Co-building an Intelligent O&M Ecosystem with China's Steel Leader

Case Duration:

2019 - Present (6+ Years)

Client Background:

As a central state-owned enterprise directly administered by China's central government, China Baowu was designated by SASAC in 2020 as a national model for world-class enterprise development. Key 2023 metrics: Total assets: 1.36 trillion yuan、Steel output: 130 million tons、Revenue: 1.11 trillion yuan、Ranked #44 on 2024 Fortune Global 500 (top global steel producer)

Client Requirements & Solutions

Assist Baowu in its intelligent equipment management, driving business processes and improving management efficiency

Predictive Maintenance Through Real-Time Equipment Monitoring:

1. Deployed smart monitoring systems across Baowu's production bases for critical assets (fans, pumps, rolling mills)

2. Enabled edge computing and platform integration to support Baowu's intelligent O&M platform

3. Achieved early fault prediction capability

Big Data and Intelligent Algorithm Services:

The customer sought to leverage RONDS' extensive expertise in industrial big data processing and intelligent algorithm development, along with its rich case library, combined with Baowu's on-site specialist knowledge in Intelligent O&M, to develop and iterate intelligent algorithms. RONDS supported the deployment of algorithms on the Baowu's intelligent O&M platform and engaged in in-depth collaboration on the development and iteration of intelligent algorithms to enhance the level of equipment management intelligence.

Driving Business Processes and Improving Management Efficiency:

Experts from both parties collaborated to address industry monitoring challenges and pain points, jointly designing specialized scenario solutions and developing smart hardware for specific applications.

Simultaneously, RONDS integrated data from on-site intelligent monitoring systems with the Baowu's intelligent O&M platform. By applying intelligent algorithm models, quantified results were generated to support business management and decision-making, providing effective support for China Baowu's remote operations, business-driven processes, and analytical decision-making.

Application Value

Full Coverage Across 60+ Production Lines at China Baowu:

Real-time online monitoring implemented across 60+ production lines at:

Ma'anshan Steel Plant

Taiyuan Steel Plant

Shaoguan Steel Plant

Chongqing Steel Plant

Kunming Steel Plant

Comprehensive Monitoring of Critical Equipment for Efficiency Improvement:

• Nearly 12,000+ key equipment units covered across:
1) Iron-making processes
2) Steel-making processes
3) Rolling processes

• Cloud-based data integration achieved

• Significant reduction in equipment failure rates

• Demonstrated production efficiency gains

1. Baoshan Base - Dedicated Smart O&M for Fan Systems
1) 90.8% accuracy rate for system alerts and diagnostics
2) Zero environmental compliance incidents caused by dust removal fan failures
3) 45% reduction in routine inspection workload
4) 25.6% decrease in maintenance workload

2. Songshan Base - Smart O&M for High-Speed Wire Rod Production Line
1) 84 accurate early warnings issued (preventing 12 major failures)
2) 132 hours of unplanned downtime avoided
3) 13,000 tons of production capacity preserved
4) 1 million yuan reduction in equipment maintenance costs

3. Ma'anshan Base - 2250 Hot Rolling Production Line
1) Integrated "Inspection + Maintenance + Spares + Materials" management system
2) 20% improvement in overall equipment condition
3) 10% reduction in per-ton steel production costs (full-cost basis)
4) 500,000-ton additional production capacity secured

Accelerating Baowu's Intelligent Equipment Management Transformation:

1. Enhanced smart O&M system through:
1) Online monitoring solutions
2) Intelligent algorithm deployment

2. Advanced China Baowu's equipment management intelligence through:
1) Digital transformation initiatives
2) Predictive maintenance capabilities

Success Cases

Taiyuan Iron & Steel Group Co., Ltd. #11 Left Coiler (3)

