glueckauf-en-1-2016

glück auf · 1/2016 · Extracts in English .......................................... 1

main focus: GoaLsglück auf1/2016

Extracts in English

The newspaper for employees, customers and friends of the GMH Group

Steel globally. European steelmakers are going through difficult times. Even the most innovative methods aimed at cost-efficient production are unable to offset the compe-titive advantages enjoyed by Chinese steel mills, including much lower levels of pay and far fewer environmental regulations.

R see pages 6 and 7

Industrial safety. Steel maker GMHütte was able to boast an excellent occupatio-nal safety record in 2015. Throughout the whole year its rolling mill did not report one single accident involving days lost.

R see page 8

Special gauge-adjustable wheelsets. The BTK route is a new rail link extend-ing from Azerbaijan's capital, Baku, via the Georgian cities of Tbilisi and Achalkalaki, to the Turkish town of Kars. Wheelsets from BVV's works in Ilsenburg will ensure a smooth changeover from broad to standard gauge at the Turkish border.

R see page 4

Gargantuan dimensions: the heavy crankshaft is heated and forged, section by section. Large photo: jb

Experts in heavy shaft forgingSchmiedewerke Gröditz · Company has meanwhile mastered the TR forging of heavy crankshafts to perfection.Customers are, primarily, marine engine manufacturers.

The trial phase was lengthy and thorough – not least because there were many

technical, organisational and operational-logistic problems to be sorted out. The manufacture of heavy TR-forged crank-shafts is now a firm part of the range of-fered by Schmiedewerke Gröditz (SWG).

Particularly the dimensions and weights of the work pieces are impressive. During the trial phase, for example, nine-throw crankshafts with a gross weight of 35 tonnes each and six-throw crankshafts with a gross weight of 24 tonnes were produced in several campaigns (and subsequently processed downstream, ready-to-install, by Gröditzer Kurbelwelle Wildau).

The long road to mastering the TR pro-duction of heavy crankshafts was however paved with many a difficulty, mental chal-lenge and obstacle for the Gröditz-based company – and called for an abundance of patience. As early as 2009, SWG’s forging experts produced the first prototypes after adapting TR tooling to their 60 MN press. In 2013 there were then trials involving the first larger work pieces – spindles up to 18 m in length with a maximum envelop-ing circle of 1,100 mm (for explanation of “enveloping circle“, see page 8).

Continued on the next page q


Unique as a supplier Mannstaedt · Supplier Award 2015 from the Unicarriers Group

The Unicarriers Group, founded in 2013, was formed from former forklift truck manufacturers Nissan,

TCM (Toyo Carrier Manufacturing Co., Ltd.) and Atlet. Its manufacturing locations lie in Japan, China, the USA, Spain and Sweden.

Mannstaedt is the only supplier to deliver to each of the Unicarriers Group’s locations worldwide. The Troisdorf-based company is even the sole supplier of forklift mast rails for the locations in the USA, Spain and Sweden. Complete, ready-to-install rails, for example, are produced for the location in Sweden, i.e. are sawn to fixed dimensions, milled, drilled, made up into sets and delivered on a just-in-time basis.

Selected suppliers, among them Mannstaedt, were invited to the last Supplier Conference of Unicarriers in Pamplona (Spain). At that conference the company was named Supplier of the Year 2015.

The Supplier Award was presented by the Japanese CEO of the Unicarriers Group, Akira Shiki, who made the journey specially from the corporate headquarters in Kawasaki, Japan, to be at the event.

Guido Glees

Unicarriers CEO Akira Shiki (right) – there specially from Japan – congratulates Head of Sales Guido Glees on the Supplier Award.

Photo courtesy of the company

In that phase, the following problem in particular proved to be a headache for the Gröditz-based company: complete heating of such large spindles was impossible, for which reason, in cooperation with a furnace build-er, three transportable, collapsible furnaces were designed, constructed and put into op-eration in late 2013.

These furnaces enable the forging compa-ny to heat certain selected parts of the crank-shafts during forging, while the rest of the shaft remains cold and thus stable. The mobility of the furnaces ensures that they do not get in the way or hinder “normal forging operation”.

The SWG forging team was extremely active during the development phase, some-thing which is also demonstrated by the many improvement suggestions so far received on the topic of TR forging. And although the

colleagues have meanwhile acquainted them-selves very well with the process, they are still working intensely hard to optimise it.

There will be ample opportunity to do so. A new shaft type is currently scheduled for production, for instance – an order that brings new challenges of its own, because the blank’s new design also involves re-designing and manufacturing the accompanying tooling.

Ralf Schreiber

q Continued from last page


Safe and healthy working practicesGood for the employees, and good for the company.

We aim to be an accident-free company and the health of our employees is

also paramount. In keeping with the “Health & Safety Day” of the World Steel Association, we will, as a group, make a clear commitment to making safe and healthy working practices part of our com-pany culture.

To underline this, on 28 April a health and safety at work day is to be held across all locations, and all employees are encour-aged to actively participate. High standards of occupational safety as well as the health of our employees are top themes within the scope of sustainable management of the company.

Safety has priority over “high volume production”

“Nothing is more important than the health and safety of our employees” – this is the uppermost principle of the World Steel Association. We are also committed to upholding this guiding value, and not only in the good times. What’s more, occupa-tional safety most definitely has priority over “high volume production”, there’s no doubt about that. In other words, fewer sickness and accident-related absences from work contribute to more safety in the work-place due to greater economic success. This is good for the employees as well as the company.

