Predictive maintenance & condition monitoring
INCREASING RELIABILITY AND SUSTAINABILITY IN STEEL MANUFACTURING PROCESSES
S
amotics, a leading provider of real-time actionable insights to eliminate unplanned downtime and energy waste, has been selected by thyssenkrupp to monitor the condition and performance of its hot rolling mill in Duisburg.
thyssenkrupp Steel installed Samotics’ SAM4 Health solution as part of a proof-of-value pilot, initially monitoring 100 critical conveyor rolls at its Duisburg plant in Germany - Europe’s biggest steelmaking site. In the first few months of the pilot, the system detected multiple critical faults at an early stage including mechanical unbalance and bearing degradation. This enabled thyssenkrupp Steel to replace the affected machines before they failed, preventing significant unplanned downtime and its associated costs. After the initial success of the pilot project, thyssenkrupp extended the use of the SAM4 Health system and integrated it into its maintenance process.
Because the rolls operate in an extreme environment, ensuring reliable operation is a challenging task: the heat and cooling water accelerate wear and tear, and performing regular inspections or installing sensors directly on the equipment is nearly impossible. To overcome this challenge, thyssenkrupp Steel selected Samotics’ SAM4 Health solution to monitor its hot rolling mill. SAM4 Health delivers continuous insight into the health and performance of the rolling mill. This empowers maintenance teams to take proactive measures against developing faults and prevent unexpected breakdowns. Continuous monitoring also enables teams to detect and address root causes that might lead to future degradation, leading to extended equipment lifetime and better performance. This way equipment runs more efficiently and saves energy. Samotics’ SAM4 technology achieves this by using a technique called electrical signature analysis (ESA). ESA analyses current and voltage data of electric-driven motor systems using sensors installed in the motor control cabinet, rather than on the asset itself. This enables continuous monitoring of assets operating in extreme temperatures, hard-to-reach places and ATEX zones. Christian Weiß, lead engineer HTM1 at thyssenkrupp Steel says: “Industrial analytics underpin our mission to improve delivery performance and reduce energy waste. The capability of Samotics’ SAM4 system to operate
48
effectively in extreme environments made it the obvious choice to help increase the reliability and efficiency of our hot rolling mills. We look forward to continuing our collaboration with Samotics and continuing to improve our service to our clients”.
Simon Jagers, Samotics’ founder adds: “thyssenkrupp’s commitment to the digitalization and automation of the steelmaking process promises environmental, safety and commercial benefits. Our technology helps thyssenkrupp
Steel address a fundamental challenge by identifying and resolving developing faults before they happen. With accurate health and performance data, maintenance teams can schedule maintenance at their convenience rather than reacting to an unforeseen fault. We’re delighted to join them on the journey toward creating a smarter, safer and more sustainable future for steel production.”
Samotics
www.samotics.com October 2023 Instrumentation Monthly
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60 |
Page 61 |
Page 62 |
Page 63 |
Page 64 |
Page 65 |
Page 66 |
Page 67 |
Page 68 |
Page 69 |
Page 70 |
Page 71 |
Page 72 |
Page 73 |
Page 74 |
Page 75 |
Page 76 |
Page 77 |
Page 78 |
Page 79 |
Page 80 |
Page 81 |
Page 82
