Fatigue cracks: Renewal of walking beam furnace for hot strip mill

About the Project

A steel manufacturer discovered fatigue cracks in the walking beam furnace of their hot strip mill. Corrosion was evident on the frame, columns, and piping, resulting in increased leaks and emergency repairs that compromised the furnace’s reliability. Consequently, the walking mechanism required replacement. The furnace, measuring 40 metres in length, operates by placing steel slabs alternately on moving and stationary rails. The moving rails lift and advance the slabs step by step through the furnace. For optimal operation, the rails and supporting columns are cooled using water.

Vicoma’s Role

Vicoma began by designing the cooling water piping system. Using a 3D scan, we accurately visualised the existing setup. We conducted a Computational Fluid Dynamics (CFD) analysis of the original column design and performed pipe stress calculations to ensure the integrity of the DN300 pipes and prevent failures.

The CFD study enabled us to improve upon the original working as part of a multidisciplinary team, Vicoma’s specialists focused on piping design within the constraints of limited space, weight considerations, and large pipe diameter. Our electrical engineers took responsibility for the control system and instrumentation. Additionally, we upgraded the machine safety by implementing “machine guarding” compliant with the latest safety standards.

Result

The steel manufacturer successfully commissioned a state-of-the-art walking beam furnace. Collaboration between Vicoma, the client, and other stakeholders was seamless, demonstrating true partnership and mutual trust. Regular clash control, weekly coordination meetings, and quick decision-making contributed greatly to the project’s success. The client’s invitation to a tour and a small celebration marked the achievement of this milestone.