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bearing wear investigation services heavy industry

Why Bearing Wear Investigations are Crucial for Heavy Industry Success

bearing wear investigation services heavy industry

In the world of heavy industry, the smallest component can bring the mightiest machines to a grinding halt. Bearings, though tiny compared to the equipment they support, play a pivotal role in ensuring uninterrupted operations. When these bearings fail, the consequences can be severe, leading to costly downtime and significant repair expenses. This blog post dives into why bearing wear investigations are essential, especially through the lens of a recent RTP project, to exemplify their impact on heavy industry.

Understanding Bearing Wear and Its Impact on Equipment Performance

Bearings are the heart of most machines, facilitating smooth rotations and reducing friction. Equipment that uses bearings, whether rotary or linear, includes anything that turns or slides during operation. Some specific items RTP has recently worked with include sliding doors, trim press roll-over tables, fans, rolling mills, and roll conveyors. However, when bearings wear out, they can cause machinery to stop, often leading to extensive investigations to find the root cause. According to Schaeffler, 85% of bearing failures are preventable, making it crucial for industries to understand and address the underlying issues, such as material fatigue, misalignment, and improper lubrication.

The Basics of Bearing Wear

Bearing wear can manifest in various forms, including small cracks, spalling, and abnormal surfaces. These issues often result from material fatigue, which can occur on the surface or subsurface. Preventable wear is typically caused by abrasive and adhesive wear, while corrosion, identified by red/brown stains or brown/black etching, results from moisture exposure or fretting. Understanding these signs is essential for diagnosing and preventing future failures.

The Dangers of Bearing Failure

Bearing failure is a complex subject involving metallurgy, tribology, operating environment, and applied loads. Sometimes a single event can cause a failure, while other times, multiple factors contribute to the issue. These factors can include poor human decisions, harsh environmental conditions, severe operational settings, and inadequate maintenance practices. All these elements can lead to premature failure.

Ultimately, this results in catastrophic failure of the rotating or reciprocating component and can cause additional damage to associated mechanisms. Given the high cost of lost production and the time constraints on maintenance teams, it is crucial to simplify and expedite the problem-solving process.

Impact on Equipment Performance

When bearings fail, the performance of the entire machine is compromised. Symptoms like overheating, abnormal wear paths, and discoloration indicate deeper issues that need addressing. For instance, an overheating bearing may result from insufficient lubrication, leading to blue discoloration on raceways. Similarly, misalignment can cause an abnormal ball wear path, affecting the machine's overall efficiency.

The Role of Root Cause Failure Analysis

RCFA is a systematic approach to identifying the underlying causes of bearing failures. By examining factors such as cracks, surface fatigue, and lubrication issues, industries can implement corrective measures to prevent recurrence. Let's explore the key aspects of RCFA in bearing wear investigations.

Identifying Cracks and Spalling

Tiny cracks and micro-spalling are often indicators of material fatigue. Subsurface-initiated fatigue and surface-initiated fatigue are common types that need addressing. Detecting these early can prevent more significant damage and extend the lifespan of the bearings.

Recognizing Dull or Shiny Surfaces

Abrasive and adhesive wear can cause surfaces to appear abnormally dull or shiny. Identifying these signs helps in diagnosing the factors contributing to premature wear, such as improper lubrication or contamination.

Corrosion and its Causes

Red/brown stains or brown/black etching in rolling elements signify corrosion, often due to moisture exposure or fretting erosion. Addressing these issues promptly can prevent further degradation of the bearings.

A Look into a Recent RTP Bearing Investigation

A heavy industrial client approached RT Patterson with a recurring problem of premature bearing failures in OEM (Original Equipment Manufacturer) supplied equipment. Despite an initial improvement that extended the Mean Time to Failure (MTTF) to 18 months, the issue persisted. RTP's investigation revealed two primary causes: oscillating motion causing lubricant voids and metal-to-metal contact, and inherent misalignment leading to axial binding.

(Original OEM Bearings)

Equipment History

The client’s equipment comprised a U-shaped rotating table supported by two stub shafts and two bearing housings. Each stub shaft held two bearings enclosed in bearing housings, featuring inboard grease seals on both ends and an outboard seal solely on the idler shaft. The equipment also included a splined shaft gearbox with a hydraulic motor attached to the driven end, which lacked a bearing seal. The rollover table was powered by a hydraulic motor/gearbox setup with valves, enabling it to rotate 180 degrees clockwise and counterclockwise at speeds between 8-12 RPM, cycling every 90 seconds. The interface of the table had five bolted connections between the bearing surfaces on each shaft and three bolted and keyed connections per bearing mounting surface.

