TECHNICAL Specification - Redesign New Gear Box and New Coupling for Skip Winch-rev.1 (2) (1)

BF 5 REVAPING PROJECT 261 / 265 / 2432 / 23.11.2010

ArcelorMittal Galati Romania

TECHNICAL SPECIFICATION Blast Furnace 5 Relining

CHARGING Contracted work: NEW COUPLING CD12 AND REDESIGN FOR SKIP WINCH a GEAR BOX WITH a BETTER DESIGNAgreed Approved Validated Validated Title Project Manager User Leader Pilot Electric & automation PM Name Constantinescu Victor Chiriac Marian Birsan Petrica Spaiuc Liviu Signature

Project leaded by: Name : Rosu Cristina-Charging PM Phone: 0040 236 803179 Mobile phone : 0040 733110752 Email: [email protected] Name : Birsan Petrica-Charging Pilot Phone: 0040 236 801910 Mobile phone : 0040 733 443709 Email: [email protected]

Signature

Signature

Rev 0 1

Data 16.12.2010 28.12.2010

Status Final

Remarks

SUMMARY

1. OBJECT OF CONTRACTED WORK 1.1 NEW COUPLING CD12 AND NEW GEAR BOX FOR SKIP WINCH WITH A BETTER DESIGN 2. CHARACTERISTICS OF THE INSTALLATION INTERFACING WITH THE CONTRACTED WORK AND LOCATIONS FOR THE EXECUTION OF CONTRACTED WORK 2.1 SITE CONSTRAINTS 2.2 CONSTRAINTS SPECIFIC TO WORKING ENVIRONMENT 2.3 INSTALLATION INTERFACING WITH THE CONTRACTED WORK 2.4 TOPOGRAPHY-SITUATION OF LOCATIONS-VERIFICATION OF GENERAL LAYOUTS OF THE COMPANY 3. DESCRIPTION OF THE INSTALLATION 3.1 EXISTING INSTALLATION 3.2 WORKING CONDITIONS 3.3 DESCRIPTION OF CONTRACTED WORK AND SUPPLY 4. DELAYS PLANNINGS 5. ANNEXES

ArcelorMittal Galati (Romania)

BF5 Relining-Redesign a new gear box with better design-rev.1 Page: 2/11

FOREWORD ARCELORMITTAL Galati plant is called hereinafter, the COMPANY. The COMPANY scope is to Overhaul BF. No. 5 and to restart perfectly the installation on July 2011. Next campaign life time will be 15 years. In this Technical Specification, the Installations represent Blast Furnace 5 (named BF5 hereinafter) as well as the complete connected installations, and the Equipment represents the complete or a part of the Installation. The COMPANY, within its project aim to reline its Blast Furnace 5 will modernize the skip winch (with new coupling CD12 and better design for the actual gear box for skip winch). The compliance with this Technical Specification from the part of the CONTRACTOR represents a commitment for results. The CONTRACTOR, within his commitment for results, will ensure that the equipment object of his work, and all the materials to be delivered by him, comply perfectly with enforced laws, decrees and standards, especially regarding security and environment, as well as with internal regulations of the COMPANY. Within the contracted work, the CONTRACTOR will strictly comply with Annex Instruction of Technical Specification as well as with all the objectives of the latter.



1. OBJECT OF CONTRACTED WORK Within the project for Overhaul BF5, this Technical Specification refers to redesign actual gear box maintaining all the existing dimensions and better type of materials of the gear box for the skip winch. All the bull wheels from the actual gear box were changed with the new ones in 2006. After 2,5 years the gear box is damaged, and we need a better design in order to assure a life time of 15 years. The coupling between gear box and drum (coupling CD12) must be improved. The object of contracted work is to redesign a new gear box while maintaining the existing two electric motors, skip cars speed as well as cable length and diameter

The work executed by the CONTRACTOR will include in particular:

The technical description for new materials of new gear box for skip winch. Basic and detail manufacturing drawings of the new gear box for skip winch. The installation and maintenance manual. Spare parts list. All drawings in AutoCAD v.2005 (dwg and tif version) with material lists. All documents in English and Romanian language.

The CONTRACTOR is the sole responsible for the solutions implemented in order to guarantee the proper operation of his installation and to obtain the results and functionalities expected by the COMPANY. The CONTRACTOR will execute in his workshop the maximum of required prefabrications The CONTRACTOR, in the scope of his work will have to strictly comply with the following principles:

Define, conceive, supply and commission the assembly of equipments described in this specification, in order to guarantee a perfect restart of the installation. Obtain the results expected and defined by the COMPANY Improve the reliability, availability, maintainability of equipments which were modified, adapted, replaced and / or related with the execution of contracted workBF5 Relining-Redesign a new gear box with better design-rev.1 Page: 4/11


Integrate the contracted work in the planning of the COMPANY Inform the COMPANY, on regular basis, about achieved results.

