Using a Honeywell wireless solution Nucor has been able to improve its furnace processes.
Nucor Corporation is the largest steel producer in the United States and it is also the nation’s largest recycler. Products include carbon and alloy steel in bars, beams, sheet and plate, girders, steel deck, cold finished steel, steel fasteners and light gauge steel framing. The Nucor steel mill in Tuscaloosa is a hot rolled coil and cut-to-length plate mill that manufacturers carbon and high-strength low alloy steels for structural and pressure vessel applications.
The challenge
Nucor’s Tuscaloosa steel mill was faced with the challenge of improving process operations on one of its furnaces used to melt and recycle steel. To help support an increase in production levels, operations staff searched for a reliable way to measure temperatures around the furnace in areas not previously monitored. The ability to gather this data initiated a furnace upgrade that resulted in a substantial increase in production.
A key requirement was the ability to know instantaneously what the temperatures were in the furnace to prevent production upsets caused if they were to get too high. Another concern was the huge magnetic field that exists around a furnace, the result of running at over 120 000 amps, and the impact this has on transmitter functionality.
The solution
The Nucor mill turned to Honeywell to help overcome the challenge of obtaining accurate and reliable temperature readings on its furnace. The use of wireless technology was seen as the best way to get these readings given the extreme environment. Nucor worked with Honeywell to design a solution that included the placement of wireless transmitters just a few feet from the base of furnace flames. The transmitters were installed on the cooling circuits for the furnace and encased in specially built protective boxes to withstand the extreme heat.
The use of wireless transmitters would allow Nucor to be able to monitor a part of the mill that was previously not accessible; a possibility that motivated an upgrade to increase production. As a result of the positive experience with the wireless solution from Honeywell, Nucor has decided to pursue the installation of wireless devices throughout the entire mill.
The company now sees huge potential for wireless technology, it is looking at extending wireless coverage right across the mill – eventually facilitating the removal of hard wires and significantly improving equipment reliability and overall mill performance. The wireless technology will allow mill staff to collect the data they need from the field more effectively.
Nucor is planning to use wireless technology to increase the amount of preventive maintenance performed by enabling field staff quick access to real-time information such as online maintenance checklists and drawings. Right now, field employees have to print out this maintenance information and walk around with it. With wireless technology in place, the field staff will have everything electronically at their fingertips.
The mill was also able to realise the following benefits:
* Increased production of 15% through furnace upgrade.
* Improved production efficiency through more accurate data.
* Improved safety through greater ability to measure process status.
* Faster, more reliable access to data.
* Improved quality of data to enable better decision making.
* Reduced maintenance requirements compared to wired transmitter alternative.
* Provided foundation to expand wireless efforts across the mill and enhance process reliability.
For more information contact Debbie Rae, Honeywell Southern Africa, +27 (0)11 695 8000, [email protected], www.honeywell.co.za
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