Endress+Hauser customer magazine

www.endress.com/metals Issue 1/2015

perspectives
04 No empty promise
The Micropilot FMR52 moni-
tors the pouring of pig iron
perspectives Metals 2015
22 All fired up...
... about innovation: Efficient
steel production at JSW Steel

Safety,
environ­mental
­protection
and efficiency
2 perspectives 1/2015

04 Reliable 12 Clean 20 Efficient

The Micropilot FMR52 radar level Aurubis increases safety and reduces Vallourec modernizes its compressed
transmitter reliably monitors the costs by using pH measurement with air system and cuts energy costs in the
pouring of pig iron. digital Memosens technology. long term.

04 No empty promise 12 Clean analysis 18 Danger eliminated

Micropilot FMR52 monitors How Aurubis, based in the ­Belgian Wireless temperature monitor-
the pouring of pig iron town of Olen, is increasing safety ing on the roll neck bearing

07 Aggressive media? No problem! 14 Analysis panel from a single source 20 Efficiency from a single source
Micropilot and Levelflex mea- ArcelorMittal in Bremen benefits Vallourec modernized its com-
sure the acid level at ANDRITZ from Memosens pressed air system

10 Simply reliable 15 Maintenance aids 22 All fired up

Complete overfill protection to Field Xpert offers unique JSW Steel in India is open to new
cut costs and save time functions technologies

11 If cooling leaks... 16 Stable processes

Reliable and robust systems Monitoring screening functions
monitor the cooling circuits for coke classification

Imprint The Endress+Hauser customer

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Editing Jens Hundrieser (Industry Manager, Metals) out more about the current topics under
Editing, production, layout Teresa Scheffler, Sven Heuer (Marketing Communication) discussion.
Cover photos © JSW Steel
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 Metals 3

The key to optimal measurement

technology
Ensuring safety, environmental protection and efficiency in production are
the main challenges faced by the metal industry. Endress+Hauser helps
­companies to meet these challenges by providing its customers with tailored
solutions.
Safety: All sectors strive to make Environmental protection: When it Efficiency: Do more with less. This
their process, systems and facilities as comes to environmental protection, is not only good for the environ-
safe as possible. This is twice impor- few sectors are as closely scrutinized ment but also reduces costs. The
tant in the metal industry, which is and as publicly criticized as the metal “People for Process Automation”
why companies in this sector look for industry. Streamlined energy manage- from Endress+Hauser assist with
partners with a high level of expertise. ment, and reliable and convenient processing raw materials by using ex-
Endress+Hauser can draw on decades monitoring of consumption, can have tremely robust and reliable measuring
of experience in the metal industry and a great impact in this regard. Precise devices which helps prevent system
comprehensive knowledge to support measurements allow the processing, downtimes.
businesses in this sector. transportation and consumption of Their work focuses on lowering
Our certified safety engineers have operating materials such as water, costs in metal production and maxi-
acquired this knowledge through air, gas, electricity and steam to be mizing energy efficiency by having
long-standing partnerships with test- recorded accurately. process experts guide customers every
ing, certification and standardization Manufacturers of steels and non- step of the way – from selecting the
bodies. Endress+Hauser has installed ferrous metals also need to provide optimal instrumentation to finding
over ten million safety devices to date. systems for effectively purifying the right package of services and
The packages offered cover not only wastewater and must comply with lo- solutions.
an extremely wide product portfolio cal environmental legislation pertain-
but also safety-related testing con- ing to the release of emissions.
cepts, services and tailored solutions.

Page 7: Aggressive media – Page 12: Clean analysis in a Page 18: Problem identified –
No problem! harsh environment danger eliminated
© Bastian Hengge – panthermedia
© Galina Andrushko – fotolia
© Hero Images/Strandperle
4 perspectives 1/2015
No empty promises
The Micropilot FMR52 radar level transmitter reliably monitors the pouring
process of pig iron at voestalpine Stahl GmbH.
The temperature of liquid pig iron is 1400°C (2552°F)when
it arrives at the steelworks, pouring out of special wagons
and into ladles under a special extraction system, creating
a huge amount of dust and smoke. Measuring their level
from a height of 15 meters presents a huge metrological
challenge given these disruptive influences and the reflec-
tive metal surface. After some initial skepticism on the part
of the manufacturer, however, this challenge was success-
fully overcome using the Micropilot FMR52
radar level trans­mitter from Endress+Hauser, providing
great precision, high speed and maximum availability.
Steel is one of the most important industrial materials
and is used in all sectors – from structural and civil engi-
neering to tool/machinery manufacturing and precision
engineering. There are over 2,500 different varieties of
steel and around 1.6 billion tons are produced each year
worldwide. Steel has been produced in Linz since 1941 and
has been manufactured using the “Linz-Donawitz” (LD)
basic oxygen steel-making process, which was invented in
the town in 1952. voestalpine Stahl GmbH opened its LD-3
steelworks in 1973; it was one of the most modern facili-
ties in the world at that time and still is today. The pig iron
is created in its blast furnace and is refined using an oxygen
supply to remove unwanted by-products such as sulfur,
phosphorus and carbon.
Pouring at 1400°C (2552°F) The liquid pig iron travels
from the blast furnace to the steelworks by rail in "torpedo
wagons" with a capacity of 300 tons. Once there, the metal,
which is approximately 1400°C (2552°F) hot, is poured into
Micropilot FMR52
Measuring in aggressive media
The new Micropilot FMR52
generation, a 26-GHz free-
space radar level transmitter,
can even be used at tempera-
tures of up to 200 °C (392 °F).
www.endress.com/fmr52
140-ton-capacity charging ladles and then taken by crane
to the LD converter. The level needs to be monitored closely
during the pouring process – which lasts no longer than
four minutes because the dosing affects the process and
thereby the quality of the product – overfilling would have
disastrous results.
In the past, the employee responsible would observe
the pouring process through a glass window in a nearby
booth, from where they also controlled the procedure. The
objective of the planned renovation work was to move the
worker from this position, which juts out and is isolated
and hot, and into the center of the action, providing them
with a more pleasant working environment – while obtain-
ing valid level values which can then be saved and further
processed in electronic systems.
Hostile environment “There are a number of level trans-
mitters available,” plant technician Stefan Aichhorn states.
“We began looking for one that could not only withstand
the hostile environment but also provide reliably accurate
readings despite the disruptive reflections from the liquid
metal, dust, and the increasing amounts of conductive
steam – while requiring no maintenance or cleaning, if at
all possible.” This task is not made any easier for the device
by the fact that it needs to measure the level in the charg-
ing ladle at a height of 15 meters (49.2 ft) and that there
is a grille between the installation site and the measuring
level.
Difficult conditions Stefan Aichhorn was pleased to
discover that five out of the seven measurement technol-
ogy manufacturers he consulted believed that his problem
could be solved and wanted to provide him with suitable
equipment. Endress+Hauser was the only company to have
doubts about the reliability of radar measurement given
the adverse ambient conditions.
One by one, all the other suppliers were forced to retract
their promises and admit that their equipment was not
suitable for the job. “With two pieces of equipment, the
selected measuring technique turned out to be unsuitable
for the hot steel surface; another one failed because the
sensor horn became dirty extremely quickly; and another
one was reduced to a maximum of 10% availability by the
high measuring frequency (78 GHz),” says Stefan Aichhorn.
“As none of the equipment we had sampled was even close
to satisfactory and all five suppliers had backed out, the en-
tire project looked as though it was going to fall through.”

