PREDICTIVE MAINTENANCE WITHADVANCED CONDITION MONITORING
MAXIMIZE MILL UTILIZATION WITH THE
INDUSTRY’S MOST COMPREHENSIVEPREDICTIVE MAINTENANCE SOLUTION

primetals.com

THE MOST TRUSTED PROVIDER
BY MORE THAN 200 STEELROD AND FLAT ROLLINGMILLS AROUND THE WORLDADVANTAGES OF PRIMETALSTECHNOLOGIES CONDITIONMONITORING• Correlates vibration signatures
to equipment design andfunction, providing our customers
with the most expert, practicalvibration analysis services in theindustry• Analyzes and reports on every
measured feature every time,
without exception, to reliably
analyze variable load, variable
speed machinery

MAXIMIZE MILL UTILIZATION
Unscheduled downtime due tomechanical equipment failure canbe costly and time consuming, whilecatastrophic equipment failure can bedevastating to a company’s bottom
line. Complex rotating equipmentwith variable speeds and loads havehundreds of bearings, gears, shafts,seals, couplings, and other component
interfaces and alignments, any ofwhich could face imminent failure ordevelop problems that could lead tosudden failure. These issues are often
undetectable through traditionalpreventive maintenance programsor standard vibration monitoring
methods such as RMS trending andscreening. If an issue is identified
using traditional methods, it is often
discovered too late in the component’s
failure cycle to allow you to react in atimely and cost-effective manner.

experience in the design andproduction of high-speed rolling millequipment and after more than three
decades as a pioneer in the vibration
condition monitoring industry,
Primetals Technologies is uniquely
qualified and capable of connecting
mechanical vibration signatures topotential issues related to equipment
design and function. Primetals
Technologies is the only vibration
analysis service provider offering fullsignature analysis and reporting on
every measured asset, every time,
without exception. Full vibration
signature analysis is the only way toreliably analyze variable load, variable
speed machinery, and is the best
analysis method available to detect
the greatest number of equipment
defect modes at the earliest point intheir development.

Detecting developing issues before
they become catastrophic failures is
one of your most challenging tasks.
Early detection of problems is key
to extending the life cycle of yourcritical equipment and maximizing
your asset utilization. Early andspecific identification of the failingcomponent provides insight into
the operating condition of yourequipment. It also provides direction
to your maintenance activities andbetter use of your fixed resources. To
identify equipment defects in theirearliest stages, your equipment needs
regularly scheduled periodic vibration
signature analysis.

What allows Primetals Technologies
to perform signature analysis 100% of
the time is our proprietary, interactive
and intelligent software, coupledwith our world-class collection ofservice technicians and analysts. Our
analysts have access to the greatest
amount of vibration data, which allows
Primetals Technologies to provide
you with the clearest possible pictureof your equipment’s condition. Our
simple yet highly practical reports
include full current and historicalanalysis summaries, alert severity, andcomprehensive reporting on what
we see. We identify the vibration
source, root causes, and suggest thepreventive or corrective action neededto efficiently and effectively focus
maintenance activities on areas ofgreatest concern.

With more than 125 years of2

Primetals Technologies partners
with our customers. Our key focus
is to keep your equipment runningat maximum production capability.

• Utilizes proprietary software
specifically designed forcomplex, variable load, variable
speed equipment.
• As process focused service
provider, Primetals Technologies
seeks to serve as mosteffective and efficient vibration
analysis provider in the world.