1. Equipment Information
Equipment Type: Coiler
Rated Speed: Undetermined
Associated Measurement Points for This Case: Gearbox Input Shaft 1 - 3H
2.2 Alarm and Analysis Process
Equipment Alarm Events:
2.1 Analysis Process
2.1.1 Explanation of Trends and Indicator Parameters
Intermittent synchronous vibration spikes observed across multiple gearbox measurement points.
#11 Left Coiler (3) / Gearbox Shaft 1&2 Output - 4A / 128k Acceleration Waveform (0.1-20000Hz) - Multi-Trend Equipment Data
2.1.2 Time-domain, frequency-domain, envelope demodulation, and other evidence explanations
Time-domain waveform: Clear rotational-frequency impacts at input shaft, with significant amplitude.
#11 Left Coiler (3) / Gearbox Shaft 1&2 Output - 4A / 128k Acceleration Waveform (0.1-20000Hz) - Time-domain Waveform
Acceleration spectrum: Elevated baseline noise energy. Envelope demodulation dominated by input shaft inner race characteristic frequency
#11 Left Coiler (3) / Gearbox Shaft 1&2 Output - 4A / 128k Acceleration Waveform (0.1-20000Hz) - Envelope Demodulation
3. Diagnosis Conclusion and Recommendations
3.1 Diagnostic Conclusion
August 21, 2022, 08:25 - Diagnostic Conclusion Push: Gearbox Shaft 1 input bearing:
1.Early-mid stage damage
2.Inner race pitting/spalling
3.Gradual degradation trend (no evident rolling element damage)
3.2 Recommendations
Current status: Safe for monitored operation
Next steps:
Schedule opportunistic inspection
Monitor for abnormal bearing noise
Verify bearing condition during next overhaul
4. On-site Maintenance Process
2022-09-07 16:12 Field team replaced Gearbox Shaft 1 bearing, confirming inner race/rolling element pitting and spalling.
5. On-site Maintenance Photos
Images show bearing inner race and rolling elements with pitting/spalling damage.
Photo_1

Photo_2

Photo_3

Photo_4
6. Post-Maintenance Verification
Significant reduction in gearbox vibration acceleration.
#11 Left Coiler (3) / Gearbox Shaft 1 Input - 3H / 128k Acceleration Waveform (0.1-20000Hz) - Multi-Trend Equipment Data
Elimination of periodic impacts in time-domain waveforms.
#11 Left Coiler (3) / Gearbox Shaft 1 Input - 3H / 128k Acceleration Waveform (0.1-20000Hz) - Time-domain Waveform
Significant decrease in spectral baseline noise.
#11 Left Coiler (3) / Gearbox Shaft 1 Input - 3H / 128k Acceleration Waveform (0.1-20000Hz) - Spectrum Analysis
7.客户反馈单
无
反馈单_1
8.监测故障范围
设备运行状态数据（振动、温度）的及时、有效采集，受网络通畅、数据传输时间的制约，也需考虑设备本身属性、生产工艺等因素的干扰。同时，设备状态的分析及诊断是基于旋转动部件故障引起振动效应的变化而进行。因此状态监测系统无法保证监控所有类型故障。该监测系统在按照乙方推荐的测点方案下进行配置，可监测故障范围及说明如下：
9.注意事项
1. 本报告委托方如不能提供基本机组参数（如：机组传动链图、齿轮箱结构图、齿轮箱齿数等、相关的轴承型号及品牌），将会影响分析诊断的准确性；
2. 本报告为容知专业技术人员对机组的分析和诊断、维护意见，仅供参考，具体维护维修措施还需委托方自行决定；
3. 本报告不作为任何理赔、诉讼等证明材料；
4. 委托方负有对分析报告保密的义务，未经受托方书面许可不得将本报告提供给第三方、印刷成其它宣传材料或发布于网络等公共信息平台。

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Taiyuan Iron & Steel Group Co., Ltd. #2 Shot Blasting Machine (3)

