 1 1957 subutted In mpport of the tax forse a search of the a 1953 proposal to build resers vas made to loesta Sayreville plant by 01. Iatpipe coverincovegring ficturing ficturing ficturing facility at the the Sayreville proposal mightme to haodpeadptasbolmee toof tthhee Biedrelaisn contained in operation Copies of the report vara subutted for staty and evaluation to rand and L. Barvic for A mooting was hold at Grill with expensisexpaensisa plans in general and R & D this gincoring to discuss C. Ritter's initial layout of the objections and suggestisonsuggestions to a third pooring lips extra proposed proposed plent driers and expension which includes includes finishing lines relocated nature and pipe 3. offware Five thousand pounds of kayle offware at Joffrey Manufacturing This dust vare couverted to arlo dust trials on the 700 pound dust betab was roshipped to Berlin for plant bination of 400 Initial plant trials using OSTA Marilled pounds offers of regular plant dust and 300 pounds of Joffrey loo exordingly good Flans are full shirt of this betab any to run cccur the plant will position If no process or product problems initiato a 90 for the facility to overt of fa) to dust Ito 730 pound dust batch par mooth la batch repromats a savings of about 10,03 dup problems at Bercolsitns and substantially reduces the disposal and AsistererAsisterer To CasIe ndapslry Provided extensive briefing of Glass T chnology and Glass Resourc personnal it request of Dr. F. Day to as to type of raw segnaint that with the produced at naterials process of defecture and type of products provide Berlin The process control objective objective of Glass Tochnology is to bully assistance t Berlis 112 Core For some explained rosson 02pressive from cement modified betah is strengths of ] core poured CJS Extensive considerably below mais est in the resoareb was condacted at Grenville Eo wohbtyaitnheed sttoredngatthes are lover or how to salve the problems haanvoevobrsoaas to Jarle Engility - Coorde Prepared cost study of moufacture of seyle in all facility reprosted by Fiberglas Caneda via our Liesasso Departmeal Dats 2. oo, Several meetings have been bold with Moalite continding toward upgrading performance of permal Efforts are Currently Dicalito is not the Dicilite in mayl batch equivalent of Celaton 1-370 ext is not 207 RezRez zzat a Rezt zat 1. Stresa SexIV^ MSexIV^ M prends Refecturing placed an order for 250,000 250,000 of 2377 this with Philadelphia Charts This will produce 1.83 million pounds of STS Laylo and will parrit as to completo extensive test process deging statles on the STS eroting and of the 2377 glass is Bronber 15. and CP Manafecturing Laylo 1 product Target date for delivery It the request of Tolado Parche for the 2377 glass propared the purchase specificatioa Otimized stress srosion batch formulations developed during tho past three to four meaths vore poured as pipe and as blook for val and stress corrosion testing Initial date physical physical formulations will yield & substantially Indicates these these stronger and harder Suplas vore mabaitted to Product Testing Testing Lab for ^ bernal product evsination and for expliance with de'out's 6 day test pe porty procedure 2. 3 rh fathe fathe fathe fathe mAenntusmbfeorr osfubreassitnesses exted fibers were evaluated in Catober as replace A. $ mples reinforced with rubber onsted glass fibers vare bittal to Product Testing Lab for testing on bot pipe for survival at 1200"} r36 dours B. Semples of farlo pipe reinforced with Lotal later onated Mbore plus a mall expt of glees chrysotile bestos to prevent mad boortiopniipnog tweosrtsinpgoured and bitted to Frainct Testing Lab for major major C. Ittepts vere made to propers Kaplo insulation reinforced with Chea Lab prepared epoxy coated glass fibers The fibers Becsoj a probles of mixing in that they were too flexible and billed rp in the mixer Stiffer fibers with higher pary contents ill be produced in an attempt to overeses the dring problem D. Thenolle costed glass fibers obtained from the group working co molding pound were also evaluated in lo The fibers cated with about 0.75 porecat phenolic and chopped at the bushing did not survive stoolsving Arrangements are morvay to have Abers easted with a higher percentage of phenolic resin prepared f r be PS. . 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