Condition monitoring
solutions for steel andother metals industry

The opportunity
Steel and other metals significantly impact our lives. From the vehicles we drive, the buildings we dwell and work in, thebridges we travel over, to the planes we fly in, and many other applications and many other uses, steel and metal are integral
parts of our society. As steel and metal have grown in demand, so has the competitive production landscape. Thus, metaland steel producers strive to improve operational reliability, efficiency and profitability, and remain viable in the competitive
global market.

The challenge
As a result of the changing competitive landscape, metal production’s reliance upon its machinery has never been more
important. Downtime is more expensive and uptime is more valuable. Operators need to maximize asset availability
and output while optimizing processes to reduce maintenance costs. The risk of unplanned downtime and its spiraling
costs must be mitigated and managed proactively. Most importantly, operators need to remain safe—for their families,communities, and the environment.
In steel and metal operations, reactive, time-based maintenance approaches create higher order maintenance costs andincreased risk levels. Thus, maintenance represents an underleveraged opportunity, ripe for operational optimization withproactive maintenance via condition monitoring solutions.

The solution
Proactive maintenance via condition monitoring solutions enables steel and metal operations to use data-driven insights
to manage operations and reach the proper balance point across competing priorities:

OutcomeEnablerMaximize ‘smart’ uptime

Understanding asset health, asset life

Minimize downtime

Preventing unplanned downtime before it occurs

Ensure/enhance safety

Automating machine monitoring to reduce risk

Meet regulatory complianceTracking key metrics

Minimize maintenance costs

Repairs are made at the lowest possible cost by scheduling themduring planned outages and before any damage escalates prior
to full failure

Condition monitoring
Condition monitoring obsoletes reactive, time-based maintenance approaches which are based on calendar intervals
or running hours. Time-based approaches are only valid for about 15% of operational assets, and are poor “predictors” offailure for many assets, resulting in two major issues. First, the majority of assets are getting “maintained” when they don’t
need to be, creating a wasteful overspend in maintenance. Second, time-based approaches do not prevent full failuresand can allow asset issues to escalate to unplanned downtime, causing costs to escalate in kind.

Failure is a process
By contrast, condition monitoring supports a proactive approach, based on the premise that failure is a process, notan event. The extended P-F curve depicts this concept by delineating a distinct span of time between the potential forfailure and functional failure.
Potential for failure is detected via asset health monitoring that measures properties, such as vibration, temperature,efficiency, oil chemistry/particulates, and other physical parameters. Together with tailored algorithms, customized
configurations, and set points, these parameters can identify both root cause failure mechanisms in progress, aswell as irreversible physical damage that has already started. As a result, failure can be averted, sound data-driven
decisions can be made and repairs can be scheduled at the most advantageous times and lowest possible costs.

The Extended P-F Curve
Root cause failure
mechanism in play

Irreversible damage – inception
to failure progression

Actual damage starts

FunctionalHealthGoodP-Proactive

No damageNo degradation

P-Preventive$$$

Damage causing
conditions exists
Damage is present
and is progressing

FailedTime
Monitoring methods that alert on
conditions that lead to damage,before damage actually starts

TimeSource: “Reliability-Centered Maintenance” by John Moubray, 1992.

Monitoring methods
that alert to the fact thatdamage has started
and is progressing

FFailureConsequence-based technology implementation

Cost consequences of unexpected failure

In terms of proactive condition monitoring, all assets are not created equal. Each asset has its own warning duration
before failure. Also, asset failure can result in varying consequences, described below as Important, Essential, andCritical. For critical assets with shorter warning durations, operators monitor their performance with a continuous,
on-line condition monitoring system. For essential assets with a longer warning duration, periodic on-line systems
work well. Lastly, important assets that also have a longer warning duration are typically monitored with walk-aroundportable devices. Matching asset characteristics and impact on production is important for aligning the propercondition monitoring approach and achieving production optimization.

Expected early warning duration

Bently Nevada helps customers get started
In steel and metal manufacturing, unreliable and underperforming assets have enormous consequences. Industry
studies show that the average facility spends approximately 5% of its Replacement Asset Value (RAV) on maintenanceeach year. In comparison, best performers spend 60% less—just 2% of RAV—while enjoying better uptime, efficiency,and profitability. It’s not simply about spending less on maintenance, it’s about working differently—and smarter—toachieve more reliable steel and metal operations.

