Ensuring production capability through modernization and security updates: a success story
Industrial companies face the challenge of keeping their heat treatment systems up to date despite limited investment and capacity expansions. Older systems must meet today's requirements for production safety, product quality and personal safety. This can be achieved through targeted modernization and safety updates.
Successful modernization of a pusher type furnace - built in 1981
One example of a successful modernization by AICHELIN Service GmbH is a pusher type furnace from 1981. In this project, major conversions were combined to minimize downtimes.
The system comprises the following individual trades:
Loading
Pre-wash
2-lane high-temperature oven
Oil bath
Aftercooling basin
Post-washing machine
Tempering furnace
Discharge
Switchgear
Modernization vs. new investment
The customer decided to modernize the system as its safety no longer met current requirements and unplanned downtimes were becoming more frequent. Due to the technical condition of the system, the maintenance intervals had to be greatly reduced. Much of the documentation had been lost over the years and there was a lack of knowledge passed on about the plant. The outdated plant documentation and inadequate previous conversions exacerbated these problems. A modernization was more economical than a new investment, as the plant delivered convincing process results and quality.
Conclusion: Modernization as a recipe for success
The successful modernization of this third-party system impressively demonstrates AICHELIN Service's many years of expertise. Targeted adjustments and innovative solutions have significantly improved both the efficiency and safety of the plant. The measures - from relining and mechanical adjustments to advanced safety and control technology as well as optimized gas technology - make a decisive contribution to increasing production capacities and ensuring long-term production capability. The customer also benefits from a significant improvement in operational safety, optimized maintenance intervals, comprehensive new documentation and a greater technical understanding.
Modernization process
The modernization process consists of successive steps, which were carried out as follows:
Schematic creation: Inspection of the drawings and creation of circuit diagrams through reverse engineering. Schematics were then created and compared with the cold system.
Risk assessment: Identification and assessment of assemblies to improve plant safety, followed by derived mechanical, electrical and organizational measures.
Re-lining: Renewal of the stove insulation with a more energy-efficient variant, partial renovation of the stove housing, modification of the intermediate door system and conversion to the AICHELIN rail system.
Gas technology: Safety update of the gas technology, including flame curtain and flaring system.
Mechanical adaptations: Conversion to gas circulator with standard motor.
Modernization of the hydraulic drive systems: Retrofitting of position-monitoring shut-off valves and adaptation of the door pressure function to the new hydraulic system.
Glow plug in cold chamber: Installation of a new glow plug in accordance with EN 746 for additional protection of the "cold chamber" during and after the vacuum phase.
Switchgear and control technology: Replacement of the switchgear, including terminal boxes and oven wiring. The new switchgear includes modern control panels, integration of a failsafe control system, PLC-internal temperature control as well as all safety-relevant functions and all operating functions of the system.
Step chains and protected area: A modern step chain layout was introduced on the system, which resulted in a new definition of protected areas and access guarding as well as sequential shutdown of the drives. In addition, the man-machine interface was safeguarded in accordance with current safety guidelines.
The modernization process was completed with successful test results. The results showed a significant improvement in operational safety and efficiency. Thanks to the close cooperation with the customer, this challenging project was successfully completed.
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