Implementing a predictive maintenance program using infrared thermography to track process equipment temperature enables a steel producer to realize many benefits, not only in time and cost savings, but also in increased workplace safety. FLIR Systems is the global leader in the development and delivery of industry-leading predictive maintenance thermography technology. Since infrared systems create images based upon an objects heat signature, using predictive maintenance to routinely scan mechanical and electrical equipment can easily bring potential trouble or “hot spots” to light. Once these issues are detected, repairs and predictive maintenance can be scheduled – averting costly equipment shutdown and production downtime.

FLIR’s high-quality infrared cameras are designed specifically to meet the challenges of setting up a predictive maintenance program within the dust-filled and high heat confines of steel mills. Durable exterior camera casings are completely sealed, creating airtight protection to eliminate the risk of dirt and debris entering the camera and damaging sensitive electrical components. Furthermore, since it is critical during predictive maintenance that the camera consumes as little power as possible to avoid overheating in the high temperature conditions of the mills, FLIR’s cameras are designed to consume very little power and therefore, operate more efficiently and effectively in these extreme conditions for an optimal predictive maintenance program. Using predictive maintenance, US Steel has realized, “Temperature tracking through the use of infrared thermography has proven invaluable within our industry, with more and more predictive maintenance applications being found every day,” states Elizabeth Patterson, United States Steel Corporation. “Before the onset of our predictive maintenance program with FLIR’s infrared cameras, the only way to know if we were going to have a catastrophic failure was to wait until equipment, upper blast furnace assemblies for example, glowed due to imminent failure. Since these assemblies don’t glow until around 1000 degrees F, and safe operating temperature is below 700 degrees, this created a very unsafe workplace.”

Now, US Steel not only has greatly enhanced employee safety, but decreased equipment maintenance costs and downtime through a proactive predictive maintenance thermography program. Catching just one instance of potential failure before it leads to a shutdown can easily save tens of thousands of dollars. Operators can even use thermography to predict the number of times equipment, like iron ladles for instance, can be safely reused before needing to be rebricked – reducing the possibility of molten metal breaking through - damaging surrounding equipment. FLIR Systems also provides accessories, software, service and training - providing a comprehensive predictive maintenance thermography solution for thousands of corporations – worldwide. “We are proud to be such a large part of the predictive maintenance solution for so many companies,” stated David Francoeur, Director of Marketing for FLIR Systems. “Knowing that customers who integrate our systems into their predictive maintenance procedures helps them create a safer and more productive workplace, makes it all worthwhile.” “Since the inception of this predictive maintenance program, we have not catastrophically lost an upper assembly in three years, resulting in increased safety, lower operating costs and increased production.

The savings to the company by preventing just one failure of this magnitude is easily over $100,000. As US Steel continues to expand its predictive maintenance program throughout its manufacturing operations, recently to the coke plant, and in the near future to determine the condition of our hot metal sub ladles, we expect to reap even greater rewards,” explained Patterson.