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 casting machines enhances the transportation of semi-furnished products.
Application of steel in various industries>

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 casting 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.

Monitoring equipment used in Steel Plants>
What is Predictive Maintenance>

Case Studies

Steel/Motor
Steel/Motor

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

Steel/Pump
Steel/Pump

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

Steel/Gearbox
Steel/Gearbox

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

Steel/Motor
Steel/Motor

vEdge notifies a minor bearing excitation on BC-motor; alerts authorities for remedial actions.

Steel/Motor
Steel/Motor

Cutting-edge Vibration Monitoring sensor overcomes unplanned downtime; saves repair and replacement costs.

Steel/Motor
Steel/Motor

IDE vEdge monitoring motor driving the AFG Exhaust Fan predicts and prevents unexpected breakdown in Steel Plant.

Steel/Fan
Steel/Fan

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

Steel/Motor
Steel/Motor

Smart vibration monitoring on a crusher in steel manufacturing plant saved downtime of 4 hours and 95 Thousand USD

Steel/Pump
Steel/Pump

vEdge installed on transfer pump in steel manufacturing plant saved downtime of 4 hours and 70 Thousand USD

Steel/Motor
Steel/Motor

Smart sensor installed on scrubber-motor in steel manufacturing plant saved downtime of 4 hours & 80 Thousand USD

Steel/Fan
Steel/Fan

Smart vEdge installed on AFG exhaust fan saved unplanned downtime of 24 hours and production loss of 750 tons

Testimonials

We have been using the real-time Diagnostic services rendered by Infinite Uptime and obtaining the customized reports along with the spectrum analysis. The System effectively triggers the alarms of impending failure, thus facilitating Predictive Maintenance in the Plant. We are now subscribing to these services in our other plants too.

Mr. E. N Patro, Maintenance Executive - Honda Motorcycle & Scooter India Pvt. Ltd., Karnataka

Infinite Uptime's Vibration Monitoring Solution for Predictive Maintenance has measured high on our expectations of quality, flexibility and in-depth knowledge and has continuously raised the bar. I must say the Diagnostic Services offered at a reasonable cost has increased the reliability of the equipment and reduced the investment in spares-inventory.

Mr. Keshav Prasanna, Senior Vice President - Reliance Industries Limited

We maintained our equipment well but still faced production losses and high downtime. Thank you Infinite Uptime for the real-time Vibration monitoring and Diagnostic services provided to monitor our gearboxes, motors, bearings and pumps. Our Maintenance Team is empowered and can now submit the history of equipment to auditors.

Mr. Sajo Paul, Plant Manager & Development Officer - TVS Motors

As promised by Infinite Uptime, the diagnostic services offered provided valuable data to find the root cause of abnormal behaviour of the helical gearbox. With the insights into the operating equipment, maintenance to prevent the breakdown turned the vibration levels to normal.

Mr. Shahikant Bhujbal, Sr. Manager - Integrated Electrical - Tata Steel Tarapur

We are monitoring our state-of-art machines using Infinite Uptime’s Diagnostic Services. The insights into critical equipment provided in real-time facilitate our maintenance to predictive. The plug and play Vibration monitoring System helps to avoid unexpected downtime and saves cost. The triggering of alarms with notifications on our mobiles has added an instantaneous rectification process increasing machine availability

Imran Hidayath, CEO - Hidayath Group of Industries, UAE

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ST
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usha martin
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