3

COMPREHENSIVE SOLUTIONSUNIQUE SYSTEMS FOR YOUR NEEDS
12365566461

No-Twist mill (NTM)

2Reducing/Sizing mill (RSM)

3

Pinch roll4

Laying head

5Gearbox

6Motor

143

25556

456

7756

7711117Motor

Reducing/Sizing mill (RSM)

8

Monitoring Node

Pinch roll49

Supervising Node44

Laying head10

Customer PLC

5Gearbox

56

Switchbox

1

No-Twist mill (NTM)

243

6

11

Notifications

78Signal fromaccelerometers

Primetals Technologies

9CellularService

10

Customer PC(OPC Client)InternetISP

Primetals PC help desk

Periodic vibration data collection and analysis process architecture

FULL RANGE OF CONDITION MONITORING SOLUTIONSCondition monitoring is the cornerstone discipline of mostPredictive Monitoring (PdM) programs and provides thecritical data for many proactive maintenance decisions.
Primetals Technologies works closely with our customers
to develop risk-based, hybrid, cost-justified vibration
monitoring and analysis solutions. As a full vibration
analysis provider, Primetals Technologies ensures the right
PdM solution is applied to each asset type based on ourcustomer’s industry, operation, and application.
VIBRATION ANALYSIS PROGRAM - HOW IT WORKS• Data collected by customer or Primetals Technologies• Analyzed by Primetals Technologies Predictive Services• Analysis report with findings and recommendations
issued to customer• Training provided to customer• No-cost lease for analyzer

Analog/Digital
Ethernet
Wireless
CellularAnalyst
CellCustomer
CellInternet

Primetals DCMS Server

Dedicated Condition Monitoring System (DCMS) process architecture

PERIODIC VIBRATION DATA COLLECTION AND
ANALYSIS
The Primetals Technologies Periodic Vibration Monitoring
Program is a route-based vibration analysis (VA) solutionthat uses trained customers or Primetals Technologies
personnel for data collection on a periodic basis, often
monthly, coupled with expert analysis and reporting by
Primetals Technologies Predictive Services. This service
is the most cost-effective and flexible option available
and can easily be expanded to monitor more of the millequipment if required. Each measurement point contains
a set of 3 data measurements taken simultaneously, one
in each of the X, Y, and Z axis. This tri-axial data collection
provides for safer and more time efficient data collection as
well as more integrated information for better analysis.
Data collection will be performed based on strategic
measurement points arranged in an efficient “route” along
the equipment to be evaluated, providing optimal coveragefor maximum reliability and minimum down time.

DEDICATED CONDITION MONITORING SYSTEM (DCMS):PRIMETALS TECHNOLOGIES DCMS PROVIDES:

Primetals Technologies engineers developed ComputerizedVibration Analysis (CVA) over 25 years ago. Since thattime, we have led the industry with our unparalleledunderstanding of how variations in speed, load, product,
product temperature, product grade, ambient temperature,operator choices and other factors can influence reliabilityand performance.

• 24/7 equipment monitoring and feedback to system
alarms independent of external networks

Many online dedicated continuous monitoring systems(DMCS) simply do not work as advertised. An effective
DCMS must be ready to act locally and independentlyof external communication networks. Primetals
Technologies, dedicated condition monitoring systems
are built with intelligent monitoring nodes that apply both
adaptive and static rules to real-time condi­tion data toprovide immediate, local alerts. In addition, local nodes
communicate with the Primetals Technologies centralized
web portal to allow its expert staff to analyze real-time data
as it happens.
With real-time condition monitoring of critical equipment ,you can have an unprecedented level of confidence in thereliability of your equipment. You can remain confident
that the Primetals Technologies system will alert you toimmediate or emerging problems with its intelligent, on-site
nodes that, even during internet outages, can alert you toimmediate potential problems.

4Analyst
PC• Expert analysis by the most experienced staff in theindustry• Full analysis of data submitted by the customer or thePrimetals Technologies Predictive Services remotesystem

PRIMETALS TECHNOLOGIES DATAMANAGER
All customers who opt for our periodic vibration
analysis program receive access to our online web
portal: Primetals Technologies DataManager™.
A Computerized Maintenance System (CMMS)
focused on PdM it automatically populates full
asset analysis data into your account. The systemallows for data sorting by date, alert severity,
asset type, etc., and includes charting featuresand collection/presentation of historical data forinternal continuous improvement activities, ISOand QC documentation and corporate reporting.
This exclusive and powerful asset management
tool is included in the cost of the Primetals
Technologies vibration analysis program.

