PRR Panhandle 2.0

Updated 8/25/2024:

I spent part of yesterday tracing wires and checking connections inside the Open Hearth.  And last night I had a very interesting e-mail conversation with a friend in my NMRA division who happens to be an electrician.  I was describing some of the odd behavior of the Open Hearth (one string of stack lights suddenly not working, all lights blinking when the big smoke stack unit is turned on) and he diagnosed the problem as not enough power.  Apparently, when I add up all the LEDS (there are a bunch!) and the smoke units, I am just over the safe limit for powering it all.

In addition, I've discovered that the fan on the big Harbor Models smoke unit has failed.  It still produces smoke, but the fan circuit is done.  As a result, the intake fan no longer propels smoke through the unit, out the exhaust and into the tubing leading to the 2 smoke stacks.  I am looking into replacing that fan and possibly adding another power supply.

More when I know it. 

George

That is a good analysis by your friend.  Overloaded power source and crazy things happen.  Failed fans can be easily overlooked in any device

Years ago when my layout was up and running but still in it’s infancy. I had a 12v 2 amp power supply for Tortoise switch machines, relays and anything else that required it. I added a few more things to it. I had some guests come over to see the RR. I can’t remember the scenario but it basically went in meltdown mode. I had to start disconnecting things to get it to function. When out the next day and bought a 7 amp supply.

Turns out that the large failed smoke unit has a different problem, probably unrelated to the total wattage.  I took it apart today to discover a broken wire.  The soldered spot where the wire joins the motor had failed.  I will try to fix that and see if it will work.

The power supply is rated for 150 watts and 10 amps.

George

Updated 8/27/2024:

• The fan on the large smoke unit has been repaired, reattached, and is working fine.  I've re-installed it in the Open Hearth.
• A length of tubing for the smoke unit needs to be replaced; that will happen later today.
• During the juggling (connecting and disconnecting of circuits during the debugging process), the one set of smokestack warning LEDs (slow red blinking) began working again.  Thank goodness that was not a connection issue inside the stack.  It would have been very difficult to reach.
• I placed an order for a Meanwell LRS-350-12 power supply.  This should have more than enough capacity to handle all the LEDs and smoke units in the Open Hearth.  We should see that in a few days.  Installing that in the OH means that I have another 12VDC power supply available for lights on the layout - more than enough!

More when I know it. 

George

It sounds like you have had a productive day

Updated 9/3/2024:

It's been awhile.  We've survived the failure of the mill's smoke unit which almost resulted in a fire.  That unit has been removed and a new power supply has been installed in the Open Hearth; that had nothing to do with the smoke unit issues but it is needed to drive all the lights and other items in the mill.  Here are a couple of shots of the mill working.

I am in the process of repairing the transfer crane and its crane hoist - both of which lost a wheel.

And finally, in response to the smoke unit threatening to ignite, I have installed 2 fire extinguishers in the train room.  Here's one of them.

There was also some serious clean up and organization of materials in preparation for the next phase of work.

Oh yeah, I also replaced a keyboard that failed.  More when I know it. 

George

Glad production is back up again.  Shareholders were worried.  Better safe than sorry with the fire distinguisher.  OSHA would love you.

Look good @G3750! The organization process before the next phase is always a problem with me. Sometimes I get to a point where I have 3 phases starting to combine... ugh. Then I'll spend a few days getting everything organized and I'm not like this at work.. LOL

Gad to hear there was no fire!

@T-Bone1214 posted:

Look good @G3750! The organization process before the next phase is always a problem with me. Sometimes I get to a point where I have 3 phases starting to combine... ugh. Then I'll spend a few days getting everything organized and I'm not like this at work.. LOL

Gad to hear there was no fire!

Thank you, but I have let things get to the point where there's so much clutter I just can't move forward.  The act of cleaning up tends to de-clutter my mind as well.  And of course, I vow to myself that I will not let it happen again, but...

Lather, rinse, repeat.

I do try to force myself to do periodic cleanups by making the layout open for people - NMRA meetings, open houses, etc.

George

Updated 9/4/2024:

Did some repair work on the Open Hearth tonight, including:

• Re-installed the 350 watt power supply.  Even with the Harbor Model smoke unit permanently out of the equation, the larger capacity unit will be needed to power all the remaining lights and the smoke units in the ladles.
• Got several strings of LEDs to start functioning again.  Turns out there were a few disconnections at the terminal block - thankfully not loose wires somewhere inside.  There are still a few strings of lights (overhead on the trusses) that are malfunctioning.  I intend to find those, eventually.
• Re-hung the transfer crane, its trolley, and the transfer ladle in front of Furnace No. 11.  That new access hole at the back of the mill made that exercise, and the photos below, possible.  I'm very glad I did it.  And it won't be visible from the aisles of the layout room when the other buildings are in place.  Good call on my part.

