Pickling line
In a steel pickling line, strip runs around the clock through an acid bath and rinse. IoT monitors the condition of the line's field instruments centrally, so faults are spotted early and technicians arrive prepared.
Pickling line at a glance
Most frequent in the projects on this page
Industries
Users in these projects
Verified projects featuring Pickling line
Steel pickling line: monitor field instruments centrally
In the solution example, the roughly 330-metre line is equipped in its chemical section with more than 100 measuring points for flow, level, temperature, pressure, pH and conductivity. More than 13 PLCs and fieldbuses with around 2,500 nodes control the plant. The Endress+Hauser solution automatically scans the instrumentation fieldbus and registers every device. The SFG500 Ethernet/PROFIBUS gateway passes the data via a second, read-only fieldbus channel to an edge device, which sends it to the cloud with TLS encryption. Netilion Analytics creates a representation of each device including readings and warnings, and Netilion Health shows device health together with maintenance information.
The example comes from metal and electronics. In its continuous pickling line, Salzgitter Flachstahl removes the oxide layer from steel before it goes to the cold rolling mill. The line processes around 2,500 tonnes of steel per shift on average and stops only every two weeks for planned maintenance. If it fails, production in the cold rolling mill is at risk. Previously, condition information had to be read on site. The solution is running as a pilot project. In podcast episode #47, Salzgitter and Endress+Hauser present the project.
Podcast episodes featuring Pickling line
Steel pickling lines: frequently asked questions
Which variables are measured on a pickling line?
On Salzgitter Flachstahl's continuous pickling line, more than 100 measuring points record flow, level, temperature, pressure, pH and conductivity. They provide all the variables needed to automate the chemical section of the line. The measuring points are networked via fieldbuses. With the Endress+Hauser solution, device health data is sent to the cloud alongside the readings.
How does IoT make pickling line maintenance easier?
Technicians receive all the information they need before they go out: the device's location, the type of fault and the tools and spare parts required. This is made possible by Endress+Hauser's Netilion, which shows the condition of the instrumentation centrally. Previously, this meant going to the plant and reading values on site. Salzgitter plans to use predictive maintenance for the instrumentation in future.
How does a continuous pickling line work?
In a continuous pickling line, coils are unwound, straightened and welded to the end of the previous strip. The resulting endless strip runs through an acid bath that removes the oxide layer and is then cleaned in a rinse. Finally, the strip edges are trimmed, the strip is oiled and wound back into individual coils. The line at Salzgitter runs 24/7.
Is connecting a pickling line to the cloud secure?
Yes, in the example the solution accesses the data read-only via a second fieldbus channel and does not affect the automation. Transmission is TLS-encrypted, and the overall system has a security architecture designed to prevent cyber attacks. According to podcast episode #47, the Endress+Hauser solution is certified to ISO 27001. The customer's wish to retain sovereignty over its own data was also taken into account.
More assets in “Machinery and Equipment”
Pump
Pump monitoring with IoT records vibration, temperature, pressure and energy consumption of running pumps. Operators detect damage and faults before a pump fails and plan maintenance by condition rather than at fixed intervals.
Compressor
With IoT, compressor maintenance follows actual condition: sensors record current consumption, pressure, temperature and running times. Operators detect creeping damage and unused running time early and cut energy and service costs.
Electric motor
Motor condition monitoring with IoT continuously measures the vibration, temperature and current draw of electric motors. Operators detect imbalance, bearing damage or winding faults early and replace motors based on condition rather than after a failure.
Packaging machine
OEE software automatically records run times, downtime, speed and rejects on packaging machines from the machine signals. Operators see where their lines lose performance, and machine builders use the same data for remote access and digital services.
Refrigeration system
A refrigeration monitoring system makes service plannable: temperatures, refrigerant circuit pressures, compressor status and energy consumption flow into a platform in real time. Operators and service partners detect faults early, avoid unnecessary site visits and reduce excess consumption.
Air conditioning system
Commercial air conditioning systems in offices, retail branches and data centres can be monitored remotely with IoT. Operators see energy consumption, temperatures and faults in one place, detect failing compressors or refrigerant shortages early and plan service visits precisely.
IIoT Use Case user group
What no project tells you
What did the project cost? Which sensor didn't survive in the field? How did you get maintenance on board? 300+ industrial users discuss questions like these with each other every month, openly and without vendors in the room.
Frequent topics in these projects, bring your questions:
- Condition Monitoring
- Corrective maintenance
Online every month
Alternating tech and business focus
Users only
No sales pitches, exchange under NDA
300+ members
OT, IT and IIoT leads from industry