5

COMPREHENSIVE SUPPORTFINDS PROBLEMS THAT OTHERS MISS

Oil analysis

Reconditioning services

Protect your critical mill assets

FULL SERVICE PROVIDER RESPONDS TO ALL YOURMILL MAINTENANCE NEEDSTECHNOLOGY AND EXPERIENCEPRIMETALS TECHNOLOGIES PROCESSIDENTIFIABLE COMPONENT FAILURE MODES

Primetals Technologies, proprietary, interactive andintelligent analysis software, coupled with vast experience
analyzing assets in the steel industry, enables Primetals
Technologies’ experienced vibration analysts to identify
complex problems that screening software packages miss.
Because of the cost and safety implications of one failure,
Primetals Technologies leverages technology to improveanalysis accuracy and speed without jeopardizing ourcustomer’s assets.

Measurement, analysis & reporting on every asset, everytime, without exception:• Combination of long-standing experience of the former
Morgan (USA), Ashlow (United Kingdom) and Pomini(Italy) companies delivers comprehensive life-cycle
support for your mill• Only reliable system to analyze variable load/speedmachinery• Vibration analysis services• Balancing and alignment• Machinery diagnostics• Root cause analysis• Motor testing• Oil analysis• Infrared thermography• Bearing failure analysis• Mechanical-lubrication-process audits• On-site training• Reconditioning services• Engineering support• Spare parts• Full modernization and upgrade projects• More than 125 years of practical machine design andbuild experience allows us to more accurately correlate
vibration data readings to equipment design andfunction, thereby providing more accurate, insightfulanalysis• Largest single collection of senior analysts in the world,
sharing information daily• Services more than 200 mills the U.S. and in 20 countries• Decades of data on similar machines means Primetals
Technologies sees everyone’s problems

Primvib etalsrat
ion Tech
sig nolnat ogi
Maure esj(O or VA
ananlinlyscoeompisr roeti
ute torShs-baocksed(SP)M) pulse
methoRoduvis tineualP
ins Ms anpectio dns

Engineering support• No shortcuts or filtering• Phase analysis performed on every bearing• Avoidable problems identified before they become actualproblems• Fewer missed problems and false alarms

Coupling misalignment/looseness±

±
±

±±






±




Overall or component looseness,soft footGear wear, worn or brokengear teeth



±±



• Analysis not limited by OTS hardware and software

Improper lubrication, worn seals• Ability to tailor service to customer needs

Vane-pass, blade-pass, cavitation


±


±Process-focused service provider with measurable
efficiency objectives:

 Effective application± Application works intermittently or occasionally Inappropriate application, ineffective or N/A

Proprietary software for complex, variable load, variable
speed equipment:• Gearbox calculations completed 50-100x faster• All potential failure modes considered
Primetals Technologies owns, develops and continually
improves its own technology:• Less than 3 day report turnaround• Dangerous and emergency conditions reported
immediately

Loose, worn or misaligned belts
Early roller bearing degradation
Early sleeve bearing degradation
Sudden sleeve bearing failure
Sudden roller bearing failure
Fan, pump, compressor imbalanceElectrical problems

Vibration signature analysis identifies more failure modes sooner• 24/7/365 emergency response available

67

CUSTOMERS WE SERVECOMPLEX MACHINERY EXPERTISE
VOICE OF THE CUSTOMER

High-speed rod rolling Morgan No-Twist MillHot strip millContinuous slab caster

HIGH-SPEED ROD, WIRE, BAR AND SECTION ROLLINGMILL LINES

PLATE AND FLAT STRIP ROLLING MILL AND PROCESSLINES

PLATE AND BILLET CONTINUOUS CASTING LINES• Roughing mills• Plate and flat strip rolling mills• Pre-finishing mills• Pinion stands and gearboxes• No-Twist® and rod sizing mils