Here are some photos from tonight's efforts.  Let's start with Charging Floor of the open hearth.

In this first photo, we get a full on side view of the transfer crane discharging the contents of the ladle (molten iron) into Furnace No. 11.  Just behind the ladle, a worker directs the pouring.  Beyond him, scrap buggies can be seen in front of Furnace No. 13.

Here's a closer look.  The winches and water pipes for the furnace doors are clearly visible on the furnace tops.  And that crane operator is really concentrating on his job.  Spill that ladle and all h*** will break loose! 

Meanwhile on the Pouring Floor, we can see down the length of the mill. 

Furnace No. 12 is being tapped as a brave soul looks on.  Baby, it's hot up there!

Here's a slightly better look at the tapping operation.  When the level of steel in that teeming ladle gets high enough, the slag (waste) floating on top will spill into the nearby slag thimble.

Finally, here's a look at the trusses that make up the roof of the mill.  I can still recall looking up at these during my summers in Weirton Steel.  Having some lights out is prototypical, too.

More when I know it. 

George

Absolutely awesome. My dad worked for US Steel for 43 years in the Lorain plant

George, that is extremely impressive!!  Thank you for the photographs!

when you wrote it is hot up there, I recalled going up on the furnace at the power station I worked at when I was in my 30s.  The furnaces for three 950 MW generators were really hot too!

George, awesome progress….There’s gonna be some major operating action going on at that steel mill! Can’t wait to see it!

Mike

Updated 9/5/2024:

Thank you @Ohio Jeff, @Mark Boyce, and @LT1Poncho for all the kind words!

Went to work with a vengeance this morning (the 7 year-old grandson is visiting the layout for the first time )!!!  That means getting the visitors log, track plan, and scavenger hunt sheet out.  And I prepared and tested some spare CAB-1 remotes.

I ran the CMX track cleaning car for the first time.  WSX #203 pulled it around most of the layout.  I will probably need to do it again several times.  The track was dirty despite being cleaned a few months back for an open house.

I also discovered a few interesting things:

• There are at least 4 spots where some extra track screws would be very helpful.  None of these affected train operations, but they do need to be taken care of.
• One of the signal relays needs a capacitor to keep from chattering.
• There's a spot where the Loads / Empties track passes through the backdrop that needs a bit of widening.  Oops, thought I had all of those fixed.
• The switcher performed beautifully, crawling over the mainline, Weirton Junction Yard, and Weirton Steel Yard.  I was very, very pleased.

More when I know it.

George

George, when you place the capacitor to stop the relay chatter, please give us an explanation of how and where it was placed in the circuit. I have the same issue, and this would be helpful. I am an electrical idiot! Thanks in advance.

Mike

@G3750 posted:

Updated 9/4/2024:

Here's a closer look.  The winches and water pipes for the furnace doors are clearly visible on the furnace tops.  And that crane operator is really concentrating on his job.  Spill that ladle and all h*** will break loose! 

Meanwhile on the Pouring Floor, we can see down the length of the mill.

More when I know it. 

George

Outsatnding!

It pours! Unbelievable!

Mike

@LT1Poncho posted:

It pours! Unbelievable!

Mike

I took this a long time ago.  It's (perhaps) one of my favorite photos.  This is Furnace No. 12 being tapped.

George

I might have to join the NMRA just to get to come see your layout. lol

George, those interiors look amazing.

@Ohio Jeff posted:

I might have to join the NMRA just to get to come see your layout. lol

You would be welcome regardless.

George

@G3750 posted:

You would be welcome regardless.

George

Yes, Jeff.  George even let me in! 😄

@naresar posted:

George, those interiors look amazing.

Thank you.  I didn’t want to make a another model steel mill that was just a big box (been there, done that).  On the other hand, I had NO IDEA how complex this mill was. And once I got into this tar pit, I had to see it through.  Two and a half years, 2,600+ parts, and God knows how much money later, here it is - the second signature item of the layout.

George

@Mark Boyce posted:

Yes, Jeff.  George even let me in! 😄

@Mark Boyce, don't be ridiculous.  You're a credit to this forum, and it's great to have you as a friend.