The PTFE coating on the Micropilot FMR52 radar level transmitter prevents deposits from building up on the antenna and eliminates the need
for cleaning.
There is no such thing as can’t be done Stefan ­Aichhorn
did not want to allow that to happen. “We are fortunate
to have a great degree of freedom in systems engineer-
ing which means that we are able to experiment until we
find a solution,” he says. Mr. Aichhorn is an experienced
technician who joined the company 13 years ago after
completing his vocational training at the Higher Techni-
cal Institute in Leonding – and he knows from experience
that Endress+Hauser's equipment is of high quality and
very robust. In spring 2013, he fitted a 26-GHz Micropi-
lot FMR245 radar level transmitter (stocked as a spare
part) which is suitable for temperatures of up to +150°C
(302°F). “By that time, our expectations were pretty low,
given our experiences with the other suppliers. They were,
however, exceeded by a long way,” explains the measure-
ment and control technician happily, delighted that his
persistent striving to achieve the project goal had paid
off. “Although the large amount of smoke generated kept
causing the measuring system to fail for a few seconds at a
time, we were able to measure the level of the pig iron ladle
Metals 5
© voestalpine Stefan Aichhorn
accurately, reliably and quickly using the 26-GHz radar
method – and with around 90% availability right from the
very beginning.”
Almost 100% availability “Performance like that is very
promising, but it is not enough,” says Herbert Springer,
Filling Level Product Manager at Endress+Hauser. It was
he who suggested switching to the Micropilot FMR52 gen-
eration. This 26-GHz free-space radar level transmitter can
even be used at temperatures of up to 200°C (392°F). Pri-
marily designed for applications that use aggressive media,
it has an antenna that is fitted flush with the flange and
completely filled with chemically resistant PTFE (polytetra-
fluoroethylene – often known by the brand name Teflon).
Even when used at voestalpine, the material robustness of
this chemically resistant plastic reliably prevents of dust
and smoke particles from forming. This not only keeps it
free from dirt, which would have a negative effect on the
measurement, but also eliminates the need for cleaning
and performing maintenance on the installation.
6 perspectives 1/2015

voestalpine AG is an
international Austrian
manufacturer of steel-based
technologies and industrial
goods. It is headquartered in
Linz and has 500 subsidiaries
and offices in over 50 countries,
which employ around 46,400
members of staff worldwide.
voestalpine Stahl GmbH is the
parent company of voestalpine
Steel Division. Its key area of
expertise is manufacturing steel

© voestalpine Stefan Aichhorn

in its fully integrated steelworks
in Linz. In the business year
2012/13, the Steel Division
employed 10,676 members of
staff and generated a turnover
of € 3921.7 ($ 4251.5).

The liquid pig iron is transported from the blast furnace to the steelworks in pipe or torpedo
cars. From there, it flows as a liquid at a temperature of 1500 °C (2732 °F) into underground
charging ladles. Their level is monitored at a height of 15 meters (49,2 ft) using a Micropilot
FMR52 radar level transmitter.

“Installing the FMR52 in fall 2013 increased the availability of the measuring
system to 99.6%.”
Stefan Aichhorn, Steelworks Plant Engineering, voestalpine Stahl GmbH

As the equipment is intermittently placed under
extreme thermal loads, Endress+Hauser recommended
the stainless-steel version. This meets the requirements
of heavy industry and, thanks to its heat conducting
properties, provides the electronics with more effective
protection against brief periods of intense heat.
This latest generation of Endress+Hauser devices uses
multi-echo tracking – i.e. analysis of echo signals using an
echo signal curve – which plays a big part in ensuring safety
and reliability when taking level measurements in these
tough environments. This function checks and monitors
all other echo signals in addition to the level signal, which
enables the level signal to be recorded even when there
are “hidden” sources of interference in the signal path.
This means that fittings such as the grille and the constant
fluctuations in the volume of the pig iron flow are no longer
a concern. “Thanks to the installation of the FMR52 in fall
2013, which we were able to put into operation unaided
thanks to the straightforward, guided way in which it is op-
erated, the availability of the measuring system increased
to 99.6% without implementing any further measures,”
confirms Stefan Aichhorn. “Since the device is operated
without signal attenuation or filters, it is just as fast as the
measuring signal of the scales.”
Reliable and straightforward The reliability and easy
commissioning of the FMR52 radar generation unit are
also appreciated by the maintenance team – thanks to
the fact that the entire product family is fitted with the
same electronics. This allows any electrician to replace
parts without needing specialist knowledge of the system,
as the electronics take the “personal data” of the current
device from the non-volatile HistoROM parameter memory
built into the housing. “Not forgetting the experts on the
Endress+Hauser Helpdesk,” adds Stefan Aichhorn, “who,
in special cases, can even extend the company’s applica-
tion support during commissioning right up to the on-site
measuring point.”
Rising to this metrological challenge with high precision,
high speed and maximum availability in spite of adverse
operating conditions has enabled plant technicians at
voestalpine Stahl GmbH to improve not only their working
environment in the facility but also the quality of their data.
Engineer Peter Kemptner,
x-technik AUTOMATION (trade journal)