(Original OEM Bearing Assembly)

Originally, the equipment utilized deep groove ball bearings provided by the OEM, which had an MTTF (Mean Time to Failure) of typically only three months, attributed to pre-packed lubrication during manufacture. Following failures, the bearings were replaced with those pre-packed with Chevron-Mulifak EP-1 grease and fitted with external shaft seals. This replacement extended the MTTF to 18 months, still short of the customer’s expectations. Upon analysis, RTP identified potential for significantly increased MTTF, surpassing the OEM's best improvement.

R.T. Patterson Study Details

RTP’s comprehensive investigation centered on several critical-to-quality (CTQ) elements:

  • Lubrication Retention: Absence of shaft seals for retaining bearing lubricant.
  • Alignment and Axial Loading: Ensuring alignment of bearing housings and mitigating axial loads caused by thermal expansion.
  • Documentation and Damage: Examination of OEM documentation, bearing race damage from installation, nearby equipment vibrations, and environmental factors.
  • Lubrication Suitability: Evaluating lubrication properties specific to the oscillating motion application.
  • Loading Conditions: Analysis based on loading scenarios derived from operational data, ensuring calculations adhered to safety factors.

Using data on bearing models, specifications, lubricants, reaction forces, and more, RTP performed static stress calculations. They identified critical load conditions under various scenarios, recommending a safety factor of 2 for permissible static load. Calculations demonstrated that the existing MTTF could be exponentially improved, with factors significantly higher than the actual failures experienced.

Study Exploration of Possible Failure Modes

RTP explored multiple potential failure modes, including:

  • Lubrication Failure: Detrimental effects of oscillation on lubricant boundary conditions and metal-to-metal contact due to lack of lubrication.
  • Misalignment and Axial Loads: Severe radial and axial loads stemming from misaligned bearings and additional axial loads.
  • Shock Impacts: Impact damage from process downstrokes and errant scrap pieces during operations.
  • Bearing Installation Damages: Impact forces during installation causing surface dents leading to spalling.
  • Environmental Effects: Potential negative effects of humidity and temperature on lubrication performance.

Study Field Notes and Conclusions

Field observations indicated that bearing failure was likely due to a combination of lubrication failure, bearing misalignment, and added axial loads. Large metal scrap pieces causing operational upsets also contributed to higher dynamic and static loads on the bearings, leading to rapid deterioration.

Study Recommendations and Solutions

Based on these findings, RTP proposed the following measures to rectify the bearing issues:

  1. Bearing Replacement: Utilize self-aligning spherical roller bearings.
  2. Spacer Redesigns: Implement redesigned spacers for both idler and driven ends.
  3. Grease Seals and Housing Modifications: Incorporate grease seals on the motor side and modify housings for external lubrication.
  4. Auto-Lubrication Systems: Install single-point auto-lube units for consistent lubrication.
  5. Optimized Lubricant: Switch to a lubricant formula suitable for oscillating motion.

(Bearing Assembly Showing Revisions)

With the RT Patterson design improvements implemented, significant gains in bearing life were already realized, outperforming any previous MTTF recorded.  The customer has also realized lowered maintenance costs and extended production time without unplanned outages, thus meeting their expectations for RT Patterson’s promise on providing a tangible solution for their equipment issues. 

Benefits of Implementing Bearing Wear Investigations

Implementing bearing wear investigations offers numerous benefits. Firstly, it enhances equipment reliability, ensuring continuous operations and minimizing downtime. Secondly, it reduces maintenance costs by extending the lifespan of machinery components. Lastly, it improves safety by preventing unexpected mechanical failures.

By investing in bearing wear investigations, industries can achieve higher productivity levels and maintain a competitive edge. The RTP project exemplifies how targeted solutions can address specific issues and lead to significant improvements in machinery performance.

Conclusion

Bearing wear investigations are not just a maintenance task but a strategic investment in the long-term success of heavy industries. By understanding the root causes of bearing failures and implementing targeted solutions, industries can achieve higher reliability, reduced costs, and improved safety. Remember, bearings usually don’t fail us. We fail them.

The RTP project serves as a testament to the effectiveness of comprehensive bearing wear investigations. By proactively addressing bearing wear, industries can ensure continuous operations, minimize downtime, and maintain a competitive edge in the market. Investing in bearing wear investigations is an investment in the future of your industry. To learn more about how RTP's solutions can benefit your operations, reach out to our team today.

Uncategorized - 06/24/2024
joseph caudle pe banner image engineering blog post

Bridging Military Service and Engineering Excellence: An Interview with Joseph Caudle, PE

joseph-caudle-engineering-quote

In the world of engineering, the blend of technical expertise and leadership is a coveted combination. We were fortunate enough to have the opportunity to delve into this unique intersection through the experience of our newest Civil/Structural Department Manager, Joseph Caudle, PE. With his impressive achievements in the engineering field and an active role in the Army Reserve, Joseph brings a wealth of knowledge and a distinctive perspective that seamlessly integrates military discipline with engineering innovation.