More safety at work and higher produc-tivity are not contradictions in terms but instead go hand in hand. Prevention of in-juries and illness provides us with a com-petitive advantage. It concerns our funda-mental understanding of how we want to earn money. Obviously, we want to be as profitable as possible because this directly influences our ability to invest, but not at the expense of our employees.

We want to be recognised as a group which has pledged to maintain and pro-mote the health as well as the performance capacity of its employees.

Approximately 560 million working days are lost in Germany every year. According to calculations of the Federal Institute for Occupational Safety and Health (BAuA), this leads to production stoppages valued

at a total of 59 billion euros.This is reason enough to undertake the tough economic task of addressing illness and accidents in preventative terms.

Healthy and productive working conditions

It is true to say that our plants are not oases of wellness. This is where the heart of Ger-man industry really pounds. And, in times of globalisation, we can indeed be proud of the efforts we are making – involving passion, brain power and manual grind – to secure competitive jobs in Germany.

Heat, dust and noise can be minimised but we cannot eliminate them completely. Nor is it possible to do away with shift work. It is therefore even more important to create working conditions where our employees can work as healthy and pro-ductive individuals until statutory retire-ment age.

Last year more than 300 accidents sub-ject to reporting requirements occurred within our group, not to mention other accidents and near-misses.

This is at least 300 accidents too many. “No accidents at work!” – this needs to be-come the rule rather than the exception. The philosophy behind this is that “every accident can be avoided”. This is our guid-ing principle.

The highest number of accidents is re-corded in the foundries – a sector which is characterised by heavy, labour-intensive and manual work. In steel production we find companies in which safety in the work-place has already become part of the DNA. In others there is still considerable room for improvement. The good and successful examples in the Group provide impetus for us to narrow the gap.

Implementation of zero-accident strategies

The number of accidents at work is also an indicator of the quality of work processes. The number and type of accidents at work are directly connected to the organisation of production and work behaviour. Acci-dents at work are a symptom of problems relating to production. A zero-accident

Harald Schartau Photo courtesy of the company

EDITORIAL

3rd Health & Safety DayOn Thursday 28 April 2016 the "World Day for Safety and Health at Work" is to take place across the globe. This event was first launched in 2014 by the World Steel Association with the intention of highlighting the five most common causes of accidents worldwide so that companies can adopt relevant counter-measures. The five most common causes are: accidents caused by moving machinery, falling from height, falling objects, gas and asphyxi-ation, and overhead cranes. Companies also use the Health & Safety Day as an opportunity to raise awareness of other causes of accidents as well as the implementation of a variety of health and safety measures.



strategy, logically, can supplement continu-al improvement processes.

Last year the Holding began to place in-creasing emphasis on developments in oc-cupational safety. The responsibilities and competences have been clarified. It is our intention to implement a zero-accident strategy at all locations, permanently.

Harz Guss Zorge has been on the ball in this regard for a long time. In Gröditz a pro-ject has been launched which is to provide new impulses for reducing the incidence of accidents. The “health management” con-trol group has been expanded to include responsibility for “occupational safety”. Independently of this group, the estab-lished “occupational safety” work group continues to meet twice a year.

We want to identify best practice in the Group and open up possibilities to ex-change information more closely on the causes of specific developments and solu-tions to problems. This allows us to pool our expertise and promote projects which improve our competitiveness.

Imitation is highly recommended

Also on the topic of health management,the sharing of good examples has mean-while taken off, with imitation being rec-ommended. Seasonal quarterly campaigns support the process. We are still in the phase of putting “good intentions” into action.

The Heath Awards of the GMH Group are presented on an annual basis: the “Red Ap-ple” for activities effective over the long term, and the “Green Pear” for particularly imaginative measures. The Apple and Pear trophies for both prizes, by the way, are cast at our very own Friedrich Wilhelms-Hütte foundry.

Seminars on the topic of health are integral parts of the further education programme at BGG. Examples include “Healthy with shift work”, “A healthy back” and also “Positive approaches to dealing with stress”.

Stress is a key word which we need to deal with more intensively within the scope of risk assessments. In the Raw Materials Re-cycling business unit, psychological strains and methods for avoiding them were picked up at an early stage. Studies show that 50-60 percent of all work days lost are due to work-related stress and psycho-social risks.

Psychological disorders are meanwhile the lead item in statistics on disability bene-fits. According to pension insurance data in Germany, they account for more than 40 percent. They also continue to increase at a faster rate than physical health problems, so the gap is widening. What in the past was concealed among unspecified com-plaints is now openly declared. Aside from taking the psychological strain of those af-fected into account, we also need to pay more attention to the effects on productivi-ty and the ability to innovate.

(Self-)responsibility from the outset

Ideally, being alert to questions relatingto occupational safety and healthy lifestylesbegins during training. Schmiedewerke Gröditz has recognised how important this is and from the outset their young workers are encouraged to take on responsibility. They were awarded the Red Apple for this in 2015.

At GMHütte a first aid course is compul-sory in the first year of training, while a sec-ond module incorporates the topics of nu-trition, exercise and health checks, and a third module includes the impacts of shift work,ergonomics, relaxation and an activity programme. So it‘s no wonder that the com-pany is in the Champions League category.

How “Health & Safety Day“ is organised is not subject to any rules or stipulations and is orientated towards plant-specific in-sights on the most important accident and illness issues. We work in partnership with employers‘ liability insurance associations, health insurances and integration offices in preparation for this particular event as well as in our daily working practices. The spec-trum of health activities ranges from eye tests and back training sessions to measur-ing venous pressure. The day should also be an opportunity for us to identify our priori-ties for the future.

There are to be a variety of hands-on activities and practical exercises on the day: fire protection exercises, driving behaviour training, crash simulations, and plenty more. Emphasis is to be placed on demon-strative and interactive measures which also foster team spirit.