Aggressive media? No problem!
The Micropilot FMR52 and Levelflex FMP52 radar level transmitters are
­acid-resistant and increase process reliability.
ANDRITZ METALS develops and plans complete production
lines for manufacturing and further processing of high-grade
hot and cold-rolled metal strips (carbon steel, stainless steel,
aluminum). From its site in Vienna, it makes the process
technology range for lines for treating cold strips with
pickling acid along with systems for acid recovery. The global
market leader achieves maximum process reliability by us-
ing the Micropilot FMR52 and Levelflex FMP52 radar level
transmitters, which are ideally suited for use with aggressive
media, to monitor the level in the numerous acid tanks.
Creating high-grade sheets requires more than just
rolling the metal out flat: Before leaving the works in the
form of rolls or sheets, it needs to be pickled, heat-treated,
coated and then brought into shape. This entire process
chain – including the rolling mills themselves, which are
extended by acid recovery after pickling and the first stages
in further processing, such as pressing and dishing – takes
place in the large-scale plants custom designed and built by
ANDRITZ METALS for its customers. Part of the ANDRITZ
GROUP – one of the world’s leading plant construction
companies, employing 23,700 members of staff at over
© ANDRITZ METALS
ANDRITZ METALS manufactures pickling lines for rolled products, which form a substantial part of cold-strip mills.
Metals 7
220 sites and generating a total turnover of more than €5.7
billion (2013) – the METALS business unit comprises of
14 companies and is the global market leader in complete
production lines for manufacturing and further processing
hot and cold strips made from stainless steel, carbon steel
and non-ferrous metals, particularly for use in the automo-
tive industry.
Viennese expertise in process engineering “Our job
always includes process automation and instrumentation
because this is the only way we can achieve the level of
process reliability for which ANDRITZ is renowned,” says
engineer Herbert Bock. “Capacity permitting, we manufac-
ture the entire automation system ourselves, including the
conveyor belt.” A specialist in automation, instrumentation
and electrical equipment, Bock has been working since
1983 at the ANDRITZ AG site in Vienna, which contri-
butes the process-related parts of the strip production lines.
On a stainless-steel pickling line, this includes not only
a neolyte/sulfuric acid pre-pickler but also the mixed-acid
pickling section with a mixture of hydrofluoric acid and
The ANDRITZ GROUP is one of the world’s lead-
ing suppliers of systems, equipment and services
for hydroelectric power plants, the chemical pulp and
paper industry, the metalworking industry and the steel
industry. It also provides solid-liquid separation solu-
tions for both municipal and industrial use. ANDRITZ
METALS manufactures pickling lines for rolled products,
which form a substantial part of cold-strip mills.
8 perspectives 1/2015
“Since we switched to Endress+Hauser radar level transmitters
a couple of years ago, we have stopped having to deal with prob-
lems of process reliability.”
Engineer Herbert Bock, Automation, Instrumentation and Electrical Equipment, ANDRITZ AG
nitric acid, which guarantees that the metal is chemically
pure. The process mixes the acid mixture with metal, which
makes it lose its acidity.
Turning waste into profit “Up until the 1990s, we had to
dispose of the mixture of used acids as special waste, which
is expensive,” explains Herbert Bock. “That was before
ANDRITZ METALS developed PYROMARS (Pyrolytical
Mixed Acid Recovery System), the first effective technique
for regenerating mixed acids.” This uses evaporation and
recondensation to separate the acid-metal mixture in
a roasting furnace.
“As ANDRITZ provides technologies both for pickling and
for regeneration, they can be adapted to complement each
other perfectly. The result is that the plant as a whole is
significantly more efficient and consumes considerably less
energy than similar facilities.”
Contactless acid level measurement A combined pickling
and regeneration plant contains a total of 20 to 35 storage
and circulation tanks. Due to the aggressiveness of the acid
mixture inside, ANDRITZ immediately started looking for
a way to measure the level of each and every one of these
Recovery: PYROMARS systems from ANDRITZ
METALS enable up to 100% of the mixed acids
used to be recovered.
© ANDRITZ METALS
tanks without contact. “In the first couple of years, we
experimented with ultrasonic devices,” remembers Herbert
Bock.
These experiments produced less than ideal results, and
so the team soon switched to trying out radar measuring
techniques. At that time, the majority of these devices still
used rod antennae and frequencies of around 7 MHz until
switching to the 26-GHz models available today which
brought about significant improvements in measurement
and analysis quality. Despite this, the level measurement
results obtained from these machines were not always sat-
isfactory. Herbert Bock states: “This is partly due to the fact
that automation and instrumentation have to be specially
adapted to the respective process conditions. This means
that the installation position and configuration of the sen-
sors need to be adapted to suit the various different tank
designs – there is a significant difference between a round
and horizontal tank with a domed torispherical head and a
vertical tank with a conical bottom.”
This requires a great deal of detailed knowledge, as the
tank geometry and any potential foam generation can
cause reflections which then cause a false measurement
result.
© ANDRITZ METALS
The Micropilot FMR52 (free-space) and Levelflex FMP52 (guided)
radar level transmitters on every tank ensure maximum process
reliability.

“Thanks to their complete PTFE insulation, the Micropilot
FMR52 and the Levelflex FMP52 offer great advantages when
used with aggressive liquids.”
Clemens Zehetner, Head of Marketing, Endress+Hauser GmbH (Austria)
Doing things well The control technology used in plant
automation is usually chosen by the customer on the
basis of how easy it is to maintain. Level transmitters are
normally integrated using a 4 to 20 mA current loop with
HART signal; they can also be connected using PROFIBUS,
although this is less common. Prudent planning is essential
here too, as interference from heavy drive technology must
not be allowed to make readings inaccurate – nor should
vibrations prevent the numerous items of equipment from
functioning correctly.
ANDRITZ has long since recouped the money he spent
on its pickling and regeneration plants in the early years.
“Since we switched to Endress+Hauser radar level transmit-
ters a couple of years ago, we’ve stopped having to deal
with problems like that,” confirms Herbert Bock. The main
product in operation is the Micropilot FMR52 free-space
radar level transmitter, which has a flush-mounted horn
antenna completely filled with PTFE (polytetrafluoroethyl-
ene – often known by the brand name Teflon). The mate-
rial resistance of this chemically resistant plastic makes this
specialist device ideally suited to applications that use ag-
gressive media and its availability increases in the process.
The Levelflex FMP52 guided radar lever transmitter, which
© ANDRITZ METALS
In addition to the roasting furnace for separating acids and metal,
PYROMARS systems feature numerous acid tanks with varying
geometries.
Metals 9
is used in processes where foam may be generated, features
complete PTFE insulation as well.
“We also benefit from outstanding user support directly
from the manufacturer,” adds Herbert Bock. This support is
not only welcome within Vienna when planning and devel-
oping plants: Given that ANDRITZ METALS conveyor belts
and acid recovery systems have to operate with maximum
availability and process reliability in the most distant cor-
ners of the world for several decades, the global presence
of Endress+Hauser with regional offices and a replacement
parts delivery service that is guaranteed to be quick, are
important criteria for subsequent maintenance. As the old
saying goes: “If something’s worth doing, it’s worth doing
well.” This is what customers of ANDRITZ METALS do
when it comes to their plants and their level transmitters.
Engineer Peter Kemptner,
x-technik AUTOMATION (trade journal)
www.endress.com/level
© ANDRITZ METALS
Endress+Hauser equipment is proving to be a good investment in the
mixed-acid pickling facility as well.
10 perspectives 1/2015
Simply reliable
A complete overfill protection solution from Endress+Hauser enables plant
operators in the metal industry to cut costs and save time.
The German Water Resources Act (WHG – Wasserhaush-
altsgesetz) stipulates that containers for water-polluting
liquids must be protected against overfilling. These monitor
the level and issue an alarm well before the maximum
permitted level is reached. This makes the WHG one of the
most important laws used to protect the environment and
ensure safety during operation. The way in which compa-
nies apply and comply with this law is monitored by institu-
tions such as the TÜV (Technical Inspection Authority).
From designing through to commissioning – and beyond
with seminars and services – Endress+Hauser offers a
complete solution that meets all relevant requirements of
both the metal industry and the law. The quickest way of
carrying out recurrent tests is testing at the touch of a but-
ton with the relative equipment installed. The latest system
from Endress+Hauser enables operators to forgo recurrent
testing for up to 12 years.
Layout and analyses At the start of implementing a
complete solution, a thorough situation analysis and needs
analysis are carried out in accordance with WHG require-
ments. An automation and equipment concept is created,
along with a budget and a schedule. The response height
and the layout of the field devices are discussed in detail
with the help of design software.
Complete solution for overfill protection
Computer
Cabinet
Overfill protection
Acknowledgment
button
Alarm signaling in
the field
Level sensor
alarm
Pump
Valve
Equipment and engineering The experts at
Endress+Hauser select the ideal instrumentation from a
wide range of WHG-certified field devices. They would,
for example, choose the Micropilot FMR52 to measure
the level of aggressive media. This stage covers complete
EMSR (electrical and industrial process control) planning,
the creation of wiring diagrams, and the setting up of data
exchange in accordance with NAMUR (standardisation as-
sociation for measurement and control in chemical indus-
tries) NE 100; cabinets and signaling equipment are built
and tested to ensure that they have been made profession-
ally and comply with standards.
Installation and commissioning WHG field devices,
cables and measurement and control instruments are
then supplied and installed by the stipulated deadlines.
Endress+Hauser takes charge of supervising building,
monitoring assembly, installing the electrical systems and
installing measurement and control equipment. Upon
completion of switching contact inspection, functional test-
ing and any required optimization, the complete solution
is put into operation and test logs are created.
Seminars and services Operators and maintenance staff
are given project-specific training. Endress+Hauser offers
specialist seminars and workshops on key themes such as
plant safety, explosion protection, safety integrity levels
(SIL) and overfill protection in accordance with the WHG.
Endress+Hauser is a complete provider of process auto-
mation solutions, and is happy to provide tailored services
such as drawing up servicing agreements, managing
maintenance, creating documentation for TÜV (Technical
Inspection Authority) inspection or conducting recurrent
tests. This means that plant operators can save themselves
a lot of time and the hassle of training their own staff
– which in turn means that they can focus on their core
competences.
The advantages The complete overfill protection solution
at a glance:
• Reliable overfill protection helps protect the environment
• Efficient process workflows, everything from a single
source: Saves a considerable amount of time and money
• Operators help to meet their obligations and the legal
requirements set out in the WHG
Sven Heuer,
Marketing Manager, Communication

