Customer Success Story
Comprehensive Concept for Converter Monitoring
The concern that a converter might fail unplanned due to bearing damage, is a permanent issue for maintenance at the Kardemir Karabük Demir-Çelik plant in Turkey. To change this, the Turkish steel manufacturer was looking for a predictive monitoring solution for the converters. The company opted for a comprehensive concept. This consists of vibration, sound, distance and strain measurements as well as grease monitoring with GreaseCheck. All sensors are recorded and evaluated with the Prolink CMS. The characteristic values are visualized on site in the control station. Schaeffler experts evaluate the data via remote diagnosis in the German Online Monitoring Center (OMC). In this way, maintenance always has an overview of the condition of the converter and unplanned downtime is prevented.
Savings per avoided downtime: ~ 6 million euros
Benefits
Predictive: always informed about the condition of the machine components via remote maintenance
Easy-to-understand reports and diagrams show changed characteristic values
Plannable maintenance work and fewer unplanned downtimes
Optimized lubricant use and less bearing damage
Challenge
“We know that measurements on the converter bearings and components are difficult to make because the bearings do not turn 360 degrees in the process, but only make a tilting motion. But it is time to find a monitoring solution for the fixed and floating bearing despite measurement conditions that are not easy.“
Kardemir turned to Schaeffler with this request.
Solution
Remote monitoring
With the help of all these measurement procedures and methods listed above, a German team monitors the bearings, housings and shaft in the Online Monitoring Center. The data is transmitted to the center via remote access and processed. The analysis, prediction and optimization by Schaeffler engineers is based on years of experience and certified vibration experts. Any anomalies and need for action are highlighted, and measures are initiated accordingly. The diagrams on the right and below provide initial insights into data analysis via remote diagnosis.
What's Special
Kardemir is absolutely satisfied with the monitoring concept. In the past, Schaeffler also supported the steel manufacturer during the installation of a large bearing. Lubrication consulting was also part of the service and Arcanol LOAD400 has been in use ever since (more on this in the PDF).
Savings
Cost of an unplanned downtime
In 3.5 days
costs arise in the amount of
7,056,000 euros.
These costs were incurred purely as a result of the loss of steel production. Repair, material and personnel costs are not included. The costs are made up as follows: One ton of steel costs around 700 euros. In one hour, 120 tons are produced.
3.5*24*120*700 = 7,056,000 €
Costs for a planned downtime
During a planned downtime, production continues up to 85 %.
7,056,000 €*85% = ~ 6 million €
SAVINGS ~6 MILLION €
Technical Information
Schaeffler sensors record the vibrations on the machine while the ProLink condition monitoring system analyzes the overall vibration condition as well as component-specific vibrations, e.g. in bearings, gears. All parameters and alarm statuses can be transmitted to the control room and the machine control system using OPC UA. The alarm condition can also be transmitted simultaneously to a maintenance planning system via OPC UA. The appropriate maintenance measures can then be initiated from there. High costs incurred by a stoppage can thus be reliably prevented.
The condition of the grease is determined by means of an optical reflection method. For this purpose, the sensor head is immersed in the grease. Monitoring of the grease is carried out on the basis of characteristic changes for automatic condition assessment. A cable provides communication between the sensor head and the electronic evaluation system. With the GreaseCheck, water content, grease deterioration and temperature can be displayed. The GreaseCheck starts measuring the grease condition within about 5 seconds after it has been connected to the power supply.
