The development and implementation of a prototype to improve thecurrent maintenance procedure applied to the SIS, SafetyInstrumented System, of the raw materials and products conveyorbelts of the Coke Plant operational unit of CST are reported. Due tothe continuous mode of operation, currently protection switches canonly be inspected visually, which does not ensure a perfect operation.The aim of this new tool is to allow the online inspection andtesting of the safety switches without interfering with the productionand to maintain its functionalities.

EMF in a blast furnace can be used to predict liquid level variationsinto the hearth. After the strong influence of some process parametershas been minimized, the variation of the EMF at the end ofconsecutive castings can be used as a criterion of liquid level variations.Currently this criterion is integrated in a mathematical modelthat sends messages to an on-line advisory tool.

The background of the development of the BRP technology(Baosteel BOF Refining Process) is presented along with the experimentalconditions and results. The relations between dephosphorizationand basicity of slag, bottom blowing, temperature at endpoint are analyzed. The effects on dephosphorization of bottom blowing,total iron of slag and silicon content in hot metal are also considered.The performance results indicate that, in the de-P converterand the de-C converter respectively, the dephosphorization efficiencyis over 84% and 64% with phosphorus contents below 0.014%and 0.005%. Steels that are difficult to elaborate, such as tire cordedor X 65 pipeline steel with HIC-resistance benefit from the BRP technologyin Baosteel.

The application of finite element techniques to modelling the longproducts rolling process, the use of a customized interface to enablethe rapid set-up of sequential simulations, and the benefits thathave been obtained are described. The paper also discusses theenhancements to incorporate a design of experiments/design optimisationmodule and to enable material tracking.

The performance of lubrication systems for cold double reductionrolling has been investigated. Pilot mill trials have been achievedwith direct and recirculated emulsion application as well as with pureoil to analyse the effect of lubrication by emulsion on role bite frictionand the associated speed effect. It is then attempted to define anoptimized lubrication system that combines the advantages affordedby the direct and recirculated application systems.

The structural durability of welded structures is determined by theinteraction of different influencing parameters like loading mode,spectrum shape, residual stresses and weld geometry amongothers. Examples from plant, offshore, transportation and automotiveengineering show how these parameters influence the fatigue lifeand to what extent they are considered in design codes.