Leakage detection system
Independent
leakage detection
system
If cooling water leaks...
Reliable, robust and precise systems monitor the cooling circuits and prevent
dangerous changes to the process from being effected.
Faults in critical cooling water circuits
are no joke: They can change pro-
cesses and affect the smelter furnace.
This has a range of consequences,
not least of which is jeopardizing
the safety of personnel. Therefore,
it is extremely important to be able
to reliably control the cooling circuit.
An Endress+Hauser package of robust
instrumentation solutions helps plant
operators ensure that they will al-
ways meet safety standards such
as IEC 61511 and EN ISO 13849-1
(SIL) reliably.
Leakage detection The same basic
principles always apply for leakage
detection, regardless of the type of
PROFIBUS DP
Safety contactor
cooling circuit: The flow rate at the
inlet and the outlet of a cooling circuit
is measured using suitable electro-
magnetic or ultrasonic flowmeters.
Temperature values also need to be
recorded. Precise monitoring solu-
tions from Endress+Hauser measure
the flow rate and the temperature
separately to ensure maximum ac-
curacy. The measuring devices used
to do this are the Proline Promag 50P
and (with DC electric arc or reduction
furnaces) and the Prosonic Flow 92F.
The temperature is measured by the
TS111 StrongSens.
If there is a leak in the cooling cir-
cuit, the system will detect that there
is a difference between the inflow and
the outflow and generate an alarm.
Metals 11
PLC
Process
Advantages of the solution
• Robust Proline Promag 50P
flowmeters
• Prosonic Flow 92F ultrasonic trans-
ducer in two-wire technology
• TS111 StrongSens thin-film tem-
perature measuring set for optimal
thermal contact with short response
time, high stability and vibration
resistance
Sven Heuer,
Marketing Manager, Communication
www.endress.com/lds
12 perspectives 1/2015

Clean analysis in harsh environment

Thanks to pH measurement using digital Memosens technology, the Aurubis
plant in the Belgian municipality of Olen increased safety and reduced costs.

Nowadays, companies involved in
metal production have to pay close
attention to the area of environmental
management – and not only due to
image concerns. The Aurubis plant in
Olen in Belgium is no exception: Most
of the processes taking place here
relate to pyrometallurgy, and as such,
the company has invested heavily in
air emissions monitoring and waste-
water treatment. As far back as 1998,
the factory in Flanders started to
prepare its systems for ISO 14001.
Today, all environmental management
programs at Aurubis in Olen are certi-
fied. The outcome has been successful,
with measures for optimizing energy
efficiency and waste gas treatment
resulting in significant improvements
in the area of emissions.
Changes in the field of process
water neutralization have also proved
to be instrumental here. Measuring
points in three reactors as well as in
the outlet filter record pH values un-
der difficult conditions. The resulting
cost savings are not inconsiderable.
Significant amounts of time were
being spent on maintenance work,
and measuring instruments required
frequent calibration. Faults were a
common occurrence, and wiring need-
ed to be replaced on an ongoing basis
due to humidity. In brief, the required
stability was completely lacking from
the measurement process. A solution
was needed that was “clean”.
That solution was found in the form
of Memosens from Endress+Hauser.
This is a technology that has revo-
lutionized the safety of data trans-
missions: The measuring signal is
converted to a digital signal in the
sensor and transferred inductively to
the transmitter via a non-contact con-
nection. This ensures that measure-
ments are completely immune to any
problems associated with moisture,
corrosion or salt bridges. Galvanic
insulation of the sensor and transmit-
ter means that interference signals
are safely ruled out. In the event of
an interruption to the signal flow, the
digital transmission of the measured
value triggers an error message. The
plant operator can take the necessary
action, and the reliability and avail-
ability of the measuring point are
optimized.
Digital instead of analog Digital
communication logging in the induc-
tive plug-in head of the sensor is,
however, just one of the differences
compared to analog instruments.
Below is an overview of the benefits of
Memosens technology:
• Up to 30% longer operating life
thanks to sensor regeneration in
the laboratory
• Reduced process downtime due to
convenient precalibration in the
laboratory
• Sensor maintenance can be sched-
uled, allowing for accurate process
management
• Improved system management due
to predictive maintenance
• Ease of use thanks to a bayonet lock
in the plug-in head
• Easy replacement of the precali-
brated sensor

Calibration and documentation

Memosens sensors (right) are
adjusted easily and accurately
in a laboratory using Memo-
base Plus. The sensor and
calibration data are stored in
the sensor and in a data-
base on a PC. The database
contains a complete history of
all Memosens sensors used in the system, including buffer
management and user administration. All data can be ac-
cessed easily via a PC connected to the network. If required,
sensor and calibration reports and safety-related activity
sequences for audit trails can be printed out easily at any
time.

www.endress.com/memosens
 Metals 13

• Plug & Play: Automatic detection/ comparability of process and lab mea- Memobase Plus records all data
identification of each sensor surements. Memobase Plus supports relating to the sensor and measur-
the entire range of functions, includ- ing point and makes it conveniently
Easing the burden on staff The op- ing measurement, calibration and available at the click of a mouse. This
erators in Olen benefit from features documentation. With this software, allows users to increase the quality
such as preventive maintenance. the sensor- and process-specific data of their processes on a sustainable
Outages have become a rare occur- in the Memosens sensor can be used ­basis. Who said environmental man-
rence, and highly accurate and stable to develop maintenance strategies. agement was not easy!
pH measurement enables a reduction These include, for example, preventive
in the consumption and addition of maintenance to prolong the operating Sven Heuer,
Marketing Manager, Communication
sodium hydroxide. The resulting cost life of the sensor by up to 30% with
savings are not inconsiderable. Lab regular cleaning and calibration.
calibrations take pressure off staff,
as employees no longer need to be out
in the field in all weathers.
These benefits were enough to
convince those responsible at ­Aurubis,
and the operators also had a very
­positive experience of the four-chan-
nel Liquiline transmitters. Analog
pH sensors remain installed in places
where pH analysis is possible under
less difficult conditions, and these are
calibrated on a weekly basis. However,
in the foreseeable future, digitization
will become the norm here too.