We can only convert our good intentions into actual abilities in terms of work safety and health protection if there are clearly as-signed responsibilities, assessments of risks, aims, planning, regularity and processes, and commitment.

Perseverance and persistence are required

The integration of health aspects, safetyand ergonomics starts as soon as a newjob position is created. It continues with regular plant inspections by company man-agement, zero tolerance of rule violation, adequate safety equipment, and implemen-tation of consequences drawn from accident analyses.

In creating safe jobs, achieving longterm behavioural changes, and preventing the development of any dangerous routines, we need to pursue our aims persistently. Although the commitment of our safety ex-perts is commendable, direct responsibility on site is in the hands of the company man-agement, and they are the motivating forces behind what goes on. Commitment to workplace safety has to be a matter of course for every manager and every employ-ee. Works councils also have a part to play in all projects. They represent the interests of the employees and are important multi-pliers.

Get involved!

And, of course, the participation of our owner-family will give the day even more importance and momentum, and the man-agement board of the Holding will also get an idea of the activities taking place at se-lected locations. This day is not only in-tended to bring about new ways of thinking in our minds. We are indeed all fully aware of the fact that our heads are round so our thoughts can change direction. Safe and healthy working practices serve as a corner-stone in our understanding of values – that is the message.

Dear employees, it is never too late to start paying more attention to your health, to sharpen your awareness of risks, to eat more healthily, to do more exercise and to banish bad habits.

Take inspiration from our “Health & Safety Day”! Get involved! Stay healthy!

Yours,



Express change of gauge BVV Ilsenburg Works · Faster cross-border traffic between Georgia and Turkey: gauge-adjustable wheelset from BVV’s works in Ilsenburg permits smooth changeover from broad to standard gauge – and vice versa.

The railway administrations of Georgia and Azerbaijan are looking to write a new

chapter in railway history for the rail link between Achalkalaki (Georgia) and Kars (Tur-key): in future, passenger trains will be able to avoid time-consuming wheelset changes when crossing the Turkish border to travel onward in the direction of Istanbul, Ankara or other towns and cities in Turkey.

The background to this is that the norm in Georgia and Azerbaijan is so-called broad gauge (1,520 mm) while in Turkey this is so-called standard gauge (1,435 mm). This has previously meant changing the bogies along with the wheelsets at Achalkalaki every time when crossing the border – which is a time-consuming, technically laborious and cost-intensive procedure. It has necessitated large capacities for the storage of bogies and wheelsets and also tied up capital of the rail-way operators.

Since the three countries signed agree-ments in 2007 to construct new rail links, an automatic break-of-gauge has also been con-sidered. As a consequence, an agreement has now been concluded with Swiss enterprise Stadler Busnang AG to retrofit the fleet of passenger and sleeper coaches that are to run on the planned or already expanded long-haul routes. The new coaches will not only replace the ageing models dating back to the

times of the Soviet Union. They will also offer modern comfort and markedly reduce travelling times.

The State Railway Company of Azerbaijan has placed an order valued at 120 million Swiss Francs for the first three trains, each comprising ten coaches. They are expected to go into service by 2018 at the latest. They will be fitted with the DBAG/RAFIL Type V from Ilsenburg, a patent-protected gauge-adjustable wheelset designed for freight wagons. BVV has adapted the wheelset for use on coaches, providing it with quiet axle-mounted brake discs in place of loud shoe brakes.

To show off the new technology, all of the partners associated with the train manu-facturer and the railway administrations from Georgia and Azerbaijan met in early 2016 at BVV’s works in Ilsenburg where the mode of operation of the wheelset in the bogie was impressively demonstrated in a gauge-changing device.

Even though the weather failed to show itself from its sunniest side, the technology delivered what it promised. In the mean-time, 44 of these wheelsets have already been delivered for the first train.

em

The rail network at a glance

Present route

Planned additional route

From 1,520 to1,435 mm In a gauge-changing system an automatic change of gauge from broad to standard functions thus: the coaches or wagons pass over a guide element (to switch from broad to standard gauge) and, by doing so, the wheels' axial locking mechanisms, which are mounted on the axles, are released and the wheels shifted to the new gauge setting. An integrated compression spring ensures that the wheels are then locked in place in the new position.

Georgia

Azerbaijan

Turkey

Kars

Achalkalaki Tbilisi

Agstafa

Genze

Rustawi

Iran

Armenia

Partners of the train manufacturer and of the railway administrations from Georgia and Azerbaijan observe the mode of operation of the wheelset in the bogie in a gauge-changing device in Ilsenburg.

Photo: Hagen Döbelt


“Buckle up!”Energietechnik Essen · Retaining rings keep 3,600 revolutions per minute under control.

Buckle up! That is precisely the function of retaining rings – making them the most

highly stressed component of a turbogenera-tor.

Electric power nowadays is produced al-most exclusively by means of so-called rotat-ing generators. Turbogenerators, which gen-erally operate at 3,000/3,600 revolutions per minute (corresponding to 50/60 revolutions per second), account for by far the largest share of electricity produced in generators.

The rotating magnetic field is generated by windings of alternating polarity that are excited by direct current. The windings pro-trude from longitudinal rotor grooves at the body ends to form the end winding, which

has to be secured against the centrifugal force.

In most cases the retaining rings are shrunk onto the ends of the rotor bodies in overhung position and secured against rotary and axial movements with a type of bayonet catch. Shrunk into the retaining ring on the side facing away from the body is, in many cases, a support ring that absorbs the end-winding forces acting in longitudinal direc-tion.