Get to know Joseph Caudle

Joseph Caudle's journey into the realm of engineering was sparked by two major influences: NASA's space exploration and the engineering marvels of the Roman Empire. "What inspired me to pursue a career in engineering was NASA with space exploration along with the Roman Empire’s feats of engineering," Joseph shares. His initial aspiration was to become an astrophysicist, driven by a desire to explore the unknown reaches of space. However, reduced government spending and job cuts in that field led him to pivot towards structural engineering, where he could channel his fascination with ancient Roman constructions like aqueducts and the Colosseum, into a fulfilling career.

Joseph's career path eventually led him to join RTP, where his dedication and expertise earned him a promotion to Manager of the Civil/Structural Department earlier this year.

The Journey to Becoming a Department Manager

The path to leadership in any field is seldom straightforward. For Joseph, the skills and discipline honed in the military played a crucial role in shaping his professional trajectory. "There are quite a few things I have learned and can apply from serving in the National Guard. Most importantly is being a leader and not just a manager," Joseph explains.

His military service instilled in him the importance of teamwork and the ethos of servant leadership. "There is no ‘I’ in team and an excellent result is due to the team, not just an individual. The team members must be empowered and feel their individual position is just as important as the next because every position supports each other," he notes, as this philosophy has been instrumental in his role as a department manager.

Insights into the Intersection Between Military Service and Professional Career

Joseph's dual careers in the military and engineering are not mutually exclusive but rather symbiotic. The leadership principles and problem-solving skills he developed in the Army Reserve translate seamlessly into his work as an engineer and manager. "While my role is the department manager, I strive to be a leader and not just a manager, mentoring and guiding the team members to their full potential," Joseph emphasizes.

The discipline and strategic thinking required in the military have equipped him with the ability to manage complex engineering projects and lead his team effectively. His approach underscores the value of diverse experiences and how they can be leveraged to drive professional success.

Advice and Perspectives for Aspiring Engineers and Military Community

For aspiring engineers and members of the military community looking to balance dual careers, Joseph offers valuable advice: "Whatever is worth doing at all, is worth doing well. Anything that you do should be done to the best of your ability and if you do not know how, don’t be afraid to ask questions. Everyone only gets to where they are by asking Why or How."

He also highlights the crucial difference between leadership and management. "For those looking to obtain a leadership position, the best advice is the key word 'Leader.' There is a big difference between a leader and a manager, and that difference is the most important to learn. Take care of your people and they will take care of you."

Joseph's insights are not just theoretical but rooted in his lived experiences, making them particularly resonant for those navigating similar paths.

The Value of Diverse Experiences

Joseph Caudle's journey emphasizes the importance of diverse experiences and the unique value individuals bring when they integrate different aspects of their lives into their professional roles. His story is an inspiring reminder that the skills and lessons learned in one sphere can significantly enrich and enhance performance in another.

At RTP, we are proud to have leaders like Joseph who embody the principles of dedication, innovation, and leadership. His contributions continue to drive our commitment to delivering exceptional engineering solutions while fostering a collaborative and empowering work environment for all.

For those looking to embark on a similar journey, remember that every experience, whether in the military, academia, or early career roles, has the potential to shape you into a well-rounded and effective leader. Embrace these opportunities, seek knowledge relentlessly, and always strive to do your best.

Uncategorized - 05/22/2024
pittsburgh engineering internship program

The Essential Role of Internships in Engineering Firms from an Insider's Perspective

pittsburgh engineering internship program

In the fast-paced world of engineering, real-world experience is the catalyst that transforms vast academic domains into practical know-how. For both students and the companies that will one day employ them, an engineering internship bridges the gap between theory and application, playing a pivotal role in career development and industry innovation. In fact, interns have a 70% chance of full-time employment with their host company, emphasizing the significance of successful internships. Our very own intern-turned-engineer, Tyler Clayton is a shining example of this crucial learning experience that resonates beyond merely filling a summer schedule or easing the transition from academia to corporate life. 

A Deep Dive into the RTP Engineering Internship Experience with Tyler Clayton

Engineering internship programs serve as a proving ground for budding engineers, with over 66,249 engineering interns currently employed in the United States. We sat down with Tyler to glean insights from his firsthand experience going from a student intern to a full-time engineer at RTP. We learned that his tenure at RTP not only shaped his future career trajectory but also offered him a holistic view of the engineering industry from the inside out.