2. CHARACTERISTICS OF THE INSTALLATION INTERFACING WITH THE CONTRACTED WORK AND LOCATIONS FOR THE EXECUTION OF CONTRACTED WORK 2.1 SITE CONSTRAINTSThe installation is located on the site of the COMPANY. The CONTRACTOR, while executing the work, will take into account the constraints applying to the site of the COMPANY, defined in the Annex Instruction of Technical Specification.

2.2 CONSTRAINTS SPECIFIC TO THE WORKING ENVIRONMENT OF THE EQUIPMENTThe CONTRACTOR, during the execution of work, will also take into consideration the following specific constraints: Wind * Outdoor temperature * Relative humidity * (*): values to be confirmed by the CONTRACTOR, based on the meteorological station near the Braila / Galati airport, for the execution period of concerned works. Installation located outdoor Heat (conduction, radiation, convection) Dust Noise Presence of gas Explosion risk as per classification procedure ATEX Location and means available for stocking Acid environment Physical aggression (shocks, vibrations) Movement of handling and transport equipment Works performed on the installation during operation or while out of order Equipments in movement (automated control)

2.3 INSTALLATION INTERFACING WITH THE CONTRACTED WORK

AM GALATI is preparing an overhaul of BF 5 during the year 2010. Actually the Blast Furnace is stopped due to economical reasons. Skip winch construction interfacing with: Stockhouse 2 Cranes 8 tones with a height of 14.5 and 16,7 meters Skip bridgewith railsArcelorMittal Galati (Romania) BF5 Relining-Redesign a new gear box with better design-rev.1 Page: 5/11

Ropes and pulleys Bell top charging system

The actual blast furnace and hot blast system have the following constructional features: Original blow-in date: 1978 Blow-in date since last relining: 15.05.2006 Hearth diameter: 11,6 m Number of tuyeres: 32 Number of tapholes: 2 2 BF area: 105,68 m Working volume: 2429,09 m Total volume: 2977 m3 Maximum top pressure: 2.0 bar Utile height 31,2 m Burdening system: skips Coal injection system: yes Slag treatment: no Top gas turbine: no Type of hot stoves: external burner shaft Number of hot stoves: 4 3 Maximum hot blast volume: 300000 Nm /h 0 Maximum hot blast temperature: 1200 C Maximum hot blast pressure: 3.5 bar Maximum gas flow to the dust catcher: 5000003/h Nm Maximum gas temperature inside the dust catcher: 0C 400 Maximum gas pressure inside the dust catcher: 2.0 bar Below, some general information regarding the installation and the history of the last campaign. LAST CAMPAIGN OF BF 5 1994 - 2005 The complete scope is subdivided as follows: Hot blast system with stoves. Blast Furnace proper with taphole and hearth, top gas ignition, square tower. Stockhouse, skip bridge with rails, skip winch, skip cars with ropes and pulleys, movable armour, burden probe, bell top charging system. Cast floor machines and runners. Gas cleaning and bleeder valves. Energy with blowers and Bishoff scrubber. Cooling system (including compensators staves, bottom cooling) Electrics, automation, instrumentation

2.4 TOPOGRAPHY SITUATION OF LOCATIONS VERIFICATION OF GENERAL LAYOUTS OF THE COMPANYThe CONTRACTOR, prior to the execution of contracted work, will conduct one or several visits of concerned locations in order to specifically verify the accuracy of layouts of existing installation. All visits of locations will take place in the presence of a member of the COMPANY.



The Equipment supplied by the CONTRACTOR must be, in any case, compatible with existing structures rather than with the layouts of the COMPANY, if due to any reasons the latter will prove to be inaccurate.

3. DESCRIPTION OF THE INSTALLATION 3.1 EXISTING INSTALATIONThe skip winch is used to transport the raw materials in the skip cars to the furnace mouth, materials which are dosed to the stockhouse bunkers over the skips cellar. The skip winch drives two skip cars simultaneously, one lifting the charge, the other descending after being unloaded. After a complete run, the skip cars switch their position, thus the skip car that was lifted is now in the unloading position, in the tilting curves, and the one descending arrives under the material loading hopper. After this skip is loaded, the (automated) control is activated to restart the cycle, but this time the rotation direction of the skip winch drum is reversed, thus lifting the loaded skip car which previously had descended. The skip winch is made : of Drum for two ropes, mounted on a frame with the help of two bearing assemblies; Gearbox with two coupling heads ; 2 c.c. electrical motors; 2 work brakes with brake blocks ; one safety brake with brake blocks ; 2 safety devices against rope loosening ; 2 control devices ; One rotation speed controller ; 2 limit switches; 2 tachogenerators. This will be changed for the future. The system of limit switches and acceleration/ deceleration will be changed(see description of the erection specification) The main characteristics of the skip winch :are Maximum load on skip car t; : 32 Skip car speed 2,3 m/s; : Maximumlength of travel: 116 m; Rope drum diameter2000 mm; : Rope diameter 52 mm; : Motor powerPm: 2 x 320 Kw, n =500 rot/min, c.c. The winch drum is a welded construction made of steel . The lateral sides of the drum have grooves for ropesone end the drum is smooth . At for the safety brake. The bearing assembly is ball bearing type. The gear unit has 3 pairs of cylindrical steps 2 coupling spindles for higher , with rotation speed and with one coupling spindle for lower rotation speed. The c.c. electrical motors provide variable rotation speeds 500 rot/min. :0 The work brakes are equipped with 2 brake blocks and are driven by an electrohydraulicbrake controller, with limit switch. This will be changed for the future. The safety brakes are equipped with 2 brake blocks , driven by counterweights. The safety devices against rope loosening stop the operation of the winch in case a rope becomes loose. The operation of the winch is achieved by 2 controlling devices mounted on the winch . The traveling speed of the skip cars is variable in order to ensure the stability of skip cars on the straight-lined part of the rolling railway and in the tilting curves .ArcelorMittal Galati (Romania) BF5 Relining-Redesign a new gear box with better design-rev.1 Page: 7/11