The trend towards ever larger power units is placing growing demands on the retaining rings, meaning that these rings and also the technology used to manufacture them have to meet the highest standards. The material

from which retaining rings are made there-fore has to satisfy a number of requirements and offer certain properties:• High yield strength• Adequate cold- and hot-workability• Suitable thermal expansion

characteristics• Non-magnetic properties• Corrosion resistance. Energietechnik Essen has developed such a material, the P900 nitrogen-alloyed steel grade (material number/DIN Code: 1.3816, ASTM A 289, Class C). It is regarded as the current material standard for this application.

Jörg Schulze

SHoWcASE

Material• High nitrogen alloyed

steel P900• “State of the Art“• Developed by Energie-

technik Essen GmbH

UseTurbogenerators (from 10 t to over 200 t in weight)

Manufacturing process

• Up to 6,000 t pressing force on an "expanding press“ unit

• Over 200 individual expand-ing steps from forging blank to finished retaining ring

• Cold expansion at room temperature

Sizes & weights• Diameters up

to 2,200 mm• Weights up to

around 4.3 t

Safety guarantee• Absolutely crack-free• No inclusions• Certified strength as well

as elasticity


No fair competition without a single set of rulesChinese steel flooding Europe at dumping prices: how is Germany‘s steel industry to remain competitive and “green“ in the face of global competition? Development on the global steel market raises fundamental issues.

German and other Euro-pean steel producers are

currently under tremen-dous pressure. Even the most innovative solutions aimed at cost-efficient production are unable to offset the competitive advantages enjoyed by China‘s steel makers. That is because, in the Middle Kingdom, environmental standards are – at least in part – considerably lower than in Germany, enabling correspondingly cheaper production there.

There is, however, no escaping Germany‘s environmental stand-ards. The questions thus arise how it is possible to remain com-

petitive and "green“ without get-ting into economic difficulties, and how the global inequalities might be ironed out. The "green component“ is, in effect, playing a key role more than ever in Ger-many‘s steel industry. That may be surprising at first glance. After all, steel production has a poor image where energy consump-tion and climate impacts are

concerned. The primary stage of making steel from iron ore is, indisputably, re-source-intensive and harmful to the climate and leaves behind a substantial eco-logical footprint.

At second glance, though,

such an assessment is untenable. It is true that using iron ore as the primary material to make crude steel (primary route) gen-erates four times more in CO2 emissions (Fig. 1) than producing steel from recycled scrap. But it is also true that steel is recycled and processed into new products without any loss of quality. And that steel / ferrous scrap is the most recycled material. And due to that fact alone steel products, at the end of their useful life, are returned to the recycling process time and again, thereby saving more than a billion tonnes of primary raw materials annually.

Producing steel from scrap as it is practiced in the melt shops of the GMH Group is one such example of effective raw materi-als recycling. Steel circulates in one continuous cycle of produc-tion, use, preparation and re-cy-cling (Fig. 2). Ecologically speak-ing, therefore, steel will always be able to score highly. Expressed in plain language:• With every new life cycle, emis-sons and energy consumption decrease, thereby reducing the ecological footprint step by step (Fig. 3). Over its entire life cycle, steel scores considerably better than other materials. As a result of such multi-recycling it is pos-sible to make more than four tonnes of steel products from one tonne of steel in as few as six recycling cycles.

• Recycling consumes only onethird of the energy that has tobe expended to produce steelfrom ore and coal. A study un-dertaken by the Boston Con-sulting Group and the German Iron and Steel Institute (VDEh) calculates that, through the use of steel in highly innovative processes, CO2 emissions are ul-timately six times lower than the levels released during its produc-tion (Fig. 4).• Since 1990 alone the German steel industry has reduced its CO2 emissions by almost one fifth. That is remarkable. It places Eu-ropean steel makers at the fore-front globally. They implement the world‘s most stringent envi-ronmental standards (Fig. 5).

There remains a broad dispar-ity between the climate pioneers and climate stragglers, that is to say between European steel producers and the competition from China or also the USA. That disparity is counterproductive environmentally as well as harm-ful economically – a fact that is quite easy to comprehend.

The steel industry is interna-tional, its members competing with one another at the global level. A disparate approach to environmental standards leads to disparate production conditions,

to disparate cost burdens – and, as a result, to a distortion of competition. The consequences for Germany‘s and Europe‘s steel industry:

Firstly, the high German standards are counteracted by industrial production moving to countries where environmental requirements are lower.

Secondly, the Chinese produc-ers flood the German and Euro-pean market with steel at dump-ing prices since, being predomi-nantly state-owned enterprises, they do not have to sell at prices

“ Steel is not consumed – steel is put to use.“

“ The EU has to fully utilise the scope that is available.“

In Focus: Global Steel Market

2

Que

lle: W

V S

tahl

Kurze Lebensdauer

Mittlere Lebensdauer

Lange Lebensdauer

WertstoffkreislaufFig. 2

2

Que

lle: W

V S

tahl

long life expectancy

Moderate life expectancy

Short life expectancy

Coke

Blast furnace

Converter

Share: 14.6 m. t

1800 kg/t crude

360 kg/t crude steel

Scrap 15.1

DRI 0.5 m. t

Hot blast 02

02

Hot metal (28.2 m. t)Scrap (5.6 m. t)

Oil, gas or coal

Pellets

Electric-arc furnace

Sinter

Lump ore Fine ore

Iron ore

Specific co2 emission:

crude steel

Fig. 1

Sour

ce: S

teel

Cen

tre,

Düs

seld

orf,

2009

68 % 31.2 m. t

32 % 14.6 m. t



that cover production costs. They dump their overcapacities onto the EU market (Fig. 6).