Can you describe a typical day at RTP for an intern? I’m interested in hearing about the tasks you handled and how you interacted with the team.

I started my internship with R.T. Patterson on May 16, 2022, in the summer before the last semester of my Mechanical Engineering degree, planning to graduate that December. Before my first day of work, I was unsure what this internship would be like. You always hear of interns not being given any substantial work and mostly acting as an assistant, grabbing coffees, doing homework, studying, taking notes for meetings, etc.

I am very thankful to say that my internship at R.T. Patterson was nothing like that. I was given plenty of real work and responsibility. Starting my very first day in my office, while still getting set up with my computer and email, I was given some information on a project, asked to review it after getting settled, and meet with the manager to discuss my first assignment. This may seem intimidating, but I was happy to hear this. From this moment, I knew this engineering internship would be incredibly beneficial and educational.

Can you tell us a little bit about the projects you were assigned as an intern?

This first assignment was a good example of the tasks I would handle throughout my internship. My first assignment was to design a shock absorber to stop the rotation of the ladle fork arm in a steel mill. To complete this project, I had to perform calculations by hand and in Excel, create 3D models in Inventor and perform Finite Element Analysis on those models, and develop the 2D AutoCAD drawings for construction.

My next project would introduce me to the other daily tasks I would perform as a full-time engineer. My second project would have me assist with coordinating the Piping Department tasks for a project involving a lot of new pipe routing at a plastics plant. For this project, I created drawing transmittals to the client, wrote discipline Scope of Work documents and Specifications, and visited the client site several times to perform field investigations of existing conditions to assist in our design.

For these first two major assignments, I interacted mostly with the Piping/Mechanical Department manager and assistant manager. Over time, when I approached the managers with questions, they would direct me to others in the department who had additional knowledge or experience on the topic. This allowed me to get introduced to the team in a natural way and learn from the best based on the question.

Bridge to the Profession

Comprehensive training and mentorship during internships assist in the transition from student to professional. Placing young engineers in the midst of live projects educates them in the nuances of the industry, from conducting technical investigations to participating in the decision-making process of engineering solutions.

During internships, students have the chance to meet and collaborate with professionals from various backgrounds. These connections often lead to valuable references and future employment through the relationships established during the program. As an intern, Tyler was able to take advantage of events Engineers Society of Western Pennsylvania Banquet which is an annual event that includes most of the engineering firms, engineers from local industry, city of Pittsburgh engineers, Allegheny County engineers, and Penndot engineers.

The experience gleaned from internships brightens students’ resumes and profiles, setting them apart in a competitive job market. Recruiters often seek applicants with relevant work experience, and internships offer exactly that—a window into the working life of an engineer.

What are some of the key skills you developed during your internship at RTP, and how did they set you up to become a full-time engineer at RTP?

I feel like I learned more in my internship about being an engineer than I did in my education. My time pursuing my degree taught me the foundation I would need to perform my job, but my internship taught me to become an engineer. The team at R.T. Patterson understood that I did not have the same knowledge as the tenured full-time engineers, but instead of treating me as a liability, I was encouraged to ask questions and learn in my time while performing meaningful tasks and given real responsibility. I was treated as an entry level engineer from day one, not a student or typical intern.

My internship taught me key skills and lessons that I would not have learned without it. I learned to be confident in my work; just because I didn’t have experience did not mean that I did not know what I was doing. I learned that performing engineering tasks is very different than the lessons learned in your degree. I learned how to communicate professionally with clients.

The list of skills and lessons I learned is probably a mile long. I am very pleased with my internship experience at R.T. Patterson. In my opinion, it was the most valuable part of my engineering education. I was so happy to receive and offer to work as a full-time engineer at the end of my internship and am so proud to work here.

A Two-Way Street: The Company's Perspective

Engineering firms are strategic in their approach to internships, leveraging these opportunities to cultivate talent, innovate, and meet organizational needs. Investing in internship programs is a long-term commitment with tangible benefits for the companies that provide them.

  1. The Power of Perspective: Interns bring a fresh pair of eyes to the table, unencumbered by the "but we've always done it this way" mindset. The out-of-the-box thinking of interns often spawns innovative solutions to lingering problems and offers a new lens through which to view projects.
  2. Cost-Effective Talent Acquisition: Recruiting interns presents a cost-effective channel for firms to evaluate potential employees over an extended period. This 'extended interview' process allows companies to experience the applicants' work ethic and suitability for their organizational culture.
  3. Sourcing Future Leaders: Through competitive internships, firms gain access to the brightest minds in engineering. Investing time and resources into these budding professionals can result in high-quality, loyal future employees who are already familiar with the company's operations.
  4. Fulfilling Corporate Social Responsibility: By offering meaningful internships, engineering firms contribute to the development of their community's skills base and fulfill a sense of corporate responsibility toward nurturing the next generation of engineers.