George

@G3750 posted:

@Mark Boyce, don't be ridiculous.  You're a credit to this forum, and it's great to have you as a friend.

George

Thank you, George!  You are a credit as well showing how excellent planning and not being afraid to take the time to make big changes pays off!!  I’m glad to have you as a friend too!  I’m glad you moved back from Harrisburg!!!

I'm totally blown away! Incredible craftsmanship! Your layout is magazine bound!

@T-Bone1214 posted:

I'm totally blown away! Incredible craftsmanship! Your layout is magazine bound!

Thank you very much.  It would great if that happened.

George

Updated 9/12/2024:

There are a number of major projects on hold at the moment:

• Open Hearth roof rebuild - awaiting the summoning of will power to tackle this large, finicky, and tricky job.  Part of it will involve me climbing up on the layout and working on my knees - can't say I'm eagerly anticipating it.
• Weirton / Weirton Junction Divider - awaiting the 2-sided backdrop.
• Crawford's Crossing highway overpass - awaiting the 3D printing of the hand rails.  I really can't begin assembly of all the gathered parts before then.

As a result, I have focused on gathering the remaining components for what I anticipate will be a short, fun project - the Standard Slag Animation.  This is an Arduino-driven effort using an LED board, relays, fans, smoke units, and (hopefully) an MP3 player.

More when I know it. 

George

Working on my knees to repair the roof, I think I would be forced to put up with it.  Knees are out for me. 

All your projects sound very interesting, including the roof.  We will wait for them to pick up at some time.

@G3750 posted:

Updated 9/4/2024:

Did some repair work on the Open Hearth tonight, including:

• Re-installed the 350 watt power supply.  Even with the Harbor Model smoke unit permanently out of the equation, the larger capacity unit will be needed to power all the remaining lights and the smoke units in the ladles.
• Got several strings of LEDs to start functioning again.  Turns out there were a few disconnections at the terminal block - thankfully not loose wires somewhere inside.  There are still a few strings of lights (overhead on the trusses) that are malfunctioning.  I intend to find those, eventually.
• Re-hung the transfer crane, its trolley, and the transfer ladle in front of Furnace No. 11.  That new access hole at the back of the mill made that exercise, and the photos below, possible.  I'm very glad I did it.  And it won't be visible from the aisles of the layout room when the other buildings are in place.  Good call on my part.

Here are some photos from tonight's efforts.  Let's start with Charging Floor of the open hearth.

In this first photo, we get a full on side view of the transfer crane discharging the contents of the ladle (molten iron) into Furnace No. 11.  Just behind the ladle, a worker directs the pouring.  Beyond him, scrap buggies can be seen in front of Furnace No. 13.

Here's a closer look.  The winches and water pipes for the furnace doors are clearly visible on the furnace tops.  And that crane operator is really concentrating on his job.  Spill that ladle and all h*** will break loose! 

Meanwhile on the Pouring Floor, we can see down the length of the mill.

Furnace No. 12 is being tapped as a brave soul looks on.  Baby, it's hot up there!

Here's a slightly better look at the tapping operation.  When the level of steel in that teeming ladle gets high enough, the slag (waste) floating on top will spill into the nearby slag thimble.

Finally, here's a look at the trusses that make up the roof of the mill.  I can still recall looking up at these during my summers in Weirton Steel.  Having some lights out is prototypical, too.

More when I know it. 

George

Late to the party but WOW you really nailed it! Love the details you put in especially with the molten iron you done up.

On a different note however I do have some updates on the prototypes. As of me typing this, the Coke Plant in Follansbee has (and still is) been in the process of being demolished. Rode out there a few weeks back and it’s eerily similar to Weirton.

I’m unsure if the bridge or the rest of the remaining buildings in Steubenville will follow so if anyone wants to photograph the area before it vanishes I’d say now’s your chance!

@Pennsy6755  Thank you!

I have been taking photos of Weirton Steel since 2000.  I knew then that it would disappear.  Heck, I knew back in 1978 when I quit a lab technician job for graduate school (computer science).    Since 2000, I have been determined to save as much of it (photographically) as possible.

I don't think the bridge will disappear any time soon.  Its 98th birthday is coming up (September 28)!

Ditto for Steubenville.  The tall buildings there seem to have some occupancy.  The last building of interest (to me) to disappear was The Hub department store on 5th Avenue.

I haven't kept tabs on Follansbee, WV.  Thank you for the update on the coke plant.