• Edgers• Pinch rolls, shears• Pinch rolls, shears• Laying heads• Payoff, take-up equipment• Motors, gearboxes, fans, pumps, blowers• Motors, gearboxes, fans, pumps, blowers• Auxiliary equipment• Auxiliary process equipment“We are very satisfied with your support and very
impressed from accuracy of analysis. We replaced
GA bearing on weekend and found strong
damages on outer race after disassembling thebearing as you can see on attached pictures…”
Gunter Korp - Maintenance Manager,
voestalpine Austria Draht GmbH

• Ladles, turrets• Tundish, oscillator, bending segment• Edgers, shears• Runout tables• Lifting and transport equipment• Motors, gearboxes, fans, pumps, blowers• Auxiliary equipment“We thought you’d appreciate some feedback onanother one of your teams’ successful predictions.
May 4th report highlighted a problem with ourstrand 1 laying head drive, suggesting that weinspect the cylindrical roller bearing, payingparticular attention to the inner race for defects.
As the photos attached show, your diagnosis
was spot-on, inner race damage. This is not thefirst time you’ve accurately diagnosed defective
equipment, which, if ignored, would have caused
us greater trouble.”
Stuart Jones - Planning Engineering,
Celsa Manufacturing (UK)Ltd Rod & Bar Mill Cardiff

89

GLOBAL
NETWORKGLOBAL NETWORK OFCOMPANY OFFICES AND
ENGINEERING, MANUFACTURING
AND SERVICE CENTERS

Nearly 9,000 employees ofPrimetals Technologies are basedin more than 40 company offices,
engineering, workshops and service
centers to provide immediate
support to our customers wheneverOulu

required. With the added backing
from the international office

Stockton-on-Tees
Sheffield Scunthorpe
London Essen Prague Ostrava
ErlangenChristchurch
Krakow
HuizingenŽďár n. S. Kiev
Saarbrücken
Legelshurst Linz Košice
Montbrison
Marnatenetwork of the parent companies
Siemens and Mitsubishi Heavy
Industries, more than 300 groupsites located in some 190 countries
are at the service of our customers.

SussexMilan Cortland Worcester
Benton HarborReading
New London
Huntingdon Valley
Canonsburg
North EastBlytheville
DecaturAlpharetta
Columbus
Huger

Ekaterinburg

Moscow

Dnipropetrowsk

AktobeIstanbul

BeijingMonterrey
Al JubailTokyo
Changzhou
Hiroshima
Shanghai
Wuhan

Delhi
JaipurDubai
Ahmedabad

Seoul

Kaohsiung CityKolkata

MumbaiBangkok
Chennai

Ho Chi Minh City

Jakarta

Ouro Branco
São Paulo

Belo Horizonte
Volta Redonda
Rio de Janeiro

Buenos Aires

London is theheadquarters ofPrimetals Technologies*Approximate values

1011

Primetals Technologies USA LLC
A joint venture of Mitsubishi Heavy Industries and partners

50 Prescott Street
Worcester, MA 01605-2615, USAPhone: +1 508 755-6111
primetals.com
Brochure No.: T10-3-N311-L2-P-V2-EN
Printed in USA© 2020 Primetals Technologies Ltd. All rights reserved
The information (including, e.g., figures and numbers) provided
in this document contains merely general descriptions orcharacteristics of performance based on estimates andassumptions which have not been verified.
It is no representation, does not constitute and/or evidence a
contract or an offer to enter into a contract to any extent and isnot binding upon the parties. Any obligation to provide and/ordemonstrate respective characteristics shall only exist if expresslyagreed in the terms of the contract.
These estimates and assumptions have to be analyzed on a caseby-case basis and might change as a result of further productdevelopment.
Primetals Technologies excludes any liability whatsoever underor in connection with any provided information, estimates andassumptions. The provided information, estimates and assumptions
shall be without prejudice to any possible future offer and/orcontract.
Any use of information provided by Primetals Technologies to therecipient shall be subject to applicable confidentiality obligationsand for the own convenience of and at the sole risk of the recipient.

No-Twist is a registered trademark of
Primetals Technologies USA LLC.
DataManager is a trademark of ITR.