Perceptiv™ Service Alerts Help Reduce Mill Torque Spikes

Application

Steel Mill

Description of problem

A Michigan-based steel manufacturing facility installed a new reducer on one of its roughing mills due to damage within the existing reducer. The mill was concerned that the loads transmitted through the gear reducer may have exceeded design limits. In order to prevent damage to the new reducer, they desired to know what the mill’s typical operating loads are.

Description of problem

A Michigan-based steel manufacturing facility installed a new reducer on one of its roughing mills due to damage within the existing reducer. The mill was concerned that the loads transmitted through the gear reducer may have exceeded design limits. In order to prevent damage to the new reducer, they desired to know what the mill’s typical operating loads are. Perceptiv Services Solution: Regal® associates from the Perceptiv installed Kop-Flex® torque monitoring equipment on Roughing Mill 1 and Roughing Mill 5 to monitor live torque as the mill operates. The collected data reflects transient (occurring very fast) torque spikes during production. These transient torque spikes may only last milliseconds but can cause damage to equipment and components downstream in the drive train. Additionally, after the new gearbox was installed, the customer requested that the mill continue to be monitored for a period of time to confirm loading of the new gearbox does not exceed the torque rating of the roughing mill.

Estimated Benefit

The data provided to the customer shows the magnitude of any torque spikes that the mill equipment is subjected to during the production of the steel slabs. With this data, the customer can be better equipped to make any necessary changes either to the process or equipment to lower the possibility of future damage or failures leading to production downtime.

 

 

 

Perceptiv Services Available

Diagnostics

Tools and techniques used to measure the performance of a customer’s application (determine the root cause of performance problems, measure the effects of product changes, establish a product / application base and confirm expected product performance

  • Troubleshooting
  • Validation before and after performance measurements
  • Asset Management Program
  • R&D / Testing


Education

Technical mechanical power transmission product, process and application training for customers

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Design

Assist customers in reviewing application needs and help select the appropriate products

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  • Product licensing
  • Custom product design
  • Certified layouts
  • BOM: Complete list of required products and accessories


Installation

Installation and startup of mechanical power transmission products

  • Can provide a project manager, general contractor or consultant for the installation as well as additional labor


Monitoring

Experts will teach customers how to use or install monitoring equipment to measure the health of products. Helps the customer transition from reactive maintenance to a predictive maintenance program

  • Electrical power consumption monitoring
  • Mechanical torque / power monitoring
  • Thermal imaging monitoring
  • Ultrasonic measurement monitoring


Repair

Repair, rebuild or refurbish damaged or worn power transmission products

  • Repaired / refurbished products come with a factory warranty at a fraction of the price of a new product

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