1. Equipment Information
Equipment Type: Shot Blasting Machine
Rated Speed: 1485 rpm
Associated Measurement Points for This Case: Shot Blaster Free End - 4H, Motor Free End - 1H
2. Alarm and Analysis Process
Equipment Alarm Events:
2.1 Analysis Process
2.1.1 Explanation of Trends and Indicator Parameters
Sudden velocity increase across all measurement points.
#2 Shot Blasting Machine (3)/Motor Free End - 1H/8k velocity waveform(2-1000)_Multi-Trend Equipment Data
Elevated low-frequency acceleration trend in shot blaster data.
#2 Shot Blasting Machine (3)_Multi-Trend Equipment Data
2.1.2 Time-domain, frequency-domain, envelope demodulation, and other evidence explanations
Velocity waveform: Near-sinusoidal pattern.
#2 Shot Blasting Machine (3)/Motor Free End - 1H/8k velocity waveform(2-1000)_Time-domain Waveform
Velocity spectrum: Dominated by 1X rotational frequency energy.
#2 Shot Blasting Machine (3)/Motor Free End - 1H/8k velocity waveform(2-1000)_Spectrum Analysis
3. Diagnosis Conclusion and Recommendations
3.1 Diagnostic Conclusion
September 26, 2022, 11:20 - Diagnostic Conclusion Push:
Sudden vibration increase with imbalance characteristics
Likely caused by shot blaster rotor wear
Ongoing degradation observed
3.2 Recommendations
Current status: Safe for monitored operation
Next steps:
Schedule inspection at earliest opportunity
Monitor vibration trends during routine checks
Verify rotor wear condition during maintenance
4. On-site Maintenance Process
2022-09-26 13:57 Field team replaced damaged shot blaster blades and provided repair photos
5. On-site Maintenance Photos
Images confirm shot blaster blade damage
shot blaster blade damage_1
6. Post-Maintenance Verification
After maintenance, significant reductions in velocity trends were observed across all monitoring points
#2 Shot Blasting Machine (3)_Multi-Trend Equipment Data
Distinct reduction in velocity amplitude
#2 Shot Blasting Machine (3)_Time-domain Waveform
Significant decrease in 1X rotational frequency energy
#2 Shot Blasting Machine (3)_Spectrum Analysis
7.客户反馈单
无
反馈单_1
8.监测故障范围
设备运行状态数据（振动、温度）的及时、有效采集，受网络通畅、数据传输时间的制约，也需考虑设备本身属性、生产工艺等因素的干扰。同时，设备状态的分析及诊断是基于旋转动部件故障引起振动效应的变化而进行。因此状态监测系统无法保证监控所有类型故障。该监测系统在按照乙方推荐的测点方案下进行配置，可监测故障范围及说明如下：
9.注意事项
1. 本报告委托方如不能提供基本机组参数（如：机组传动链图、齿轮箱结构图、齿轮箱齿数等、相关的轴承型号及品牌），将会影响分析诊断的准确性；
2. 本报告为容知专业技术人员对机组的分析和诊断、维护意见，仅供参考，具体维护维修措施还需委托方自行决定；
3. 本报告不作为任何理赔、诉讼等证明材料；
4. 委托方负有对分析报告保密的义务，未经受托方书面许可不得将本报告提供给第三方、印刷成其它宣传材料或发布于网络等公共信息平台。

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Taiyuan Iron & Steel Group Co., Ltd. Critical Equipment Online Monitoring #5 Main Rolling Mill