And thirdly, 4.2 million more tonnes of CO2 find their way to Europe as an ecological rucksack, as if the same quantity had been produced there.

We have only this one world, however. China is not yet a mar-ket economy. Only by competing on a level playing field can there be any meeting on equal terms in future. Only under equal con-ditions of competition can the bar be raised higher and higher technically. In short: without a single set of rules there will be no fair competition.

A look at the dramatic devel-opments on the steel markets shows just how urgently such a correction is needed. The inter-national competitive environ-ment is distorted to a degree never before experienced in the steel industry. Even Germany‘s steel industry, which is so com-petitive, is reaching its limits.

There is also clear statistical evidence of this. According to Hans Jürgen Kerkhoff (President of the German Steel Federation), global steel exports rose last year to a record level of 355 million tonnes, with nearly every third tonne originating from China. While China has doubled its steel exports to 111 million tonnes in the past three years, the rest of the steel world has seen its exports reduced by 20 million tonnes. What is more, the Chi-nese are offering their material largely at dumping prices.

The European steel market is an open steel market – and par-ticularly at risk because of it. This

is evidenced by the increased imports in 2015. Exports, on the other hand, have declined significantly as a consequence of crowding-out effects on the international markets. Both together yield an alarming find-ing: the EU has suffered a drastic deterioration in its external steel trade balance like no other coun-try – minus 9 million tonnes. In the same period China recorded a plus of 20 million tonnes.

But what makes the EU so vulnerable? The cause, according to Kerkhoff, is the “lesser duty rule“, among other things. It of-ten leads to the situation where the protective duties in the EU are lower than in other countries – and are unable to offset the dumping margin.

Who, though, prescribes such a disadvantageous rule for the Europeans? Neither the World Trade Organisation nor other institutions. Nor is it practised by other industrial nations. The EU should abandon it as quickly as possible and fully exploit the scope available to it. This also applies to the time periods taken for proceedings, which need to be shortened to similar periods as in the United States.

The dumping margin, by the way, is also ecologically defin-able: in China, on average, one tonne of steel is produced with roughly 40 per cent more CO

2

emissions than in Europe.

ikw

Multi Recycling Approach (MRA)

Fig. 3

China

USA

EU

India

Russia

Japan

co2 emissions of the six largest emitters (1990 to 2014, in m t)

Fig. 5

7 m t oF STEEl

EXPEcTED To BE IMPoRTED FRoM cHINA To THE EU IN 2015

THIS MEANS THAT

4.2 m t MoRE co2ARRIVE AS AN EcoloGIcAl RUcKSAcK IN THE EU THAN IF THE SAME AMoUNT HAD BEEN PRoDUcED THERE

co2 EMISSIoNSFoR PRoDUcT IN THIS QUANTITY

in the EU (28 members)

9.7 m tin china

13.9 m t

2.1 mTHAT IS EQUIVAlENT To THE co2 EMISSIoNS oF ARoUND

MID-SIzE cARS ANNUAllY

Fig. 6

“ Nothing will happen to me, with all my experience I’ll be ok’ – we have to stop thinking in these terms.“

Innovative steels save six times as much co2 as their production generates

Emissions12 m t

Savings potential~74 m t

Efficiency of fossil fuel-fired power plants

Wind power plants

Weight reduction in passenger cars

Combined heat and power generation

Further regen. energy forms

More efficient transformers

Efficient electric motors

Weight reduction in heavy goods vehicles

29.5 %

14.2 %

11.2 %

9.2 %

5.0 %

2.1 %

1.9 %

1.0 %

0.1 %

0.4 %

8.4 %

1.0 %

0.03 %

0.1 %

0.7 %

0.9 %

Quelle: BCG, Stahl-Zentrum

Fig. 4


kg CO2 equiv.

Only 6 life cycles, even when conservatively calculated

Real greenhouse gas potentialt CO2 equiv./1 t steel


G u e s t c o l u m n : Robe r t Ha r t i ng

A question of honourPersonal responsibility: Why you should take responsibility

for your own health and safety seriously.

Personal responsibility sounds rather ab-stract at first. But when I think about it

more carefully, I believe it is only possible to be personally responsible for a matter about which one is personally concerned. When you are directly concerned yourself, you have an especially clear sense of what responsibility actually means – which is perfectly logical because you are the person who experiences the direct conse-quences of your decision.

And this sense of responsibility also applies in a broader context: at your work-place.

Now, however, you will ask yourself what personal responsibility for your health and safety has to do with your boss? Quite a lot, in fact. Just imagine you were in charge of the entire company and had 12,000 employees. And they behaved irresponsibly with work items, equipment and tools, or even behaved a bit stupidly and injured themselves. How would you feel then?

You would be confronted by enormous losses every month and would no longer be in a position to handle your orders. And it wouldn’t only be a case of no longer be-ing able to meet your delivery deadlines. You would also have to repair the damage to your own premises. In other words, you would have to cope with financial losses because you couldn’t deliver and, further-more, you would have additional costs because you would have to rectify dam-age within your company. With the consequence that, sooner or later, you would have to make some employees redundant in order to protect the re-maining jobs.

Change of role: just imagine you were a manager. Such people set themselves ob-jectives, have ambitions and make a higher contribution to the work themselves be-cause they stay in the office longer, often take work home with them and work for the company virtually 24/7. These people normally earn more money. As “major cost factors”, therefore, they are usually the people who need to go first. In our role

play that would be you (or your colleague, or the manager of your department).