Maintenance strategies By choos- Highly accurate pH measurement using Positive experiences: Liquiline transducer.
ing Memobase Plus, Aurubis looked Memosens.
forward to benefits not least from the

Aurubis is the world’s leading integrated

copper producer and largest recycler of
copper. With approximately 6,500 employees,
the company produces more than 1 million
tonnes of copper cathode annually. It employs
approximately 500 employees at its facility
in Olen (Flanders) producing anodes, cathodes,
continuous cast rod and specialty wire.
14 perspectives 1/2015
Analysis panel from a single source
ArcelorMittal in Bremen enjoys the benefits of Memosens technology:
Reduced process downtime with improved system management.
3.5 million tons of crude steel are
produced each year on the ArcelorMit-
tal Bremen GmbH premises on the
lower course of the River Weser. The
company is a modern integrated steel
works plant, which means that all the
different plants – from those for creat-
ing pig iron to those for processing
sheet metal – are located on the same
premises. Its varied portfolio of flat-
steel products ranges from hot- and
cold-rolled coils to surface-treated flat
products, and the close proximity of
everything on site makes for optimal
process workflows.
ArcelorMittal Bremen saw the need
to optimize the analysis of condensate
use. The company therefore started
looking for a partner able to offer and
put into action an analysis panel pack-
age – a modular panel – first hand.
Their criteria were proven expertise in
analytical measurement technology
and sensors designed with the Memo-
sens digital communication protocol.
The analysis panel offers numerous advantages.
Longer operating life The Memosens
concept is the optimal solution for
ensuring greater reliability and ease of
operation in analytical measurement
technology. The advantages it offers
plant operators are numerous:
• Sensors can be regenerated to make
their operating life up to 30% longer
• Fewer process downtimes: The sen-
sors are calibrated in the laboratory
before use
• Accurate process management
thanks to the ability to plan sensor
maintenance in advance
• Improved plant management: Pre-
dictive maintenance as an integral
part of sensor technology
The company required the parameters
of inlet temperature (for protection),
pH, conductivity, turbidity and hard-
ness to be ordered in a freely combin-
able and space-saving way. The fixed
panel size enables complete racks to
be quickly and easily adapted to suit
customer requirements.
Memosens ensures that availability remains high in the process.
Less downtimes The panel is con-
nected to the sample flow. The sample
flow for the individual measure-
ments can be adjusted to the relative
parameters and disconnected to carry
out maintenance on the sensors. This
allows the measuring systems to be
maintained easily on site – which in
turn keeps the downtimes necessary
for taking measurements short. Last
but not least, the panel enables opera-
tors to decide whether the condensate
can be fed in directly as feed water or
whether it requires further treatment.
In combination with Endress+Hauser
Memosens technology and the use of
precalibrated sensors, ArcelorMittal
in Bremen benefits from maximum
availability and reliability in measure-
ment technology.
Jens Hundrieser,
Industry Manager, Metals
www.endress.com/memosens
 Metals 15

Mobile maintenance aids

The new Field Xpert boasts a number of unique functions and is the ideal tool
for maintenance staff to take on their rounds in industrial plants.

Accurate documentation of the information collected dur-

ing maintenance rounds in a plant provides a solid basis
for optimizing the maintenance processes. Why not benefit
from the technical capabilities in process automation made
available to us by smartphones and tablets? This is why
Endress+Hauser now offers a new hand-held mobile solu-
tion: The Field Xpert.
Operators working in various sectors of the industry are
already using this tool. The benefits of the Field Xpert are
especially benefical in large-scale plants, such as those
in the metal industry. Demand for this convenient solu-
tion has been growing due to the increasing requirements
placed on testing and accurate documentation of plant
components. Field Xpert helps operators optimize many of
their tasks in a quick and easy way. The flexible tool can,
for example, be used to wirelessly configure and document
4 to 20 mA HART or FOUNDATION fieldbus devices during
commissioning or while carrying out diagnostics. Using
Field Xpert and a Bluetooth HART Modem, the HART signal The Field Xpert demonstrates its strengths in the field on the device.
of the field device to be documented is connected directly
on-site or in the control room. The handheld device works
with equipment made by any manufacturer and a version auto­matically – which is quite a accomplishment consider-
suited to explosive atmospheres is available, which can be ing that over 1,300 HART device drivers are being con-
used in Zone 1 environments without restrictions. stantly updated.

Unique functions Users have been impressed by features
that are not found in numerous PC-based device operating
tools. One such feature allows a set of parameters saved on
the field device to be called up in order to compare it with
a set of parameters on another device of the same type.
When replacing part of the electronic system or an entire
device, the same parameters are applied.
A simple yet effective alternative for having the most
important parameters of a specific device to hand is the
ability to assign settings to a favorites folder. This reduces
time needed when operating devices that often contain
hundreds of parameters, only a tiny fraction of which is
actually of interest to the user. The Field Xpert would not
be an expert in the field if it were not capable of operat-
ing everything that speaks HART or FF, regardless of
the manufacturer. This discipline requires the very latest
driver technology. The Field Xpert comes supplied with all
manufacturer-independent HCF (HART Communication
Foundation) drivers. Driver handling is important: The
hand-held device is linked to a docking station to carry out
document synchronization via a Windows PC. This not only
charges the battery but also compares its driver database
with the HCF database at the same time. If more re-
cent device drivers are available, these are synchronized
RFID ready RFID (Radio Frequency IDentification) tech-
nology offers convenient techniques for clearly identifying
measuring points and other system components, both now
and in the future. The option exists to fit the Field Xpert
with a suitable reading/writing head which, for example,
reads industry-standard passive RFID chips or writes the
data that is relevant to the user on them. In combination
with the right maintenance software package, this enables
a maintenance round accompanied by an “asset” inspec-
tion to be accurately documented electronically: Remove
the maintenance ticket, inspect the relevant components
on site and identify them using the Field Xpert. Carry out
the tests required on the asset in accordance with the
stipulated test processes and synchronize the resulting data
centrally using the master Maintenance Management Sys-
tem. It is precisely for this kind of maintenance work that
the new mobile tool offers substantial benefits in terms of
creating more accurate documentation.
Stefan Gampp,
Marketing Manager, Solutions
www.endress.com/sfx370
16 perspectives 1/2015
Stable processes, higher quality
ArcelorMittal Bremen GmbH monitors the screening functions for coke
classification using the Solimotion FTR20 flow indicator for bulk solids.
A blast furnace cannot be operated smoothly without using
additives. These not only help bind the unwanted elements
of the ore in the slag, but they also lower the melting tem-
perature of the iron. The coke that falls in layers during the
process is an important energy source and reducing agent.
Coke comes in different granulations, such as coarse
coke, which has a grain size of more than 20 mm (0,78
inch) or more than 40 mm (1,57 inch), depending on the
process and the furnace used. The coke is stored in silos
and enters the blast furnace via transport systems. The
screening process and the monitoring of the screening pro-
cess play key roles in coke classification. The screens work
in different ways depending on the design of the system
and the properties of the material. It is important to make
sure that the screen – ArcelorMittal Bremen uses a flip-
flow screen – does not become clogged.
The screening process Depending on the consignment,
the coke used has different levels of moisture owing to the
fact that it is cooled with water after coking. A conveyor
belt transports the coke to the screen in varying quanti-
ties. The material falls onto the “blank” surface of the
screen (to prevent material from becoming trapped) and
ArcelorMittal Bremen GmbH has been produc-
ing steel since 1957 and is a subsidiary of the
world’s largest steel manufacturer ArcelorMittal,
which is headquartered in Luxembourg. The company
is the second largest industrial employer in the region
and produces around 3.5 million tons of crude steel
with its technically advanced facilities.
is transported further across the screen using vibrations.
The fine material, known as coke breeze, falls through the
holes in the screen while the coarse material remains on
the surface. The coarse material falls into the culm coke silo
once the screening process has finished.
The goals of optimizing screen inspection at ­ArcelorMittal
Bremen were to improve process stability and screening
quality. It must be possible to detect the following fault
states for this process:
• Overloading (fine material in coarse material/
overflowing)
• Defective screen surface: Coarse material falling through
the holes in the screen
• Screen surface becoming clogged (trapped material),
resulting in fine material remaining mixed in with the
coarse material
• Coke delivered is moist and sticks together, causing coke
breeze to end up in the furnace
ArcelorMittal Bremen and Endress+Hauser tackled these
problems using Solimotion bulk solids motion detectors.
Following a successful initial field test, a second FTR20 was
permanently installed on a Solimotion FTR20 with current
output in order to monitor the entire filtering system.
© ArcelorMittal
 Metals 17

