At Aperam’s Genk site in Belgium, installing an intelligent condition monitoring system (CMS) transformed maintenance operations and improved plant availability. As part of the construction of a new Argon Oxygen Decarburization (AOD) converter line, Aperam selected Primetals Technologies to deliver the Asset Life Expert (ALEX), a cutting-edge digital solution and intelligent digital assistant. Installed in 2024, ALEX now monitors critical assets across the AOD 2 converter and the dedusting plant. This enables predictive maintenance and reduces unplanned downtime.
Challenge
Challenge
Recognizing the importance of maintaining optimal plant performance, Aperam made a CMS an essential requirement when specifying the new AOD 2 line. Aperam aimed to digitalize its maintenance expertise and leverage intelligent systems capable of handling large, complex datasets to identify recurring trends and potential failure modes.
The goal was clear: implement a robust, intelligent condition monitoring solution that could detect anomalies early, avoid false alarms, and provide actionable insights and recommended corrective actions. This would require advanced technology, expert collaboration, continuous system refinement, and a scalable platform that could evolve with the plant’s needs.
Solution
Solution
To ensure long-term performance and continuous optimization, Aperam signed a service contract with Primetals Technologies for the ALEX system. This agreement guarantees priority access to key experts, software updates and upgrades, advanced vibration analysis, and additional services upon request, reinforcing Aperam’s commitment to digitalization and operational excellence.
Primetals Technologies installed ALEX, a modular and scalable digital assistant designed to support reliable plant operation. In March 2024, ALEX was installed alongside the new AOD 2 converter line and began monitoring the condition of over 50 assets across the converter and the dedusting plant.
Aperam Genk's Asset Life Expert (ALEX) System
- Server and client hardware and system software
- Online and route-based vibration monitoring equipment
- Special sensors for monitoring the condition of the converter main bearing, e.g., axial displacement and trunnion pin inclination
- Integration of more than 500 signals and process values from several PLCs
- More than 100 evaluation packages
ALEX provides online monitoring of rotating equipment, including tilting drives, main bearings, ladle transfer cars, ID fans, dampers, and motors. This includes vibration analysis and predictive diagnostics. Additionally, the intelligent acoustic plant monitoring solution from Primetals Technologies is integrated into ALEX. The project involved detailed workshops with experts, software development, in-house testing, on-site commissioning, and remote fine-tuning. Regular review meetings ensure continuous performance optimization.
Service Contract for the ALEX System
Recognizing the importance of expert support, Aperam signed a service contract for ALEX with Primetals Technologies.
The contract includes:
- Priority access to key experts
- Guaranteed response times
- Software updates and upgrades
- Maintenance, troubleshooting, consulting, and training services
- Remote vibration analysis and detailed reporting
- Additional premium services upon request
This proactive approach ensures that ALEX remains up to date, aligns with changing operational and maintenance needs, and continues to provide valuable insights into equipment condition.
Results
Results
The ALEX intelligent condition monitoring solution enabled the early detection of abnormal motor currents in the ladle transfer car at Aperam’s AOD 2 converter line. After evaluating various failure modes, the evaluation package identified point friction and recommended inspecting the rails at a specific location. Aperam confirmed that the rails were skulled. Using ALEX's predictive insights, the maintenance team was able to repair the rails during scheduled maintenance, thus avoiding unplanned downtime and preventing potential damage to critical equipment, such as the ladle transfer car becoming stuck in a hazardous area.
Trend in ALEX showing an early indication of an upcoming issue at the ladle transfer car.
Benefits
- Valuable insights into the condition of plant equipment
- One central solution for monitoring the condition of the AOD 2 converter line
- Reduced workload for Aperam’s maintenance team
- Improved plant availability due to ALEX's predictive maintenance capabilities
- Ability to determine the optimal time to address issues based on ALEX's recommendations
Conclusion
- Customer: Aperam Stainless Belgium NV Genk
- Plant type: AOD 2 converter and dedusting plant
- Software product: Asset Life Expert (ALEX) with service contract
- Scope: More than 50 assets monitored via more than 100 evaluation packages, integrating more than 500 signals and process values
- Result: Early detection of equipment issues, timely maintenance actions, and improved reliability
