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Metal

METAL

Because the Artesis system is simple to install and requires little user intervention in operation, it combines low start-up costs with the significant benefits of predictive maintenance. Since it doesn’t require any sensor installation on the equipment itself, and it can be installed in non-EX areas, Artesis eMCM is a particularly good solution for inaccessible equipment in the metal industry.

metal sector

SERVICE DETAILS

Typical applications where you can monitor either electrical, mechanical and process conditions:

In the steel production process, this is the first step after receiving the raw material. Monitor excavators and conveyors that make possible the transfer of this material to the next step of the process.

The raw material to produce steel is iron ore. However, this needs to be converted into metallic iron which is the one good for steel production. This is done in what is known as the direct reduction plant. Here, there is important rotating equipment which is essential to complete the conversion process.

Artesis technology monitors process gas compressors, inert gas compressors, the power stack fan and the blowers. The condition monitoring is performed continuously and both mechanically and electrically speaking, helping to ensure there are no inner components failures due to misalignment, imbalance or loop wear (among others), and/or any load fluctuations due to any other external factors such as gas leakage.

One of the most common methods used to produce metal is heating and casting it. In this process, exhaust fans and cooling pumps are critical. Artesis technology allows to continuously monitor their condition remotely from their control panel without the need of reaching the area where very high temperatures create health risks.

The final shape and size of the metal is very important to meet the requirements of the clients. For this, the milling process must take place smoothly and without any problems. Monitor motors and gearboxes, cooling pumps, and preheat furnace fans in bar mills, rod mills and flat mills. Also, monitor non-tension finishing blocks in rod mills, and pickling line fans in flat mills.

OTHER APPLICATIONS

In any metal production facility, there is service equipment that needs to be monitored. Artesis technology allows to monitor this equipment without the need of reaching them to install any kind of sensors. Monitor cooling towers, air compressors and water treatment pumps.

In addition, the metal industry also involves other production methods, such as injection molding and machining. All of them involve moving parts and rotating equipment that need to be monitored, including machine tools and conveying systems. Make sure to use the best monitoring system.

CASE STUDIES

Dirty Filter Problem of a Rolling Mill Fume Fan

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This section elaborates on the details of a plugged filter detection by the Artesis early warning system at a steel manufacturing plant. The equipment monitored by the MCM is a rolling mill fume fan which discharges dust-laden air out of the factory via a filter.

 

 

MCM started to warn the user by giving a “Watch Load” alarm on 15th April.

The examination of the motor current trend shows that the motor current had been gradually decreasing since 17th November. This indicates that the filter blockage started on that date and had been gradually deteriorating to the point where it exceeded the MCM alarm level on 15th April.

That drop off in current shows that the fan had not been extracting the desired volume of air, and hence the ventilation in the plant would be below design levels.
 

metal case 2
metal case 3

 

 

 

The maintenance team attempted to clean the filter with compressed air on 25th April, but it was not fully successful. MCM started giving a “Watch Load” alert again after just one month of operation.

The team changed the filter completely on 20th August. After that, MCM stopped giving alert signals and the motor current reverted to its nominal value.