But even if you are not personally af-fected, a lot would change – appreciation of your work performance, the established work process, the social relationship be-tween colleagues. Furthermore, the output of your entire team would suffer. Your own workload would increase and, into the bar-gain, you would have to cope with a con-siderable number of additional tasks.

Consequently there would also be changes at home and in your private life. You would be spending longer at work, and also experience serious insecurity be-cause, all of a sudden, your job would be at risk – due to no fault of your own. This

scenario could be developed even further... I just want to make clear that in these mat-ters the degree of personal responsibility is intricately linked to social status.

With regard to your own health and safety at work, personal responsibil-ity should also play an important role. Because of course you also want to be respected and appreciated. So what is the connection between these factors? It is a question of honour: anyone with a sense of respect and self-esteem, and who places reasonable demands on themselves, will not have any difficulty in handling re-sponsibility and will also be respected and appreciated by others. On the other hand, people who lack a sense of self-esteem and do not impose any demands on themselves will not be in a position to emanate this attitude – and therefore cannot expect to experience respect and appreciation from others.

People require a sense of security in a social context. In the world of work this means they must be able to convert con-trol into trust, in other words it must be possible to have innate confidence in a

colleague acting in your interest without having to exercise any form of control.

But what role does each individual want to play in this confidence versus control chain? The more personal re-

sponsibility someone is prepared to exercise, the more his credibility in-

creases in the eyes of his colleagues. Seen from this perspective, there-fore, personal responsibility is the starting point as well as the main impetus for mutual confidence.

Look after yourself and your health, because your colleagues need you!

Yours,

glück auf · 1/2016 · Extracts in English ........................................ 10

Anything but patchwork IAG MAGNUM · Spectacular repair: fractured top roll of a three-roll bending machine restored. After welding, the more than 19 m-long roll displayed a deviation of only 1.5 mm.

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Europipe GmbH in Mülheim an der Ruhr,Germany, produces spiral- and longitu-dinally welded tubes and pipes in diam-eters ranging from 609 mm to 1,524 mm on four modern lines. During operation, the top roll of a three-roll bending ma-chine fractured. IAG MAGNUM was con-tracted to repair it. No easy task. Andreas Vogele, Welding Supervisory Team Leader at IAG MAGNUM, gives details in an in-terview with glückauf.

glückauf: Cut away defective end section, weld on new piece and then machine to installation dimensions. That sounds like a routine assign-ment, Mr Vogele.Andreas Vogele: It was nothing of the sort, unfortunately. The difficulties lay in the spe-cial characteristics of the top roll, specifically its length, its shape and its material. It was over 19 metres in length and had a maxi-mum diameter of half a metre.

How do you mean “maximum“?Vogele: The shape of the roll was not cylin-drical but convex, in other words crowned.

So the roll was at its thickest in the centre and tapered off towards both ends.Vogele: Exactly. That crown together with the slenderness ratio – meaning the ratio of diameter to length – was a real challenge when it came to the turning process. Added to that, the material was a high-carbon quenched and tempered steel, made entirely of one material that was not easy to weld.

And the weight of 30 tonnes?Vogele: Was not a problem.

How did you approach the assignment?Vogele: There were several meetings with the customer beforehand regarding the special features of the assignment. Based on those meetings, on inhouse consultations and an exact measurement of the component dimensions we prepared detailed design drawings for which Europipe then gave the green light. Only then were we able to place an order for the 6 metre-long replace-ment piece weighing over 13 tonnes with Schmiedewerke Gröditz.

And after that?Vogele: The defective section of the roll was first of all cut away using a band saw. We

then shrunk special bearing rings onto the remaining top roll piece. They had an indi-vidual inner and identical outer diameter and were intended to help align the roll later on the turning machine. But they were also ideal for our Welding Department to set up and align the top roll and replacement piece on five roller bearings and to inspect the re-sults during the welding.

Did you know from the start how and with what the welding had to be done?Vogele: No, the material certificates unfortu-nately did not permit an absolutely certain and exact identification of the material com-position.

But without the exact chemical analysis of the parent metal it‘s not possible to select either the matching welding technology or the right weld-ing filler material. Vogele: Which is why our Quality Depart-ment had first of all to determine the precise chemical composition by means of spectral analysis. Only then did we learn that we had to carry out the welding work after preheat-ing at a minimum of 300 degrees Celsius, for which we used induction hoses wound onto specially fabricated annular baskets. These annular baskets were important, as the top roll had to be rotatable. We first of all elec-trode-welded the core area manually until a diameter was reached from which it was then possible to carry out submerged-arc welding during roll rotation.

What was the outcome?Vogele: It was most remarkable, because the dimensional inspection revealed a deviation

of only 1.5 millimetres over the entire length of 19 metres!

What followed after that?Vogele: The heat of the welding process was directly followed up with several hours of stress-relief annealing, for which we used the inductors already installed on the annular baskets, after quickly re-arranging them.

Without inspecting the welds beforehand?Vogele: We had to keep the roll in a con-stantly hot state, meaning that we were able to inspect the welds only after the welding and annealing treatment. During the ultrasonic inspection, all involved were correspondingly nervous as the weld was turned over for the first time on the turning machine, supervised by the customer. After the complete weld had been 100 per cent in-spected, the inspector and the customer gave the thumbs-up – and we, of course, were very relieved, because we now had the certainty that our work so far had been successful.

But that was not the end of the assignment.Vogele: No. Only then did the actual turning work on bench 052 begin. The previously mentioned bearing rings were a crucial factor in successfully achieving an exact alignment. The crowned shape of the roll was perfectly modelled by our CNC programmers. Our turners now had to concentrate particularly on the transition from the old section to the new section. The customer was completely satisfied with the result. After that it was pos-sible to roller burnish the two bearing loca-tions at the ends of the roll.

