IRON & STEEL INDUSTRY

60% of the equipment defects are predicted by vibration analysis and 85% of the predicted defects can be prevented by remedial actions to reduce the equipment downtime and avoid the production loss

  • Currently the steel industry envisages more than 300 million tonnes (MT) steel-making capacity which will gradually be 160 kgs per capita steel-consumption by 2030-31.
  • Steel making processes are highly energy-intensive and comprised of many complex unit operations.
  • Steel is more or less utilized in every industry.
  • Equipment in steel manufacturing plant operates 24 X 7 for maximum productivity.
  • Failure of smelting process results in delay in the production of steel and the inability to achieve production targets.
  • Improper handling of bearings and its lubrication affects the sintering process. Inspecting vibrations on the equipment can safeguard the operational performance.
  • Preventing the time-consuming dismantling process of gear assembly by monitoring it, facilitates operations of the conveyor belts and Blast Oxygen Furnace.
  • Tracking the harmonics of the bearings of low speed overloaded casing machines enhances the transportation of semi-furnished products.

The implementation of IDE in steel plants, especially to monitor

01. Process of smelting and sintering.

02. Split bearings on the conveyor belts.

03. Tapered roller bearings in continuous casing machines.

04. Gear boxes in the Blast Oxygen Furnace.

Can turn more of the critical unknowns into knowns.

The following equipment has to be monitored during different processes carried in steel manufacturing.

Case Studies

Steel/Motor

Industry 4.0 Solution prevents hammer mill crusher breakdown; saves USD 6,000

Steel/Pump

Wireless, Vibration monitoring sensor predicts misalignment of Cold water Circulating Pump in automotive plant.

Steel/Gearbox

Pocket-sized Vibration monitoring sensor detects and notifies failure of Gearbox; ensures unstoppable production.

Steel/Motor

Vibration monitoring system indicates discrepancies in motor-operations; provides insights for remedial actions.

Steel/Motor

vEdge predicts and prevents AFG Exhaust Fan breakdown in a Steel Plant.

Steel/Fan

Monitoring~125000 data points per second prevents an unexpected fan-breakdown.

Testimonials

We worked carefully with all our equipment that helped us for our living. We maintained them as and when required but still faced production losses and high downtime. Thank you Infinite Uptime for installing the IDE, to monitor gearboxes, motors, bearings and other critical mechanical rotating parts at real-time. We are so happy, we could save our maintenance cost, spares, wear and tear, and the million dollar life of the operator.

Sajo Paul - TVS Motors

Thanks to Infinite Uptime for providing insights into our critical equipment. The plug and play real time monitoring IOT 4.0 solution, avoided unexpected breakdowns and detected large savings capabilities. We are so happy, we could save our maintenance cost, spares, wear and tear, and the million dollar life of the operator.

Mr. Bhide / Mokashi, - Bharat Forge

We installed the IDE on our helical gearbox to get a deeper understanding of the root causes of its failures and prevented them becoming catastrophic. Outstanding product and people make Infinite Uptime an awesome part of the predictive maintenance.

Mr. Shashikant Bhujbal - Tata Metaliks

Thank You very much to everyone for installing the IU devices, integrating them with PLC in optimal time. We are now able to have an insight into tool life monitoring and can schedule predictive maintenance for the machines.
We look forward to continue work with you. We appreciate your dedicated time and efforts invested to achieve our goals.

Mr. Rahul Nalawade - Hirschvogel Components India Ltd.

Used By Leading Industries Around The World

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