According to RTP’s General Manager of Engineering, Larry Friedline: “Internships help the intern learn what we do at RTP and helps us learn about the intern and how they may best fit within our team.”

The Proactive Path Forward

As engineering continues to evolve and expand, internships will remain a linchpin of industry progression. Engineering firms and students must be proactive in initiating and participating in internship programs to secure their place at the forefront of the field.

  • For Students: Seek out internships that align with your interests and career goals. Investigate a company's internship program as you would their project opportunities and apply with enthusiasm and purpose.
  • For Engineering Firms: Invest in your future by investing in internships. Develop robust programs that offer genuine learning opportunities and recognize the potential for new ideas and talent that these aspiring engineers bring to the table.

Conclusion

From developing the skills of future engineers to steering the innovation of today's firms, R.T Patterson understands that these programs are the foundation upon which the industry grows. Companies that take an active role in shaping the intern experience are not only fulfilling a responsibility to the next generation but are also ensuring their own vitality and competitive edge in an increasingly dynamic engineering landscape. To learn more about our engineering internship program, contact Larry Friedline.

Engineering Solutions - 04/16/2024
air-insulated-and-gas-insulated-substation-design-blog-post

Empowering Tomorrow: Innovations and Challenges in Substation Design

air insulated and gas insulated substation design blog post

The beating heart of any reliable, robust electrical grid system lies in its substation design. A substation might not be the most visible aspect of a power distribution network, but it's undeniably one of the most critical. Its efficiency, safety features, and resilience determine the overall stability and reliability of the electrical supply to infrastructure, industries, and homes alike. Any failure in this crucial component can lead to widespread power outages, significant economic losses, and potentially hazardous situations. Thus, the importance of investing in high-quality substation design and maintenance cannot be overstated—it's a foundational pillar for a secure, dependable energy future. 

In the United States and around the globe, there is a need for electrical grid upgrades to meet the needs of a growing population and severe weather events. High-voltage substations, which serve as crucial points in the intricate power transmission setup, are vital in meeting increasing demands securely and dependably. There are a variety of types of switchgear designed for high-voltage substations that offer the flexibility to provide customized solutions, including:

  • Air-Insulated Substation (AIS): cost-effective, suitable for outdoor locations, low maintenance 
  • Gas-Insulated Substation (GIS): compact, reliable, safer, minimal environmental impact, suitable for densely populated urban areas
  • Hybrid Substation: flexible, offers a balance between cost effectiveness and space optimization

At the time of this article, the gas-insulated substation market is projected to grow significantly over the next two years, and potentially by more than 10% by 2030. This is due primarily to the growing need for environmentally friendly solutions across a variety of sectors, as well as the smaller footprint. Our team at RTP is currently designing modifications to an EHV GIS substation located in the downtown area of a major city that provides power to a large number of residents, businesses, and institutions. While this 500,000 volt substation is a powerful and critical source of energy, the average passerby will not even realize that they are walking past a substation.

The Rise of Gas Insulated Switchgear Stations 

As our infrastructure ages and our population increases, the need for modernizing our grid could not be greater. Challenges such as increased demand, the need for renewable energy integration, and the incessant pull for efficiency have made Gas Insulated switchgear substations the preferred choice to define the future landscape of electricity distribution. 

The key to GIS lies in its design, representing a quantum leap in substation technology. With the ability to compress massive power distribution infrastructure into a fraction of the space needed by conventional air insulated substations (AIS), GIS is a game-changer in efficiency and environmental impact.

The GIS approach offers safety and environmental advantages that can't be overlooked. Since the GIS system is totally encapsulated and insulated from the external environment, it is impervious to particle or mist pollution, making it a preferred choice for densely populated urban areas and other locations where land is a premium. Its compact design and ability to withstand high voltages make it a preferred choice for urban areas, where space is limited.

The cost of installation might be higher initially, due to the sophisticated design and materials involved, but the long-term economic benefits of GIS, including reduced land usage and operational costs, often outweigh the upfront expense. The reduced environmental footprint is a welcome bonus in today's world, where sustainable practices are increasingly becoming a priority.

Mitigating Arc Flash Hazards in Substations

In today’s rapidly advancing technological landscape, ensuring the safety and efficiency of industrial plants can’t be overstated. One of the critical challenges in substation design is effectively mitigating the dangers posed by arc flashes – a sudden and potent discharge of electrical energy that occurs when a significant fault condition or short circuit flows through the air from one conductor to another, or to ground. These incidents are not only hazardous to the electrical equipment within substations but also pose a deadly risk to personnel working within or near substation environments.