George

@G3750 posted:

@Pennsy6755  Thank you!

I have been taking photos of Weirton Steel since 2000.  I knew then that it would disappear.  Heck, I knew back in 1978 when quit a lab technician job for graduate school (computer science).    Since 2000, I have been determined to save as much of it (photographically) as possible.

I don't think the bridge will disappear any time soon.  Its 98th birthday is coming up (September 28)!

Ditto for Steubenville.  The tall buildings there seem to have some occupancy.  The last building of interest (to me) to disappear was The Hub department store on 5th Avenue.

I haven't kept tabs on Follansbee, WV.  Thank you for the update on the coke plant.

George

No problem! I knew you'll make a mad-dash on photographing on what's left there and you'd be correct on the NS bridge being safe. I was more-or-less referring to the other similar one further downstream just before the ex P&WV one that was built a decade prior in 1917 (Photo Attached)

From what I read and recalled online, nothing ran across it in well over a decade and is structurally dangerous! Heck, even the toll bridge in Steubenville ain't even safe! That's closed now too and rumors of it being knocked down as well are flying in the air!

@Pennsy6755 posted:

No problem! I knew you'll make a mad-dash on photographing on what's left there and you'd be correct on the NS bridge being safe. I was more-or-less referring to the other similar one further downstream just before the ex P&WV one that was built a decade prior in 1917 (Photo Attached)

From what I read and recalled online, nothing ran across it in well over a decade and is structurally dangerous! Heck, even the toll bridge in Steubenville ain't even safe! That's closed now too and rumors of it being knocked down as well are flying in the air!

The above bridge was built for the LaBelle Iron works, right?  Here are some of my photos of it from about 10 years ago.

I believe it was originally intended to transport coke or molten iron from blast furnaces across the river to the open hearths on the Ohio side.

George

@G3750 posted:

The above bridge was built for the LaBelle Iron works, right?  Here are some of my photos of it from about 10 years ago.

I believe it was originally intended to transport coke or molten iron from blast furnaces across the river to the open hearths on the Ohio side.

George

If I recalled correctly I think so.. During its final years the bridge was used for moving coke hoppers from Mingo Junction to Follansbee. Probably as a way to save time from moving whole trains through downtown Steubenville and hitting the abundance of road crossings.

But with it being unsafe, it only could handle their mill switcher and iirc like five or eight fully loaded/empty hoppers.  

Compared to Weirton, I shockingly know little on Mingo/Steubenville/Follansbee Mills outside of the few bits and pieces here and there.

Thank heavens for the Internet to bail me out!

Updated 9/27/2024:

There are still major projects blocked, but other smaller things are moving forward.

• A model railroader friend (who is also an electrician) installed a whole-house surge protector for me.  Big relief!
• I am now thinking about the woodworking aspect of my slag dump.  The sizing and cutting of the 4' x 8' x 1/4" Masonite sheet that will form the base of the slag dump as well as how to support everything are all in play.  We're doing a lot of test-fitting and mock-ups to see how all the pieces will end up.
• The dump is going to be permanently installed on the layout, but the Arduino and other circuitry will sit on a small (6" x 12") base that must be removable.  That's not going to happen every day, but thought must be given to access and to powering the board.  All of these affect the placement of components.

More when I know it. 

George

Updated 10/1/2024:

• Last night I held a 2-hour virtual meeting with the designer of the 2-sided backdrop that will provide a view block between the City of Weirton and Weirton Junction.  I am pretty happy with the conversation and progress and now look forward to seeing the proofs prior to production.
• On a much less positive note, I am becoming disenchanted with the 16x32 LED board (part of the Arduino driven animation I'm currently chasing) that I purchased a few years back.  The inadequate documentation and the indifferent support are beginning to frost my cake.  The rest of this week is committed to things other than layout building, but I am hoping to devote some time to this project next week.
• Some house guests are coming who want to see the layout and run trains, so layout preparation has jumped to the top of the priority list.

More when I know it. 

George

George, the backdrop sounds like it will be great.  All of us will be anxious to see it as well when it is in place!  😃
Bummer on the LED board. 😑

George, I don't remember seeing reference to it before, but what was the LED board supposed to be for?

@naresar posted:

George, I don't remember seeing reference to it before, but what was the LED board supposed to be for?

I want to use the LED board to simulate the dumping of slag.  I have to figure out how to connect the board (very poor documentation) and then how to write a program that will accomplish the effect.

George