What does that involve?Vogele: Roller burnishing chiplessly smooths and work-hardens the surface, thus greatly increasing the bearing area.

How did you manage to get the almost 20 metre-long top roll to final dimensions, cut two grooves and grind a thread?Vogele: We had to use two boring machines at the same time. We conducted the final acceptance and dimensional inspection together with Europipe. When doing so, it became clear that the time initially invested in the extensive job planning had more than paid off in the end.

Many thanks for talking to us.

Andreas Vogele Photo by courtesy of the company


State of the artSchmiedag/Hagen · More versatile and flexible software: systematic preparation enabled smooth transition during CAD changeover.

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Since 1988, Schmiedag in Hagen has been using the lat-est CAD programmes for all its tool and die designs and accompanying drawings. The requirements of the custom-ers and their engineers where design and product develop-ment are concerned are varied and challenging, however – and becoming steadily more demanding, as Klaus Pfeiffer, Head of the Engineering Office at Schmiedag, knows. To meet those requirements, there has now been a changeover to a new software. Klaus Pfeiffer gives details:

glückauf: How big is the CAD Depart ment at your company, Mr Pfeiffer?Klaus Pfeiffer: As many as five workstations, depending on the scope of the work involved.

And what work is done there? Pfeiffer: Extensive 2D and 3D designs for customers and for inhouse production applications, as well as complex geometric bodies for inhouse FEM calcula-tions for forging simulations. Be it simple operating materials – for instance a metal template – or complex fixtures for inhouse five-axial production, everything done at our company is based on CAD.

Which system has been in use to date ?Pfeiffer: Pro/Engineer Wildfire 4.0 from software firm PTC Para-metric Technology.

Your company has, of course, been using that software successfully for years. Now you have changed over to a new one?Pfeiffer: To Creo 3.0, a software that is upgradable with various modules. It, too, is sourced from PTC Parametric Technology.

What makes the new software better than the old one?

Pfeiffer: Its 2D and 3D CAD functions are more versatile and flexible, enabling us to develop our products faster than before. Another forte is the higher level of automation for recurring tasks – such as the production of technical drawings.

… in other words the use of techni-cal details or their drawings which are needed on a recurring basis.Pfeiffer: Exactly. This helps us to avoid errors that would oth-erwise cost a great amount of time and, consequently, money. The new software also enables our design engineers to carry out better analyses and create animations. And it raises our productivity in a whole number of other design activities.

Nowadays it is not so easy just to change design software and start working.Pfeiffer: Very true. It is sadly not as easy as changing from an op-

erating system such as Microsoft Windows 7 to Windows 8.

Why not, in fact?Pfeiffer: The reason is, among other things, the PDM, or so-called Product Data Management system, where all the stored 3D data and CAD drawings are deposited. This system man-ages not only all the activities in terms of data and drawings, it also supports important pro-cesses such as managing the content, change and release of information.

In other words, information that should not be lost, if possible.Pfeiffer: That would be disas-trous – the worst case, so to speak, which is why any move-ment of data to a new system always has to be prepared well.

How much data was involved?Pfeiffer: Several terrabytes.

And how did the “move“ go?Pfeiffer: Things did not happen that quickly. First of all we had three months of preparation set-ting up new servers, for instance. Without those we would not have been able to handle the new volume of data at all. After that, the first computers were able to commence test operation with the similarly new PTC Creo Parametric 3.0 design software.

Were the staff also well-prepared for the new software?Pfeiffer: All of the staff were prepared for the new software within the space of just four weeks in three training mod-ules, The “data move“ then took place in parallel with day-to-day business. Once that had all been completed, we were able to start working with PTC Creo Parame-tric 3.0.

Many thanks for talking to us.

Working with the new Creo 3.0 software (from the left): Mathias Hellwig, Bodo Rahner and Frank Kobuszewski. Photo: Karin Kriebel


A woman ‘mans up’Bochumer Verein · Operating a metalworking machine is considered a male occupation. Hanna Krämer proves that it can also appeal to women.

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Her training as a metalwork-ing machine operator is actu-ally her second, as occupations go. After finishing secondary school in 2009, namely, she began an apprenticeship as a hairdresser which unfor-tunately she was unable to complete. Her employer had to file for insolvency while she was preparing for her exams. It was an unpleasant experi-ence and not so easy to get over. But today she knows that occupation would not have been fulfilling for her over the long term. Which is why she looked for something new – and decided on something practical: metalworking.

glückauf: Why the occupation of a metalworking machine operator?Hanna: Of the practical work I did at school, metalworking left a positive impression on me. And as it is work you can get to grips with, I made a very conscious de-cision to take it up.

Your preferred job?Hanna: You could put it that way. That is how I would gauge things in the meantime after two-and-a-half years - especially as my training place in the main-tenance workshop, which also involves conventional turning operations, is never boring. Every assignment is different. Repeat parts tend to be the exception.

What, actually, does a metalwork-ing machine operator do?Hanna: Put purely and simply, “machining work“; seriously, though, technically anything that can give shape to metal through turning, milling, grind-ing and planing, and has to be produced to drawings or pat-terns. There is, of course, an enormous difference between CNC and manual turning opera-tions. Manual turning appeals to

me more as it really has some-thing “hand-crafted“ about it.

What is fascinating about machin-ing?Hanna: Seeing what repairs de-fective parts require as a result of hot shaping processes. And how fast an assignment has to be completed so that other areas do not 'grind‘ to a standstill. I am able to see my work and “grasp” in the truest sense of the word what I am doing. And there are ever new challenges to surmount or parts to produce – be they only simple turned parts or ones that include drilled holes or cut threads. And that I find fascinat-ing.