According to the National Fire Protection Association (NFPA), there are over 30,000 arc flash incidents in the United States every year, leading to severe injuries and even fatalities. The intense heat from an arc flash can reach temperatures as high as 35,000 degrees Fahrenheit, over three times the surface temperature of the sun, causing catastrophic burns and igniting flammable clothing instantly. Beyond the immediate physical danger, arc flashes can also result in costly downtime for facilities, loss of equipment, and legal liabilities for companies.

Well-designed substations are crucial in minimizing the risk of arc flashes, along with in depth arc flash studies and strictly adhering to OSHA standards. According to Substation Safety’s 6-point plan for arc flash OSHA compliance, an in-depth safety program must be provided to employees, along with an accurate analysis of the degree of arc flash hazard presented on the substation, and training and equipment suitable for the hazard present.

By incorporating advanced protective technologies, spatial layouts that reduce the likelihood of fault conditions, and isolation features that help contain incidents should they occur, a thoughtfully engineered substation can significantly decrease the chances of such dangerous events. In essence, through meticulous design and adherence to the highest safety standards, substations play an indispensable role in safeguarding lives and maintaining continuous, reliable power distribution in industrial plants.

The Market Matters: Substation Design Across Industries

It is vital to understand that successful substation design is not a one-size-fits-all affair. Industries such as the steel, chemical, oil & gas, and general manufacturing sectors each have their specific needs and regulations. A substation designed for a steel plant might differ vastly from one serving an oil refinery, both in terms of the equipment used and the safety standards imposed.

At RTP, we take a thorough substation design approach to cater to various needs, encompassing GIS, AIS, and hybrid configurations. Our process covers defining equipment specs, crafting clear diagrams, prioritizing safety measures, and optimizing functionality. We ensure power distribution and integrate security features like the Kirk Key System. Our designs prioritize stability and accuracy, providing reliable solutions for our clients’ needs. 

Our vast portfolio of over 50 completed substation projects includes:

  • 69 KV Switchyard Substation for the Bauxite Mine Project in Toll Gate, Jamaica, owned by ALCOA Minerals of Jamaica. The scope involved protective device setting and relay coordination studies for the utility tie-line, as well as a ground grid analysis using ETAP Powerstation software.
  • 100 KV Transformer/Thyristor Rectifier Substation for the Zinc Facility Project in Mooresboro, North Carolina, owned by Horsehead Corporation. RTP conducted ground grid analysis to meet ABB requirements and ensure the design met standards.
  • 100 KV Harmonic Filter Substation for the same Zinc Facility Project, involving protective device setting and relay coordination studies for various equipment, along with ground grid analysis.
  • SVC PLUS Substation for the Steel Melt Shop Project in Calvert, Alabama, owned by Thyssen Krupp Corporation.
  • 161 KV Aluminum Potline Rectifier Substation for the Aluminum Facility Project in New Madrid, Missouri, owned by Noranda Aluminum, Inc. This included installation engineering for various equipment such as thyristor bridges, rectifier transformers, harmonic filters, and transformers.

RTP has also untaken projects for clients, including MEPPI, Dominion Power, Hitachi Energy, ConEd. Caribbean Utility Company, First Energy, Ohio Star Forge, Jamalco, ALCOA, Noranda, and USS, encompassing various voltage levels and configurations across different locations.We pride ourselves on the ability to deliver substation designs that not only meet industry-specific requirements but also surpass client expectations in terms of reliability and long-term performance. Whether it's an industrial facility or a city's backbone power grid, our solutions are tailored to safeguard against downtime and deliver power uninterrupted.

Engineering Solutions - 03/18/2024
EAF blog post

Revitalizing the Steel Industry: The Transformative Role of Electric Arc Furnaces in Sustainable Steelmaking

electric arc furnaces steel industry engineering firm

In the quest for more sustainable practices, the steel industry has found a promising ally in Electric Arc Furnaces (EAFs). Unlike traditional methods, EAFs utilize scrap metal and electric current instead of iron ore and coke. This shift in approach has significant implications for reducing the carbon footprint of steel production, marking a departure from the perceived inflexibility of the industry.

Steel, the backbone of modern construction and manufacturing, has long been an essential component of our everyday lives. However, its production comes at a significant environmental cost, contributing approximately 8% of total global emissions. The conventional method of steel manufacturing involves heating coal to produce coke, which is then burned in massive blast furnaces to melt iron ore. This process releases substantial carbon emissions, making the steel industry a notorious contributor to climate change.

Steel's ubiquity in our daily lives, from cars and airplanes to household appliances, underscores the urgency of finding cleaner and more environmentally friendly manufacturing processes. The steel industry sees its responsibility for a substantial portion of global emissions, and has embraced sustainable alternatives for the well-being of our planet.

