alexis noël - iaom-mea.com
TRANSCRIPT
Alexis NoëlProduct Manager Digital Services Milling Solutions
Moving towards predictive maintenance with Temperature &Vibration Management TVM
Challenges in the Operation
3
What are the main challenges of operating a mill?1. Listening to the milling industry, it’s all about delivering to their customers
• The right product
• At the right quality
• At the right quantity
• At the right time
2. With lots of roadblocks on the way
• Breakdowns
• Raw material
• Traceability
• Energy
• People
Challenges in the Operation
4Time
Temperature
Critical area
• Quality/yield impact
• Excessive energyconsumption
• Additional wear
Optimal grinding area
• Highest energy efficiency
• Constant quality
WithoutTVM
WithTVM
*Graph for visualization purposes only
Solution in Maintenance
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It’s an all-included service!
• Temperature monitoring on the whole length of the roll
• Vibration monitoring
• Proprietary algorithms to detect critical operating
conditions
• All running on Bühler Insights platform
What is TVM?
Solution in Maintenance
6
Service FeaturesHow the service can help you
Automated over-temperaturedetection
Detect over-temperature early tomitigate impact on production.
Automated detection oftemperature imbalancesOptimize your grinding withcustomized threshold.
Temperature & vibrationvisualization
Understand your process atthe blink of an eye.
Alarms & notifications
Get alarms when our algorithmsdetect an optimization potential.
Benchmarking & trends
Benchmarking and trendsare detected in your plants.
New featuresreleased continuously
Maintenance support, rolllifetime calculation, etc.
Product winding indication
Detect product winding onyour rolls in real time so youcan act fast.
Features of TVM
Solution in Maintenance
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Look and FeelTemperature and Vibration Management
CASE STUDY
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Can we detect uneven and faster roll wear?
CASE STUDY
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Actions
• Adapt the rolls to an optimal temperature distribution over
the whole length of the roller
Temperature imbalance side-to-sideImpact
• Uneven granulation over roll length
• Uneven roll wear
• Additional energy consumption
• Throughput loss
High temperature difference between left/right side of the rollcompared to the middle of the roll.
– Not recognized by the operator
CASE STUDY
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Temperature imbalance middle-to-sideImpact
• Uneven granulation over roll length
• Uneven roll wear
• Additional energy consumption
• Throughput loss
High temperature difference between left/right side of the rollcompared to the middle of the roll.
– Not recognized by the operator
Nearly 100°Cin the middle
Oct 9 changedfeeding gapActions
• Adapt the rollers to an optimal temperature distribution over
the whole length of the roller
• In this case: feeding gap adjustment
• Alternatively: Roll cambering adjustment
CASE STUDY
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Actions
• Inspect passage for proper product feed and gap alignment
• Inspect the roll pack, including scraper knives
Over-temperature detectionImpact
• Safety risk due to high temperature
• Damage of roll surface / machine
• Uneven granulation over roll length
• Unstable process, dry run possible
• Additional energy consumption
High temperature difference between left/right sideof the roll compared to the middle of the roll.– Not recognized by the operatorTemperature spike on smooth passage
– Not recognized by the operator
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Can we detect winding/cakeing?
High temperature difference between left/right sideof the roll compared to the middle of the roll.– Not recognized by the operator
Temperature spike on smooth passage– Not recognized by the operator
CASE STUDY
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Actions
• Inspect passage for proper product feed and gap alignment
• Inspect the roll pack, including scraper knives
Winding and cakeing indicationImpact
• Safety risk due to high temperature
• Uneven granulation over roll length
• Additional energy consumption
High temperature difference between left/right sideof the roll compared to the middle of the roll.– Not recognized by the operator
Temperature spike on smooth passage– Not recognized by the operator
Over-temperature detection and alarm occurred
– Not recognized by the operator
over-temperaturealarm
CASE STUDY
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Actions
• Correct scraping knife adjustmentHigh temperature difference between left/right sideof the roll compared to the middle of the roll.– Not recognized by the operator
Temperature spike on smooth passage– Not recognized by the operator
Vibration in suspend(automated detection coming soon)
Critical condition invisible to operator standing in front of themachine but detected through the vibration in suspend
Before
After 2 hoursrunning with a
touchingscraping knife
Impact
• Higher energy consumption
• Refurbishment more frequent leading to
higher maintenance cost
Benefits for a MillingOperation
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Assumptions300 tpd mill310 days production$0.10 / kWh75 kWh/t (millsection: 50 kWh/t)$5’000/recall (12.5tflour)Miller wage 15$/hour
Detection of criticaloperation condition
Consistent productquality - low energy
Data transparencyPrecise processknow-how
By detectingcritical operationcondition early, likeover-temperature orhigh imbalances, youcan ensure a safe,reliable and predictableoperation.
With TVM, you canmake sure that yourproduct qualityremains constantwhile minimizingenergy consumption,even remotely.
TVM offers thechance for the miller tounderstand the grindingprocess based on data.This is crucial when itcomes to recipe/joboptimization.
TVM providesdetailed temperature &vibration information tocompare your plantsand production lines.