Why did you apply to Bochumer Verein?Hanna: Because I had made up my mind that it was to be metalworking, in combination with certain handicraft require-ments…

In other words, manual work in preference to CNC …Hanna: Precisely! ... I searched for suitable training opportuni-ties on the internet, of course. BVV have very good web pages, including images, with attractive advertising on training places for a multitude of metalworking occupations. It was an easy deci-sion for me to apply to BVV as a training enterprise in the Ruhr region, because I didn‘t wish to be too far away from home, either.

Many have to send off countless applications. How was it for you?Hanna: I sent off six unsolicited applications to various enterpris-es which led to three interviews – among them, one at BVV, which then turned out to be the best training opportunity.

What advice would you give to young people who are searching for a training place? Hanna: They should choose an

occupation that they are really sure of being able to carry out in terms of what is required both mentally and physically. In near-ly all metalworking occupations, of course, a good knowledge of maths, physics and chemistry is certainly an important require-ment, without which nothing is otherwise possible. Before

deciding on an occupation, it would be important perhaps to get a feel for things through an internship and, by doing so, then certainly gain a better idea about a future job and its requirements, instead of just reading about them on paper or in abstract de-scriptions.

Are you content with your present situation?Hanna: I am optimistic about also achieving my goals by Feb-ruary 2017. I find the work to be very great fun. I have won-derful support from my other colleagues. I can reliably turn to them at any time with any ques-tions and always receive fitting answers that contribute to my knowledge.

What do you currently like the best about the training?Hanna: During the first six months it was mainly theory and manual work – in other words, simple metalworking such as filing, measuring, filing. The dominant feature now is machin-ing work on a proper lathe. It‘s fun to watch a work piece slowly be “turned“ and crafted from a piece of steel.

What improvements could be made?Hanna: The management and use of measuring instruments in practice. Particularly in vocation-al school, there might be greater opportunity to practise with different gauges and measuring devices and thus avoid measur-ing errors on the practical side, thereby minimising costs.

How do you see your future? Hanna: Well, firstly I have to complete my vocational training successfully. Then it would be nice to be able to carry on work-ing in maintenance. I have al-ways been aware of the fact that it involves doing shift work. That is the way things are in large en-terprises.

How will things continue vocation-ally?Hanna: First of all, gain work experience. Then I‘ll have to see. Perhaps further training.

Where would you like to work most within the company?Hanna: Wherever there is a lathe.

Thank you for talking to us.

Away from homeI come from a small community of around 300 inhabitants in the Sauerland region, have moved to Essen to do vocational training, and have meanwhile become a real city lover. Being separated from my family is not quite so bad at 23, and there are of course modern means of communication for keep-ing in touch, despite the distance. At home I used to actively do showjumping and play football. Neither is possible at the moment, because keeping a horse in the city is not practical, unfortunately. And where football is concerned, it is more a matter of spectating, most preferably when my favour-ites, Real Madrid, are playing (and winning). I live in shared accom-modation, rented together with like-minded people who simply cannot afford a flat of their own. It‘s very interesting. You also learn to be considerate of others – and it works out well.

Hanna Krämer prepares a new work piece. Photo: em


Give it a guess!

In front of which famous tourist attraction in Turkey is glückauf editor Dorothea Raspe reading her glückauf? The name consists of six letters. Answer the following questions and use the first letter of each answer to make up your solution word. BVB midfield player of Turkish origin (surname)? Federal Chairman of the German Green Party who is of Turkish origin (surname)? Turkish national drink flavoured with anise? Prime Minister of Turkey (surname)? Turkish espresso variant? The col-our "purple" in Turkish? Solution word:

And where is your photo? Would you also like to submit a picture puzzle? Just take a photo featuring glückauf in the foreground. In the background there should be enough specific details to be able to rec-ognise in which place or in which town the photo was taken. Mail your photo to [email protected].

Fan Shop Summer SetBarbecuing is still reputed to be a man's domain. And sothat he can fulfil that role well, this time around theprize will be a barbecue set with tongs,fork and turner from the GMHFan Shop – complete withbarbecue case and barbecueapron. Only authentic with the GMH logo.

We wish you good luck!

Did you know? GMHütte employee Vera Loose is standing in front of Germa-ny's largest wooden church in Clausthal-Zellerfeld. The win-ner, Jürgen Beck of StahlwerkBous (Accounts), was drawnfrom all correct entries submit-ted (thank you for taking part!).(The judge's decision is final.) Congratulations!

YoUR PRIzE

Photo: privat

glück auf on the move

Photo by courtesy of the company

SPoT-THE -D I FFERENcE PUzzlE – 5 To F IND

It is not so easy: spot the five differences between the original and the altered picture. What is missing in the altered picture? This time, the

original photo was taken at Schmiedewerke Gröditz. Felix Treppschuh from Rohstoff Recycling Osnabrück captured the shot and manipulated it to incorporate the alterations. If you have trouble spotting all five differences, you will find the solution to the puzzle online a

www.glueckauf-online.de.

oRIGINAl AlTERED PHoTo

Photo: privat

Masthead

Publisher:Ge orgs ma ri en hüt te Hol ding GmbHNeue Hüt ten stra ße 1, 49124 Ge orgs ma ri en hüt tewww.gmh-hol ding.de/uk/

Responsible in accordance with press law:Iris-Kath rin Wil ckens

Translations: Carol Hogg, Michael Snowley

Design: elemente designagentur, Münster

glueckauf-en-1-2016

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