The Electric Arc Furnace (EAF): A Sustainable Revolution

Electric Arc Furnaces, which have been around for decades and are heralded as a beacon of change in the steel industry, offer a sustainable alternative to conventional blast furnaces. The most recyclable material globally, steel can now be produced entirely from scrap metal feedstock in EAFs. This process significantly reduces the energy required for steel production compared to traditional methods reliant on primary steelmaking from ores.

The numbers speak volumes – over 70% of U.S. steel comes from scrap steel melted in EAFs, resulting in carbon emissions as low as 14% of those associated with conventional processes. Beyond emission reductions, EAFs present a more flexible production model, allowing for rapid start-ups and shutdowns to align with fluctuating demand. This adaptability provides a critical advantage over the rigid operational nature of traditional blast furnaces.

The Inner Workings of Electric Arc Furnaces

Understanding the inner workings of EAFs unveils the intricacies of their contribution to sustainable steel production. Industrial EAFs come in various sizes, ranging from small one-tonne units used in foundries to large 400-tonne units employed in secondary steelmaking. Operating at temperatures surpassing 1,800 °C (3,300 °F), these furnaces play a pivotal role in transforming scrap metal into molten steel.

The process begins with the meticulous sorting of scrap metal into shred and heavy melt grades. Loaded into baskets, the scrap is carefully layered for optimal furnace operation, with considerations for furnace efficiency and safety. Some operations include pre-heating the scrap to enhance plant efficiency before the actual melting process begins.

The moment of meltdown is initiated with electrodes bore into the scrap, creating arcs that release potential energy and ignite a fiery spectacle. As the scrap melts, a byproduct known as slag forms, capturing impurities and reducing heat loss. This process involves multiple cycles of melting, refining, and superheating until the desired chemistry and temperature are achieved.

Tapping molten steel into ladles follows, marking the culmination of the production cycle. A portion of liquid steel and slag is intentionally left in the furnace to form a "hot heel," which aids in preheating the next charge of scrap and accelerates the melting process. The furnace then undergoes maintenance, including refractory inspections, ensuring a safe and efficient process at the heart of steelmaking.

Flexibility and Adaptability: Key Advantages of EAFs

What sets EAFs apart is their adaptability to varying production needs. Unlike blast furnaces, which operate continuously for extended periods, EAFs can be rapidly started and stopped, enabling steel mills to adjust production based on demand fluctuations. This flexibility aligns with the modern industrial landscape, where responsiveness and efficiency are paramount.

In scenarios where high-quality scrap is scarce, EAFs exhibit further flexibility by allowing the supplementation of lower quality scrap with direct reduced iron (DRI) and alloy additives. This versatility positions EAFs as a superior alternative to traditional blast furnaces and basic oxygen furnaces.

Looking Towards a Greener Future: The Role of Renewable Energy and Green Hydrogen-Produced DRI

As the global steel market is expected to grow by approximately 30% by 2050, the industry faces the challenge of reconciling growth with sustainability. To meet net-zero emissions goals set by major steelmakers, significant changes are required. The integration of EAFs powered by renewable energy, especially those utilizing green hydrogen-produced DRI, presents a transformative opportunity.

Renewable energy sources offer a cleaner and more sustainable power supply for EAFs, reducing the carbon output per ton of steel produced. Green hydrogen-produced DRI, when incorporated into the steelmaking process, brings the industry significantly closer to achieving carbon neutrality. This represents a crucial step forward in aligning steel production with broader environmental objectives and addressing the urgent need for more sustainable energy infrastructure.

A Local Perspective: R.T. Patterson's Commitment to Sustainable Steel Production

In Pittsburgh, a city synonymous with steel production, R.T. Patterson stands at the forefront of the industry's modernization. With a legacy of completing 13 melt shop engineering projects and winning ESWP's Industrial Project of the Year two decades ago for a Melt Shop at Wheeling Pittsburgh's Steel plant, our firm has a deep understanding of the importance of sustainable steel production.

The awarded project included a powerful 250-ton AC electric arc furnace and a state-of-the-art ladle furnace, representing a significant leap forward in sustainable steel production two decades ago. The advancements made in that project, coupled with our ongoing commitment to innovation, underscore our dedication to pushing the boundaries of what's possible in the pursuit of sustainable steelmaking.

Considerations for EAF Installation: A Holistic Approach

While the benefits of EAFs are evident, the installation process requires a thoughtful and holistic approach. Factors such as shop configuration, furnace capacity, existing infrastructure, and the age of the facility (brownfield vs. greenfield) must be considered to ensure a seamless integration and maximize the environmental and operational advantages offered by EAF technology.

