The Condition Monitoring System (CMS) with HAINZL know-how installed by iba AG detected wear damage to a particularly critical part of the hot rolling mill of Salzgitter Flachstahl - a leading European steel manufacturer - already in the first year of operation. By jointly determining the optimum time for repair, significant production downtime costs were saved.
While conventional systems do not detect this damage, the CMS from HAINZL and iba AG, by taking into account process parameters from the production plant, allows early detection and thus precise testing by the vibration experts. "This enabled us to plan our repair measures optimally and to carry them out at the ideal time", says Rebecca Dittkrist, the responsible maintenance engineer at Salzgitter Flachstahl.
The detected damage only showed up in certain operating modes of the plant and was therefore very difficult to detect with conventional vibration measurement. "The built-in monitoring unit differs from commercially available systems in that it communicates directly with the ibaPDA process data recording system and can easily read in the parameters required for correct monitoring," explains Herwig Eichler, Sales Manager for Condition Monitoring at HAINZL.
After the repair was completed, the replaced gearbox was examined in detail and the perfectly chosen replacement time was confirmed by the mechanical experts.
Günter Spreitzhofer - application engineer at iba AG - and Herwig Eichler from HAINZL agree: "This incident is a prime example of a perfect maintenance strategy. If the communication between mechanical maintenance and the vibration experts works well, a CMS can show its strengths and provide maximum benefit for the plant operator".