Überwachung
Monitoring of der
the Siebfunktion
screen function
A B Section A:
Schnitt A: Section B:
Schnitt B:
Solimotion FTR20 Solimotion FTR20
Typischer Trenn-
Typical separation Screen
Sieb
(Sensor 2) (Sensor 1)
prozess
process im Siebscreen
in the
Dust
Staub-
protection
schutz

Mechanische
Mechanical
Entkopplung
separation

Accurate calculations This combination of two Solimotion Easy commissioning

FTR20 enables the company to accurately determine the
quantity of coke falling through the filter in comparison
with the quantity of coke placed on the conveyor belt. If the
process is working correctly, the FTR20 in the maximum
material flow area will display a higher value than the
second FTR20, which is positioned in the minimum mate-
rial flow area. If the screen is clogged – at the front, for
example – the analogue value of the first Solimotion FTR20
will decrease considerably. If the screen is clogged at the
rear, the output value of the second measurement will
decrease as well. The measuring points also detect whether
the screen is overloaded or the coke is moist. If the output
signal of the relative FTR20 increases significantly, this
indicates that the surface of the screen is defective.
Decoupled installation The strong vibrations on the
screen pose a challenge in terms of installation. A solu-
tion with a sight glass cannot be used in this instance as, if
installed in a fixed position in front of it, the FTR20 would
also detect the movements of the window, which would
then make the trend display inaccurate. Fixed installation
would also be inadvisable due to the vibrations produced.
Specialists opted for a special process adapter with a vibra-
tion damper (bellow) thats separates the Solimotion FTR20
from the process while concluding the process at the same
time. The first FTR20 was temporarily positioned in front of
an opening to the process. However, this resulted in a large
amount of dust being formed outside of the process. The in-
stallation with the process adapter and bellow, by contrast,
proved successful in operation.
This motion detector solution with analog output enabled
the company to achieve the level of process stability it was
looking for and monitor its screens reliably. This in turn has
allowed ArcelorMittal Bremen GmbH to improve its produc-
tion quality and significantly reduce its costs.
The Solimotion FTR20 flow indicator
for bulk solids motion detector
(pictured: The process adap-
ter with bellow acting as a
vibration damper used at
ArcelorMittal Bremen) uses
microwaves to work contact-
lessly with a frequency of 24 GHz
and a transmission power of less than
100 mW. Particles are detected using microwaves, which are
transmitted and then reflected by the bulk solids in motion.
Solimotion measures the strength of this reflected energy,
the frequency of which has been changed (Doppler effect),
and uses it to create the display value. The FTR20 works like
a binary switch and detects two states: “Material movement”
and “No material movement”. The optional analog 4 to
20 mA output signal enables continuous detection of changes
in the mass flow as well, meaning that changes in conditions
are identified immediately. A range of up to 20 meters can be
achieved if the radiation path is unobstructed (depending on
the reflection properties of the bulk solid).
The system is commissioned for the first time by running
an automatic comparison function at the touch of a single
button. The option to make comparisons manually offers
flexibility by allowing the application to be adapted to meet
individual requirements using configurable functions. In ad-
dition to adjustable hysteresis, switching delay and damp-
ing functions, the detection range can be adjusted so that
even bulk solids with a very low relative permittivity (e.g.
polystyrene foam) can be reliably detected.

André von Cossel,

Seller in the Field Sales Force

www.endress.com/�r20
Solimotion FTR20 used by ArcelorMittal Bremen.
18 perspectives 1/2015

Problem identified – danger

eliminated
Wireless temperature monitoring on the roll neck bearing: Simply retrofitting
WirelessHART technology can save a lot of trouble.

Every company wants its processes to
run as efficiently as possible. Incidents
that cause downtimes in a system can
result not only in costly repairs but
also in considerable losses. Although
preventative measures can help to
reduce the likelihood of systems fail-
ing, they are often far from the ideal
solution.
Predictive action is better: ­Suitable
characteristic quantities enable ac-
curate information to be obtained so
that necessary maintenance can be
planned more efficiently. Ilsenburger
Grobblech GmbH optimized its system
availability by measuring the tempera-
tures on the roll neck bearings and us-
ing simple WirelessHART tech­nology
to transfer the results.
The four-high rolling stand at Ilsen-
burger Grobblech comprises two work
rolls, which reshape the steel slabs
directly, and two back-up rolls, which
transfer the pressure to the work rolls.
The four-high stand has a maximum
rolling force of 80,000 kilonewtons.
These are extreme requirements
that also put a strain on the roll neck
bearings.
however, make it difficult to wire up
the temperature sensors securely.
Wireless solution TR13 resistance
thermometers with a weld-in thermo­
well and replaceable insert are used to
measure the temperature. These have
already proven their worth a thousand
times over in challenging industrial
applications. Each temperature sensor
is equipped with an adapter that en-
ables data to be transmitted wirelessly
using the WirelessHART standard.
Fitting the adapter directly to
the temperature sensor would have
been inadvisable here because of the
limited amount of space and number
of wireless connections. Therefore,
the adapter was installed remotely
and connected to the temperature
Monitoring of storage temperatures
sensor with a short cable. The adapter
not only facilitates data transmis-
sion, but also powers the connected
device via the battery integrated in the
adapter.
Each adapter works as a transmitter
and a receiver, making it possible to
transfer data up to the WirelessHART
gateway even if there is no direct
wireless connection. The Wireless-
HART gateway forms the central
access point to the WirelessHART net-
work and manages communications.
The gateway automatically assigns
the communication paths in the net-
work as well as the times for the data
packets. This means that new measur-
ing points, for example, are very easy
to retrofit.