As we navigate the path toward a greener future, RTP remains committed to providing cutting-edge solutions that balance the operational needs of the steel industry with the imperative of environmental responsibility.

Forging a Sustainable Path Forward

The global EAF market was valued at 730 million in 2023, and is expected to reach 1,473 million by 2023. The rise of Electric Arc Furnaces marks a significant shift in the steel industry's trajectory towards sustainability. By embracing these innovative technologies, the industry has the potential to not only reduce its environmental impact but also thrive in a rapidly changing global landscape.

In the coming years, the continued evolution of steel production processes, guided by principles of environmental stewardship and technological innovation, will play a pivotal role in shaping a world where progress and sustainability coexist harmoniously. The journey towards a carbon-neutral steel industry is underway, and Electric Arc Furnaces are lighting the way.

Uncategorized - 02/15/2024
Wayne interview blog post

Driving Excellence in Engineering Leadership: Interviewing the President at RTP, Your Trusted Industrial Engineering Firm

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With a wealth of engineering and leadership experience spanning 40 years within R.T. Patterson, Wayne Johnson, PE embodies the very essence of our industrial engineering firm. His journey mirrors the evolution of RTP, from its founding to becoming a leading force in the engineering landscape. Wayne’s visionary leadership has not only steered us through industry shifts but has also fostered an environment where innovation and collaboration thrive. In this blog post, we dive into Wayne's unparalleled contributions as our President, exploring how his expertise continues to drive RTP's commitment to excellence and lays the groundwork for future successes.

As someone who has dedicated over 40 years to R.T. Patterson, what's motivated you to stay with the company for such a significant period?

During college I, I worked at RTP for a summer job as a draftsman. After graduating college, I went to work for one of the largest engineering companies in the country, but I realized the work was very limiting, you were pigeonholed into only one bit of a project and that's all you did every day. So after about six months of doing that, I thought I'd like to come back to Pittsburgh, and RTP immediately came to mind. At RTP, the projects you were a part of weren’t huge projects, but you did every aspect of it, you weren't doing just in charge of one little piece. I started advancing in my career, from Project Manager to General Manager of the Pittsburgh operations, to Vice President of Engineering, and then to President of RTP when Roy Patterson stepped down. As I was doing these interesting projects and advancing my career, I felt no need to go look elsewhere. I truly enjoy working here!

What do you believe sets your team apart from your competitors?

We were and continue to be a family organization. RTP really looks out for their employee’s well-being and happiness in the workplace, and what’s happened over the years is when people come here, they come to stay. We actually have several people that have put in around 25 years, and a few that are approaching 40 years! We even had one employee who was with us for 50 years before retiring. And I think that kind of sets us apart quite a bit. It’s the people, and the environment created by our people.

What is RTP looking forward to as a new member of the ARG family?

I am genuinely excited about moving the company into new markets, with a special emphasis on mentoring the new generation of engineers. Most of our people are very experienced, being in the later stages of their career with many years under their belts. I'm really looking forward to creating a synergy that blends the fresh perspectives of our new engineers with the seasoned expertise of our veterans to see how we can continue to expand RTP for the next 60 years as a top industrial engineering firm serving clients across the United States.

Uncategorized - 11/16/2023
Steel industry growth article

Powering Pittsburgh's Steel Engineering Industry: RTP's 50-Year Legacy

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With a steadfast commitment to excellence, RT Patterson (RTP) has been a pillar of strength for Pittsburgh's steel industry for over five decades, solidifying our place as the leading engineering firm in Pittsburgh. Recently, the global steel sector experienced a notable upswing, with world crude steel production seeing a 6.6 percent surge compared to the same period last year. As we move forward, this promising momentum in steel production showcases a robust industry ready for further expansion. 

In July alone, 63 countries reported a collective production of 158.5 million tons, marking a significant boost in steel output according to an enlightening article from Metal Center News. In the U.S., July saw the production of 6.9 million tons, indicating a 0.5 percent increase from the previous year. Although the year-to-date figures remained relatively flat globally, RTP has been at the forefront of supporting US steel production, contributing to the sector's resilience and growth.

RTP's extensive experience in the steel industry spans various projects, reinforcing our position as the go-to engineering firm for steel clients. From revitalizing production lines to designing cutting-edge steel facilities, our expertise has been pivotal in propelling the steel industry forward. At RT Patterson, we stand as dedicated supporters of U.S. steel production and are eager to witness the trajectory of this industry's growth throughout the remainder of 2023. RTP is poised to continue its legacy of excellence, driving innovation and progress in Pittsburgh's vibrant industrial engineering and steel sector. 

Uncategorized - 09/19/2023

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