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How to improve plant safety

How do you quickly and easily improve plant safety? This was a key question at Acciaierie di Calvisano, a steel works in the Italian province of Brescia that primarily manufactures steel blanks in various qualities as intermediate products that are eventually turned into wire rod or reinforcement steel. A critical aspect of the manufacturing process is the production furnace cooling system. If tensile fractures or small water leaks are not detected early enough in the cooling circuit, this can lead to production outages or system damage – or in the worst case even accidents.

Through fire and flames: The Acciaierie di Calvisano steelworks in Italy produces steel blanks.
Through fire and flames: The Acciaierie di Calvisano steelworks in Italy produces steel blanks.

“Endress+Hauser was selected based on positive references and feedback from the other plants.”

Nicola Mora, plant manager at Acciaierie di Calvisano

With this in mind, Acciaierie di Calvisano wanted to install a safety system, eventually deciding on a leakage detection solution from Endress+Hauser. The system, which is IEC 61511 and EN ISO 13849-1 compliant, is especially precise and reliable. The solution monitors the flow of liquid as it enters and leaves the cooling circuit as well as the temperature in order to compensate for temperature-dependent volume changes. The volume flows of the inlet and outlet lines are continuously compared. Alarms are triggered whenever defined thresholds are exceeded.

“Endress+Hauser was selected based on positive references and feedback from the other plants,” says Nicola Mora, plant manager at Acciaierie di Calvisano, which belongs to the Feralpi Group, one of Europe’s leading steelmakers. Another plus was the system’s ease of use. At start-up, the user is guided through the individual configuration steps using a touchscreen panel. The high expectations at Acciaierie di Calvisano were met. “The cooperation with Endress+Hauser during the project definition and installation phase worked out extremely well. We look forward to continuing the collaboration in the future,” summarizes Nicola Mora.

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