1. Equipment Information
Equipment Type: Cold Rolling Mill
Rated Speed: 500/1000 rpm
Associated Measurement Points for This Case: Gearbox Input Shaft 1 - 3H
2. Alarm and Analysis Process
Equipment Alarm Events:
2.1 Analysis Process
2.1.1 Explanation of Trends and Indicator Parameters
Low-frequency acceleration vibrations remained relatively stable across gearbox measurement points
#5 Main Rolling Mill/Gearbox Input Shaft 1 - 3H/ 128k Acceleration Waveform (0.1-20000Hz)_Multi-Trend Equipment Data
2.1.2 Time-domain, frequency-domain, envelope demodulation, and other evidence explanations
Time Domain Waveform: Clear rotational frequency impacts at input shaft
#5 Main Rolling Mill/Gearbox Input Shaft 1 - 3H/ 128k Acceleration Waveform (0.1-20000Hz)_Time-domain Waveform
Spectrum Analysis: Meshing frequency harmonics with significant rotational frequency sidebands (wide distribution)
#5 Main Rolling Mill/Gearbox Input Shaft 1 - 3H/ 128k Acceleration Waveform (0.1-20000Hz)_Spectrum Analysis
Notable Finding: Abnormal high-frequency impacts at 3H measurement point
#5 Main Rolling Mill/Gearbox Input Shaft 1 - 3H/ 128k Acceleration Waveform (0.1-20000Hz)_Time-domain Waveform
Elevated noise energy in high-frequency band
Envelope demodulation dominated by rotational frequency energy
#5 Main Rolling Mill/Gearbox Input Shaft 1 - 3H/ 128k Acceleration Waveform (0.1-20000Hz)_Envelope Demodulation
3. Diagnosis Conclusion and Recommendations
3.1 Diagnostic Conclusion
December 5, 2022, 14:32 - Diagnostic Conclusion Push:
Gearbox Input Shaft Damage: Significant tooth surface damage (spalling/local tooth breakage)
Potential contributing factors: Bearing positioning looseness at input side. Coupling wear
3.2 Recommendations
Immediate Actions Required: Verify actual equipment condition (high failure risk if operation continues)
Check for:
• Abnormal noise/temperature rise at input side bearing
• Metal debris in lubrication filter
• Coupling wear condition
• Tooth surface damage extent
• Bearing positioning/fit condition
4. On-site Maintenance Process
2023-01-09 19:01 Technician Wang reported replacement of coupling liner plate for #5 Main Rolling Mill
5. On-site Maintenance Photos
Images confirm liner plate wear
Photo_1
6. Post-Maintenance Verification
Slight reduction in overall acceleration values
#5 Main Rolling Mill/Gearbox Input Shaft 1 - 3H/ 128k Acceleration Waveform (0.1-20000Hz)_Trend Analysis
Elimination of impact characteristics in time domain waveforms
#5 Main Rolling Mill/Gearbox Input Shaft 1 - 3H/ 128k Acceleration Waveform (0.1-20000Hz)_Time-domain Waveform
Reduced rotational frequency harmonics in spectrum analysis
#5 Main Rolling Mill/Gearbox Input Shaft 1 - 3H/ 128k Acceleration Waveform (0.1-20000Hz)_Spectrum Analysis
7.客户反馈单
无
反馈单_1
8.监测故障范围
设备运行状态数据（振动、温度）的及时、有效采集，受网络通畅、数据传输时间的制约，也需考虑设备本身属性、生产工艺等因素的干扰。同时，设备状态的分析及诊断是基于旋转动部件故障引起振动效应的变化而进行。因此状态监测系统无法保证监控所有类型故障。该监测系统在按照乙方推荐的测点方案下进行配置，可监测故障范围及说明如下：
9.注意事项
1. 本报告委托方如不能提供基本机组参数（如：机组传动链图、齿轮箱结构图、齿轮箱齿数等、相关的轴承型号及品牌），将会影响分析诊断的准确性；
2. 本报告为容知专业技术人员对机组的分析和诊断、维护意见，仅供参考，具体维护维修措施还需委托方自行决定；
3. 本报告不作为任何理赔、诉讼等证明材料；
4. 委托方负有对分析报告保密的义务，未经受托方书面许可不得将本报告提供给第三方、印刷成其它宣传材料或发布于网络等公共信息平台。

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Taiyuan Iron & Steel Group Co., Ltd. Critical Equipment Online Monitoring Primary Mixer Support Roller (3)

