Enhanced diagnostic capabilities by integration of digital models into a condition monitoring system

Offline simulation is often used by plant builders for the design of metallurgical plants and to ensure that performance expectations are met. Whereas some simulation models cover operations across the complete plant (e.g., throughput calculations), smaller simulation models focus on individual topics such as closed-loop control, vibration behavior and the functionality of single components. The concept of using offline simulation in an online mode for plant operation is not new. Nonetheless, the necessary steps for its application are complicated and timeintensive. These require extensive technological know-how, the buildup of digital models (using, for example, Matlab or Simulink) and the compilation of software that is ready to be used in the automation platform or in a condition monitoring system. As a plant builder with IT competency, Primetals Technologies has mastered this challenge and has defined a concept known as Control Builder. As described in this paper, it allows the reuse of offline digital models or simulations in the condition monitoring system (CMS). These digital models support condition-based maintenance activities by providing deep insight into parameters that cannot be measured directly (soft sensor methods), or by comparing complex operation states with design parameters. An example is the monitoring of hydraulic closed-loop control and the associated cylinder to determine the degenerative status of valves or if internal cylinder leaks are evident. Key performance indicators (KPIs) that are the output of such simulations can be further monitored with the CMS, and they also serve as an additional indicator for root causes.