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Mill Drive System Chassis Issue

In the critical equipment of the mining sector, the mill, which is monitored online by nine sensors, a fracture in the mill’s foundation was detected through the obtained data. By reinforcing the foundation, the occurrence of more significant issues has been prevented.

Energy Efficieny in Mill Motors

Alignment issues in our mining sector client’s mill motor were detected and resolved through online monitoring. Additionally, by establishing the correlation between mill feeding parameters and vibration data in the drive system, we identified the optimal feed rate, resulting in increased production efficiency.

The Detection

of ID Fan Resonance Issue

During the variable-speed operation of the ID Fan, online monitoring identified resonance at 650 RPM levels, a critical speed. The system was prevented from operating at this speed to eliminate operational risks, ensuring the safety of the equipment.

Detection of Crack Problem in

Rolling Mill Drive System Gearbox

Early from the occurrence of a gear crack in the rolling mill drive system, it was detected and replaced during the initial scheduled downtime.

Rolling Mill Bearing Issue

The bearing issue in the crucial rolling mill bearings, vital to the rolling process, was initially detected through online ultrasound monitoring.

Energy Efficieny in Process Fans

After detecting imbalance and resonance issues in the process fans, simultaneous maintenance was performed on three fans, resolving all issues. This led to an annual energy saving gain of approximately 1 million TL from these three fans.

Early Detection

of Gearbox Bearing Issues in the Mill

Early from the occurrence of a gear crack in the rolling mill drive system, it was detected and replaced during the initial scheduled downtime.

Energy Saving

in Pneumatic Conveying Systems

During the online condition monitoring of the X Pump motor used in the pneumatic conveying system, high vibration levels were detected in the motor’s front bearing. By correlating energy analyzer data, feed parameters, and machine health data, optimal values were obtained, resulting in both increased machine lifespan and nearly 5% energy savings.

Early Detection

of Bearing Failure

in the Compressor Motor

In the critical equipment of the mining sector, the mill, which is monitored online by nine sensors, a fracture in the mill’s foundation was detected through the obtained data. By reinforcing the foundation, the occurrence of more significant issues has been prevented.