1. Equipment Information
Equipment Type: Mixer
Rated Speed: Variable Frequency Drive
Associated Measurement Points for This Case: North Input West Side - 2H
2. Alarm and Analysis Process
Equipment Alarm Events：
2.1 Analysis Process
2.1.1 Explanation of Trends and Indicator Parameters
Significant vibration increase at north input west side
Primary Mixer Support Roller (3)/North Input West Side - 2H/ 128k Acceleration Waveform (0.1-20000Hz) - Multi-Trend Equipment
Synchronous temperature rise observed
Primary Mixer Support Roller (3)/North Input West Side - 2H/ 128k Acceleration Waveform (0.1-20000Hz) - Multi-Trend Equipment Temperature Data
2.1.2 Time-domain, frequency-domain, envelope demodulation, and other evidence explanations
Time-domain waveform: Abnormal spike impacts
Primary Mixer Support Roller (3)/North Input West Side - 2H/ 128k Acceleration Waveform (0.1-20000Hz) - Time-domain Waveform
Spectrum: Elevated baseline noise
Primary Mixer Support Roller (3)/North Input West Side - 2H/ 128k Acceleration Waveform (0.1-20000Hz) - Spectrum Analysis
Envelope demodulation: Suspected bearing-related fault frequencies
Primary Mixer Support Roller (3)/North Input West Side - 2H/ 128k Acceleration Waveform (0.1-20000Hz) - Envelope Demodulation
3. Diagnosis Conclusion and Recommendations
3.1 Diagnostic Conclusion
July 16, 2023, 12:03 - Diagnostic Conclusion Push:
Abnormal conditions at north input west side:
· Significant temperature rise
· Abnormal mechanical impacts
Probable causes:
· Bearing damage
· Support roller bearing failure
· Roller surface abnormality
Status: Accelerated degradation (prior notification sent to control room)
3.2 Recommendations
Immediate inspection required:
Verify roller temperature abnormalities
Check for:
• Bearing damage
• Roller surface defects
Critical risk: Continued operation may cause catastrophic failure
4. On-site Maintenance Process
2023-07-17 10:35 Field team replaced support roller
Findings:
• Bearing failure
• Cage fracture
• Misaligned rolling elements
5. On-site Maintenance Photos
Images show:
Mispositioned rolling elements
Severe cage damage
Photo_1
Photo_2
6. Post-Maintenance Verification
Significant reduction in vibration level
Primary Mixer Support Roller (3)/North Input West Side - 2H/ 128k Acceleration Waveform (0.1-20000Hz) - Trend Analysis
Elimination of waveform impacts
Primary Mixer Support Roller (3)/North Input West Side - 2H/ 128k Acceleration Waveform (0.1-20000Hz) - Time-domain Waveform
Spectral noise: Returned to normal baseline
Primary Mixer Support Roller (3)/North Input West Side - 2H/ 128k Acceleration Waveform (0.1-20000Hz) - Spectrum Analysis
7.客户反馈单
反馈单1
8.监测故障范围
设备运行状态数据（振动、温度）的及时、有效采集，受网络通畅、数据传输时间的制约，也需考虑设备本身属性、生产工艺等因素的干扰。同时，设备状态的分析及诊断是基于旋转动部件故障引起振动效应的变化而进行。因此状态监测系统无法保证监控所有类型故障。该监测系统在按照乙方推荐的测点方案下进行配置，可监测故障范围及说明如下：
9.注意事项
1. 本报告委托方如不能提供基本机组参数（如：机组传动链图、齿轮箱结构图、齿轮箱齿数等、相关的轴承型号及品牌），将会影响分析诊断的准确性；
2. 本报告为容知专业技术人员对机组的分析和诊断、维护意见，仅供参考，具体维护维修措施还需委托方自行决定；
3. 本报告不作为任何理赔、诉讼等证明材料；
4. 委托方负有对分析报告保密的义务，未经受托方书面许可不得将本报告提供给第三方、印刷成其它宣传材料或发布于网络等公共信息平台。

Learn More

Co-building an Intelligent O&M Ecosystem with China's Steel Leader

Client Requirements & Solutions

Application Value

Success Cases

1. Equipment Information

2.2 Alarm and Analysis Process

2.1 Analysis Process

3. Diagnosis Conclusion and Recommendations

3.1 Diagnostic Conclusion

3.2 Recommendations

4. On-site Maintenance Process

5. On-site Maintenance Photos

6. Post-Maintenance Verification

7.客户反馈单

8.监测故障范围

9.注意事项

1. Equipment Information

2. Alarm and Analysis Process

2.1 Analysis Process

3. Diagnosis Conclusion and Recommendations

3.1 Diagnostic Conclusion

3.2 Recommendations

4. On-site Maintenance Process

5. On-site Maintenance Photos

6. Post-Maintenance Verification

7.客户反馈单

反馈单_1

8.监测故障范围

9.注意事项

1. Equipment Information

2. Alarm and Analysis Process

2.1 Analysis Process

3. Diagnosis Conclusion and Recommendations

3.1 Diagnostic Conclusion

3.2 Recommendations

4. On-site Maintenance Process

5. On-site Maintenance Photos

6. Post-Maintenance Verification

7.客户反馈单

反馈单_1

8.监测故障范围

9.注意事项

1. Equipment Information

2. Alarm and Analysis Process

2.1 Analysis Process

3. Diagnosis Conclusion and Recommendations

3.1 Diagnostic Conclusion

3.2 Recommendations

4. On-site Maintenance Process

5. On-site Maintenance Photos

6. Post-Maintenance Verification

7.客户反馈单

8.监测故障范围

9.注意事项

Start Your Journey to Intelligent Industrial Equipment Maintenance