3.2 WORKING CONDITIONSThe skip winch is used to haul the skip cars loaded with the materials necessary for the BF in the weighing hoppers cellar and then lifted up to the furnace top and tilted at the bunkers of bell top charging.

3.3 DESCRIPTION OF CONTRACTED WORK AND SUPPLY

COUPLING BETWEEN GEAR BOX AND DRUM :

For 15 years of operation we need a proposal to improve the actual coupling. Technical descriptions and data sheets for a better type of materials for the coupling between gear box and drum. The actual dimensions will be maintained.

GEAR BOX:

The outside dimensions of the gear case with the fixation of the bottom plate to the main support must be kept, as well the diameter and level of the incoming and out coming axles.

The calculations of the gears for pitting resistance and bending strength are to be made according the AGMA standard and MASSCHINEN-ELEMENTE of G. Nieman / H. Winter. The most severe is to accept. o safety factor for pitting resistance: > 1,3 o safety factor bending strength: > 1,8 Gears and bearings are calculated for a lifetime of 30 years. Accuracy of the gears: o First train (motor side): DIN 6 (AGMA 12) o Second train: DIN 7 (AGMA 11) o Third train: DIN 8 (AGMA 10) Engineering lubrication: splash or forced circulation.ArcelorMittal Galati (Romania) BF5 Relining-Redesign a new gear box with better design-rev.1 Page: 8/11

Installation of sufficient air breather surface, foreseen of an inside filter of 10 . Defining type of oil and viscosity to install: o Winter time: - 20C o Summer time: + 30C LOAD

Motor power Pm : two identical DC motors of 320kW speed: 500 rev / min Motor rated output: 320kW Motor rated torque: 6370 Nm Number of motors: 2 Maximal motor torque: 13377 Nm Absorbed power Pa : 279 kW Absorbed torque Ta = 6 370 Nm Running time in h/day: 24 Number of starts/stops per 24 hours = 800. Bidirectional load. Drum speed: 21,407 rev/min RATIO

I = 23.248 SPEED

Variable speed

PRIME MOVER

Motor type : DC motor CONNECTION MOTOR/GEAR UNIT

Flexible coupling CONNECTION TO GEAR UNIT/APPLICATION

Solid shaft with flexible coupling BRAKES.

Operation brakes are used to stop and hold the skip car in its requested (end) positions. Brakes are not designed forArcelorMittal Galati (Romania) BF5 Relining-Redesign a new gear box with better design-rev.1 Page: 9/11

slowing down the skip. Skip speed has to be lowered by electrical drives first! As late as minimal skip speed reached the brakes would be activated to clamp and hold the hoist drum. Technical descriptions and data sheets for a better type of materials for the gear box. The following documents will be delivered by AM GALATI: o Skip hoist technical report D 00021226_rev B. o Drawing IPROMET 64821 255707. Technical assistance during the installation and commissioning of the new coupling and new gear box for skip winch.

4. DELAYS PLANNINGS. The key dates for the development of the business are: Submission of CONTRACTOR Proposal Ordering on: Submission of Project Quality Plan and Security Action Plan on : Submission of main studies on : Launching of main procurement on : Starting the manufacturing in shop on: Delivery DDP on COMPANY site on: Industrial commissioning (depending on operation objectives), on: Reception, on: 15 May 2011 30 April 2011 31 December 2010 11 January 2011

The CONTRACTOR draws up and provides his Planning by specifying the main phases, including the preparation studies and works. The CONTRACTOR also establishes the following different planning and ensures the compliance with:

General Planning of the project, allowing the time positioning of thefollowing: 4 4 4 The dates for the submission of documents The reviews of conception The procurementBF5 Relining-Redesign a new gear box with better design-rev.1 Page: 10/11


4

The tests and the industrial commissioning.



Documents

TECHNICAL Specification - Redesign New Gear Box and New Coupling for Skip Winch-rev.1 (2) (1)