Bently Nevada solutions for integrated
steel and other metal manufacturing plant
Sinter and coke plants
Waste gas fan
Cooling fans
DeNOx
Combustion air fan
Hot air fan
Dedusting fan
Coke oven fan
Gas booster fan
Coke oven by-productcompressor

Slab and casting
Hot saws

Power island (heat recovery)
Steam turbine/generator
Boiler feed pumps
Cooling tower fansReheat furnace
Fans

Pickling lines

Rolling bridle stands(variable speed/load)
Process pumps
Extraction & drying fans
CranesCold rolling millCold rolling mills(variable speed/load)
Rolling bridle stands(variable speed/load)
Process pumps
Extraction & drying fans
CranesOxygen furnace

Blast furnace

Process fans

Extraction & cooling fansConveyor

Metallurgic drum Vacuum degassing
Arc furnace
Fans

Hot strip mill

Rolling mill stands
Process cooling pumps
Extraction & cooling fans
Saws

Warehouse/storage
CranesAnnealing line

Cold rolling mills(variable speed/load)
Rolling bridle stands (variable speed/load)
Cold saws (if applicable)
Process pumps
Extraction & drying fans
CranesBently Nevada services
Key benefits
Get it right the first time

Implementationservices• Ensure your assets are protected andmonitored when you’re ready to startup• Avoid costly delays and rework• One source to design, plan, manage,and execute the installation• Avoid startup trips due to improper
installation and configuration

Keep your system healthy and optimized

Proactivesupport• Prevent instrumentation-related false trips• Prevent and minimize potential data loss events• Keep up-to-date and compliant with the best
technologies available• Access the expert support you need when youneed it mostActionable insights you can trust

Asset healthand consulting• Understand your asset health to optimize
outage and maintenance planning• Plug in to our global network of machinery
experts with remote monitoring• Professional OEM-agnostic machinery
diagnostics when and where you need it• Custom analytic development and tuning
to pinpoint specific conditions
Stay ahead of evolving cyber threats

Cybersecurity1Trainingand education• Ensure your system is up-to-date and protected
as threats continually evolve• Identify and mitigate cybersecurity risks
to your operation• Keep your system both secure and accessible
with advanced security technologies andarchitectures leveraging data diodes anddatabase replication
Critical skills that amplify yourmachinery management capabilities• Enable your personnel to operate and maintainyour monitoring and protection system• Enable your operation to maximize the valueof your system leveraging expert product andapplication training and knowledge

Up to$1M/day

100%

Avoided costfrom lost
production,
secondaryprocess &equipment
damage80%

Industry widemachineryalarms & eventsare due to
instrumentation

100% ROI

Service work
guarantee
1 year warranty
standard on
all service work

>90%

Typicalreduction in
non-actionable
alarms & events

5-10X

A singlemachine saveoften, resulting
in completemonitoring
contract
payback andmore

Cost reduction
for well-planned
maintenanceoutage vsunplanned
reactive outage29%

243 days

Patchmanagement
can reduce
your attack
surface up
to 29%

Average time
before detectionthat a system iscompromised

400+

Customer courses delivered eachyear in 10 languages and over 45
global locations

1. https://www.us-cert.gov/sites/default/files/documents/Seven%20Steps%20to%20Effectively%20Defend%20Industrial%20Control%20Systems_S508C.pdf

Why partner with Bently Nevada?
A trusted partner with a proventrack record and deep expertise
We are a trusted partner with a proven track record anddeep expertise. For over six decades, our Bently Nevada
experts and offerings have supported the most demanding
proactive maintenance applications across multiple
industries. Our quantified results speak volumes, and wecreate significant benefits for our customers. Even as weprotect and monitor your machinery, we constantly strive torefine and improve our offerings to enable your success.
We design and deliver integrated solutions for all of yourmonitoring needs—including sensors, distributed and rackbased monitors, software, and supporting services—with thefollowing goals:• Increased availability and production• Lowered maintenance costs• Reduced risk in safety, environmental, andasset performance

You can rely on us
For more than 60 years, we’ve been supplying condition
monitoring solutions to machinery-intensive industries. We
also bring over two decades of experience implementing
reliability improvement projects. Customers turn to us fora simple reason: lasting value. Our solutions demonstrate
their worth, day in and day out, and often result in expanded
implementations because of their proven ROI. We combine
the highest quality products and responsive customer support
with a service team that takes the time to understand theuniqueness of your plant, your personnel, and your goals.
Our products can be found in many of the world’s metal
plants. Today, many of those same plants are turning
to Bently Nevada for a more comprehensive solution totheir needs, moving beyond just machinery protection
instrumentation on a few assets to plant-wide strategies andsystems for improved environmental compliance, safety,
asset production, quality and reduced operationand maintenance costs.

Quantifiable, proven results:• 60+ years of innovation in asset protection,
condition monitoring• 240+ international patents, including 150+ U.S. patents• 350+ international patents pending,including 95+ U.S. patents• 8+ million sensor monitoring points• 1,600+ System 1 software users worldwide• Extensive services support provided globally

Please contact us here to speak with a subject
matter expert about your specific needs.

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BHCS33836		(08/2021)

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