Combustion fans are critical for many processes in the metal production industry. Continuous monitoring can prevent failures of fan wheels, belt/sheave/alignment, and bearings.
In metal production, piston pumps supply pressure for a variety of vital operations. Equipment failure can result in safety hazards and expensive downtime.
If a failure occurs at a tension reel—where steel is rolled into a coil at the end of the line—production will grind to a halt. Costly downtime can be minimized with predictive analysis.
Proper control of excess contaminants through dust collection systems is vital to a clean, safe, and efficient manufacturing process. Failures on these dust collection systems can lead to lengthy downtime and incur unnecessary costs.
In metal production, having up-to-date information is critical for decision-making and planning processes, but that information does not generally move to decision-makers quickly enough to leverage its full value.
Unexpected gearbox failures can halt production, cause costly downtime, and pose safety hazards. Maintaining optimal gearbox health through proper monitoring and targeted maintenance maximizes their availability and ensures operational efficiency.
Many mills rely on steam turbines for power, making cooling tower fans crucial assets. Continuous monitoring of these large cooling fans enhances plant efficiency, reduces downtime, and supports effective maintenance practices.
Although cooling towers are a simple asset, their downtime can be detrimental to production efficiency. Loss of a cooling tower results in hours of unnecessary unplanned downtime.
Looper cars are essential for maintaining a continuous process, operating consistently unlike the tension and payoff reels. They play a critical role in a continuous finishing line by ensuring uninterrupted operation. A failure in a looper car can result in a downtime of up to 22 hours.
“KCF offers the opportunity to make data-driven decisions for asset reliability.“
Gareth Taylor
Plant Engineering Manager
CMC
Overhead cranes are the lifeblood of several industries in manufacturing and are of extreme criticality. For many facilities, unplanned downtime on a crane could mean a complete halt of all production, resulting in massive expense.
At first glance, cranes can be intimidating, but as with everything, they can be broken down into simple components to effectively monitor their health. A crane is just a collection of motors, gearboxes, and bearings. The challenge is that these components operate intermittently and almost never make the exact same motion repeatedly. From a monitoring perspective, this has made cranes nearly impossible to extract valuable machine health data.
Using a network of monitoring sensors on your metal production assets, machine health data is transmitted to KCF’s central cloud database. Our vibration sensors are wireless, magnetic, and purpose-built for industrial environments.
Data collected is visualized in actionable machine health information using SMARTdiagnostics. It is customizable by job function so the right member of your team will be informed of long-term recommendations and/or immediately alerted of potential combustion fan or gearbox failures, misalignment of belts/sheaves, or abnormal fault frequencies.
SMARTdiagnostics is the least expensive and easiest way to achieve continuous monitoring on recirculation fans to prevent coupling damage.
Respond to critical operational questions with data-driven decisions. KCF Technologies’ SMARTdiagnostics machine health platform will uncover blind spots in your processes so you can optimize performance and improve employee safety.
Take control of your equipment with holistic asset monitoring and analytics, application-specific insight from engineers, and predictive maintenance support.
Achieve your short and long-term performance goals with our team of engineers experienced in metal production asset health monitoring, root cause analysis, and problem-solving.
We’ll help you mitigate unplanned downtime, reduce maintenance and equipment spending, and increase productivity.
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