Monitoring the plain bearings 

The roll neck bearings, known as
Morgoil® plain bearings, are located
on the operating side and the drive
side of the upper and lower back-up
rolls. An oil circuit, the temperature
of which is monitored at the inlet and
WirelessHART
the outlet, provides the necessary Memograph
adapter
lubrication. Temperature RSG40 SPS
An increase in the temperature sensor TR13
differential indicates a higher degree
WirelessHART
of friction inside the bearings, which gateway
may result in damage. The ambient Modbus RTU Alarm signal
conditions around the rolling stand,
 Metals 19

“Using this wireless solution from Endress+Hauser, we were able to retrofit our
system with a lot less work than we had expected. We are confident that we
now have an optimum overview of the condition of our roll neck bearings and
that we can maintain the system and replace bearings according to schedule,
regardless of any faults.”
Jörg Wahnfried, Head of Measurement and Control Technology, Ilsenburger Grobblech GmbH

From the gateway via Modbus RTU,

the measured values are displayed Ilsenburger Grobblech GmbH is a sub-
on a Memograph RSG40 graphic sidiary of Salzgitter AG. It produces
display recorder. From there, they can more than 800,000 tons of heavy plate
also be transferred to downstream annually. Plates ranging from 5 to 125 mm (0,19 to 4,92 inch)in
control systems. The eight measured thickness are rolled from steel slabs supplied by its sister company,
values are monitored permanently. If Salzgitter Flachstahl AG, for use in a range of applications e.g. heavy
a set threshold is exceeded, an alarm plate for the central railway station in Berlin or shipbuilding steel for
is triggered via the control system. the “Maersk Beaumont” container ship (almost 300 meters (984,3
ft) long). Up to 17,000 plates a month are shipped to customers all
Predictive maintenance This solu- around the world.
tion ensures that, with little instal-
lation and commissioning work,
any impending damage to the plain
bearings is detected and mainte-
nance is carried out in a predictive
manner. This type of plain bearing is
extremely costly, both in itself and in
terms of its installation, its removal,
and the loss of production incurred in
the event of faults.

Arne Kröger,
Marketing Manager, Solutions

www.endress.com/wirelesshart
© Dariusz Kuzminski – Panthermedia
20 perspectives 1/2015
Efficiency from a single source
Vallourec collaborated with systemplan to modernize the compressed air sys-
tem in one of its works in Düsseldorf and is now reaping long-term benefits.
Using the rolling process to manu-
facture seamless steel pipes requires
a relatively large amount of energy.
Manufacturers that produce steel
piping therefore continuously moni-
tor their energy use and are con-
stantly optimizing the stages of the
process – and Vallourec Deutschland
GmbH, which operates three produc-
tion plants in Düsseldorf and one in
Mülheim an der Ruhr, is no exception.
The structures of the steel works
have been developed over a long
period of time and the demands made
on processes and production are
constantly changing – these changes
then increase the demands placed on
auxiliary circuits such as coolant and
compressed air.
Compressed air, in particular, is
one of the most expensive forms of
energy, which is why it is important
to use efficiently. While completing
Energy Solutions - Compressed air application
t-mass 150
t-mass
150
Cerabar M
PMP51
EngyVolt
RV12 or RV15
Water
separator
Compressor Air receiver
essential plant expansion work at its
site in Düsseldorf-Rath, Vallourec took
the opportunity to completely mod-
ernize its compressed air generation
and distribution systems.
On-site specialists Vallourec chose
systemplan GmbH, a company of the
Endress+Hauser Group, to help them
carry out this project. The target
concept comprised renovating and
optimizing the compressed air genera-
tion system with the aim of being able
to recover heat from the process.
The objective was to tailor the gen-
eration system to meet requirements,
process compressed air in a cost-
effective way and create redundancies.
They also agreed to strike a balance
between achieving high efficiency
and availability and using energy
economically.
Memograph M
t-mass 65
Data
recording
Cerabar T Cerabar T Cerabar T
PMP131 PMP131 PMP131
Filter Filter
Dryer
Situation analysis and measure-
ments The basic conditions in
Düsseldorf-Rath had changed over
the years. The considerable age of the
compressed air stations meant that
they were no longer able to demon-
strate the required level of operational
safety. The compressed air was only
partially dried, which reduced its qual-
ity and caused parts of the compressed
air system to suffer increased wear.
The company now uses more
energy-efficient drying solutions, such
as HOC (Heat of Compression) dryers,
in place of the electric dryers that it
used to operate. The redundancy situ-
ation also required urgent improve-
ment, as the existing compressed air
generation system would not have had
sufficient redundancy available if one
of the compressors had failed at peak
times.
Cerabar T
PMP131
© Vallourec
Steel production is energy intensive.

© Vallourec
As an emergency measure during
the transition time, it was there-
fore decided to install a systemplan
GmbH First Aid rental compressor
in order to guarantee the supply of
compressed air in case of need. Situ-
ation analysis included specifically
analyzing the data obtained from
preexisting volume flow measur-
ing instruments. Vallourec also used
the Endress+Hauser t-mass 150 to
measure the mass flow. The aim was
to obtain reliable measured data that
could provide a solid basis for plan-
ning the layout of the compressors.
Seeing the measures through The
integrated approach from systemplan
GmbH covered a range of media and
opened up huge savings potential.
Once the customer had given the
target concept the go-head, system-
plan was commissioned to create a
bill of quantities based on this concept
and carry out a market research sur-
vey. The next steps were to compare
the different bidders and help the
company select the supplier that was
best suited to the job. After the con-
tract had been awarded, systemplan
GmbH took charge of supervising
construction and conducting metro-
logical testing to check whether the
newly installed compressed air gen-
eration system delivered the perfor-
mance characteristics that had been
promised.
Using new compressors and absorp-
tion dryers, designed to meet demand,
offered significant improvements
in the specific power consumption
of compressed air generation and
processing. The new compressors with
heat recovery have noticeably reduced
the strain on the existing heating sys-
tem of the building, allowing around
300 kW of (thermal) energy to be
removed in the form of hot water.
33% reduction in energy costs 
The key result of the project has been
the improvements in specific power
consumption, which has decreased
from 0.163 to 0.110 kWh/Nm³ –
this is equivalent to reducing energy
costs by 33%. When converted to a
delivery volume of 23.7 million Nm³
a year, this results in annual sav-
ings of 1.2 million kWh or €150,000
($190,000). The use of heat recovery
Metals 21
The Vallourec Group produces
seamless hot-rolled steel pipes
for the energy markets and other
industrial applications. The German
contingent of the Group (Vallourec
Deutschland GmbH) operates
four production lines – three in
Düsseldorf and one in Mülheim an
der Ruhr – and employs around
4200 staff. Vallourec Deutschland
GmbH is a wholly owned subsidiary
of Vallourec, one of the largest
public limited companies in France.
With around 23,000 employees,
the Vallourec Group is the world’s
leading provider of premium pipe
solutions and recorded a turnover
of approximately €5.7 billion in
2014.
reduces costs by approximately
€35,000 ($44,000) a year.
Collaborating with systemplan
GmbH brought Vallourec Deutschland
GmbH numerous long-term benefits:
The amount of time required to
complete the project was considerably
reduced. The Düsseldorf-based plant
operator had a strong partner by its
side in the form of systemplan GmbH,
who operated as a complete provider
in seeing the project through from
start to finish, from conception to
implementation. Thanks to metrologi-
cal testing of the promised perfor-
mance characteristics, the company
can now be confident that it has an
efficient compressed air station that
is fit for the future.
Volker Rink,
Sales Engineer
www.endress.com/
compressed-air-e�ciency
22 perspectives 1/2015
All fired up about innovation
Nowhere in India is steel produced so efficiently than at the JSW Steel plant in
Vijayanagar. Behind this achievement is the ambition to be a little better each
day – and an extraordinary openness for new technologies.
There is no lack of superlatives to de-
scribe the giant steel plant in southern
India. Vijayanagar is home to the sub-
continent’s two largest blast furnaces.
Never before has the Corex steelmak-
ing process been implemented on such
a large scale. And it’s the country’s
first integrated steel mill with an an-
nual output of 10 million tons. How-
ever, most important for owner JSW
Steel is the fact that no other steel
plant in India is more efficient.
Vijayanagar produces 800 metric
tons of steel per employee each year.
“It was a lot of small steps that helped
us achieve this leading position,”
explains Harish K Nair. The Associ-
ate Vice President and member of the
plant’s management team identifies
automation as one of the keys to
efficiency. “While much depends on
the skills and experience of our em-
ployees, we have achieved enormous
© JSW Steel
efficiency gains by automating manual
processes.”
The site’s first hot rolling mill for
producing strip steel went into opera-
tion in 1997. Since then, the entire
steel manufacturing and forging pro-
cess has been implemented step-by-
step across the 40-square-kilometer
site. Today, the fully integrated iron
and steel works consist of more than
30 individual plants, including four
conventional blast furnaces and two
Corex facilities for producing molten
iron, two power plants and four coke
ovens, three continuous casting sys-
tems, two hot strip mills and two cold
rolling mills.
Broad product palette The plant,
which is located in the rural Torana-
gallu region, has long been manu-
facturing a wide range of different
products. “The share of high-quality
Iron giant JSW Steel is India’s
leading integrated steel
producer with a current capac-
ity of 14.3 million tons per year.
In fiscal year 2013/2014, the
company counted net sales of 7.9
billion US dollars and a workforce
of more than 11,000. With an an-
nual output of 10 million tons, the
Vijayanagar plant in Toranagallu in
the state of Karnataka is one of the
largest steel mills in the world. JSW
Steel has ambitious growth objec-
tives. Within ten years, the steel
producer wants to ramp up produc-
tion to 40 million tons a year. The
company is part of the JSW Group.
This conglomerate, one the largest
private companies on the subconti-
nent, is active in the areas of steel,
energy, infrastructure, logistics,
cement and IT.
steel is meanwhile more than 40 per-
cent,” reports Harish K Nair. Custom-
ers include the automotive industry
among others. “We can quickly shift
our production depending on the mar-
ket situation however.” Up to one-fifth
of the production is exported.
Harish K Nair has watched the plant
grow and thrive. “Part of our strategy
is to be at the very forefront of new
developments,” emphasizes the man-
ager. This is why the management
team in Vijayanagar relies not only on
the more than 100-year-old mature
blast furnace process, but also on the
Corex process that was introduced
less than three decades ago. Because
this smelting reduction process works
without coke, it is considered a highly
economical and environmentally-
friendly approach.
State-of-the-art process measure-
ment technologies are at the core
 Metals 23

© JSW Steel

© JSW Steel
Reliable measurement technology: the integrated steelworks in Large-scale flow measurement: the smelting process gases flow
Vijayanagar boasts more than 12,000 Endress+Hauser instruments. through gigantic Venturi pipes.

“We have equipped more than 12,000 measurement points. You will find here
virtually the entire Endress+Hauser portfolio.”
Prakash Gangadharan, Sales Engineer at Endress+Hauser India

of many innovative solutions. “Our
installed base in Vijayanagar is enor-
mous,” says Prakash Gangadharan.
The Endress+Hauser Sales Engineer
knows the plant in and out. “We have
equipped more than 12,000 measure-
ment points. Flow, level, pressure,
temperature, analysis, system com-
ponents – you will find here virtually
the entire Endress+Hauser portfolio.”
As the sales engineer shared, many
of the measurement tasks have their
own story. “More than one-third of
the measurement points are engi-
neered solutions,” reports Prakash
Gangadharan. One example is the
measurement of the Corex process
gases, which are recovered nearly 100
percent by the power plants. The gas
flow is measured using the differential
pressure principle. Conical constric-
tions transform the pipes, which can
measure up to 2.8 m (11.02 inch),
into gigantic Venturi tubes.
Leakage detection systems that
monitor the cooling of the lances are
critical to ensuring process and equip-
ment safety. The lances are used to
inject oxygen into the molten metal to
turn iron ore into steel. “Our flowme-
ters monitor the cooling water flow.
When the values suddenly change, the
leakage detection system triggers an
alarm,” explains the sales engineer.
Technology pioneer It is solutions
such as these that affect production
efficiency and quality at JSW Steel.
The processes at the Vijayanagar plant
are continually improved and revised.
“That is why an ongoing dialogue with
our suppliers is so important,” empha-
sizes Harish K Nair. “We want to know
what is new on the market and apply
new technology.”
Measuring the level of the ladles
that transfer the molten iron present-
ed another challenge for the engi-
neers. The liquid metal has a tempera-
ture of 1,350°C (2,462°F). To protect
the radar sensor’s antenna, nitrogen
is blown directly into the surrounding
area. “The temperature in the area
of the sensor is still 100°C (212°F),”
says Prakash Gangadharan, making it
clear that the process conditions are
nonetheless harsh.
Robust instrumentation Heat, dust,
vibration… “In a steelwork, the mea-
surement instruments must be able to
withstand a lot,” says Harish K Nair.
He understands that wear and tear or
material fatigue can lead to an outage.
“But with the electronics in the mea-
surement instruments, we expect ab-
solute reliability.” His experience with
Endress+Hauser has been positive.
“We have been using Endress+Hauser
measurement technology from the
start and none of the instruments
have ever failed.”
Most important for the operations
manager is support from the supplier.
“When a problem arises, we need a
quick solution,” says Harish K Nair.
That means sales engineer Prakash
Gangadharan is also facing logistical
challenges. The plant is located in the
so-called iron belt between Bellary
und Hospet, nearly one travel day
from Bengaluru, the next major city.
The urgent delivery of Coriolis
flowmeters by Endress+Hauser was
therefore all the more impressive.
“We need reliable measurements
of the mass flow to precisely con-
trol the injection of gas in the Corex
process,” explains Harish K Nair.
Endress+Hauser delivered the instru-
ments that were produced in India
within one week. “That was really
outstanding service!”
Martin Raab,
Media spokesperson Endress+Hauser Group
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