{"id":3553,"date":"2018-12-09T23:30:51","date_gmt":"2018-12-09T22:30:51","guid":{"rendered":"https:\/\/onload.reinhausen.com\/de\/?p=3553"},"modified":"2023-05-31T14:05:19","modified_gmt":"2023-05-31T12:05:19","slug":"steel-mill-alarm","status":"publish","type":"post","link":"https:\/\/onload.reinhausen.com\/en\/12-2018\/steel-mill-alarm\/","title":{"rendered":"Steel Mill Alarm"},"content":{"rendered":"

19 Novem\u00adber 2016,<\/span> The alarm is going off at a steel\u00adworks in Poma\u00adlaa. It\u2019s late in the after\u00adnoon on the island of Sulawe\u00adsi in Indone\u00adsia. A pro\u00adtec\u00adtive device of the on-load tap-chang\u00ader has shut down the trans\u00adformer for safe\u00adty rea\u00adsons and pro\u00adduc\u00adtion has come to a stand\u00adstill. Now the clock is tick\u00ading. A solu\u00adtion has to be found with\u00adin one week, oth\u00ader\u00adwise the molten steel will cool down with huge\u00adly dam\u00adag\u00ading con\u00adse\u00adquences for the steel\u00adworks.
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<\/i><\/i>Discover what has happened in these 5 days<\/a><\/h3>\n
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\nAn employ\u00adee at the steel\u00adworks picks up the phone and calls Hen\u00addra Kur\u00adni\u00adawan<\/span>, his con\u00adtact at MR\u2019s Indone\u00adsian sub\u00adsidiary in Jakar\u00adta, where two ser\u00advice tech\u00adni\u00adcians work local\u00adly.<\/p>\n<\/div>\n

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Because of the time dif\u00adfer\u00adence, it is cur\u00adrent\u00adly 8 o\u2019clock on Sun\u00adday morn\u00ading in Ger\u00admany. Kur\u00adni\u00adawan from Jakar\u00adta reports the prob\u00adlem to his col\u00adleagues in Regens\u00adburg. Christoph Zieglschmid<\/span>, Head of Trou\u00adbleshoot\u00ading, then con\u00adsults with Andreas Birk<\/span>, who is respon\u00adsi\u00adble for order pro\u00adcess\u00ading in the region. The case is imme\u00addi\u00adate\u00adly giv\u00aden top pri\u00ador\u00adi\u00adty.<\/p>\n<\/div>\n<\/div>\n

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First, all avail\u00adable infor\u00adma\u00adtion is checked and ana\u00adlyzed. The cus\u00adtomer has pro\u00advid\u00aded a check\u00adlist, pho\u00adtos, and audio and video files to help with this process. It quick\u00adly becomes clear that the dam\u00adage is too great and the prob\u00adlem needs to be resolved on site.<\/p>\n<\/div>\n

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The tap-chang\u00ader spe\u00adcial\u00adists in Regens\u00adburg and Jakar\u00adta con\u00adsult with one anoth\u00ader and decide how to pro\u00adceed. They quick\u00adly agree that an expe\u00adri\u00adenced engi\u00adneer from Regens\u00adburg will have to rec\u00adti\u00adfy the prob\u00adlem on site in order to get pro\u00adduc\u00adtion up and run\u00adning again.<\/p>\n

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A short time lat\u00ader, engi\u00adneer Andreas Hart\u00admann<\/span>, who is a Tech\u00adni\u00adcal Spe\u00adcial\u00adist at MR, is prepar\u00ading for the task. He works through the mate\u00adr\u00adi\u00adal pro\u00advid\u00aded by the cus\u00adtomer, stud\u00adies the rel\u00ade\u00advant tech\u00adni\u00adcal data, and plans his jour\u00adney. The case con\u00adtain\u00ading his safe\u00adty equip\u00adment is always packed and ready. He now puts togeth\u00ader the tools he will need for the job. He will request spare parts as nec\u00ades\u00adsary, once he has diag\u00adnosed the prob\u00adlem on site.<\/p>\n<\/div>\n<\/div>\n

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Mon\u00adday, 10:10 a.m. \u2013 take\u00adoff from Munich. His jour\u00adney takes him via Doha and Jakar\u00adta to Makas\u00adsar, where he is wel\u00adcomed by his Indone\u00adsian col\u00adleague Hen\u00addra Kur\u00adni\u00adawan who will act as his inter\u00adpreter and pro\u00advide the nec\u00ades\u00adsary local knowl\u00adedge. Togeth\u00ader they make their way to Poma\u00adlaa at the oth\u00ader end of the island of Sulawe\u00adsi.<\/p>\n<\/div>\n

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Wednes\u00adday morn\u00ading. To avoid los\u00ading any time, the cus\u00adtomer picks up the spe\u00adcial\u00adists direct\u00adly from Poma\u00adlaa air\u00adport so they can be tak\u00aden to the steel\u00adworks as quick\u00adly as pos\u00adsi\u00adble. Every\u00adthing required for the secu\u00adri\u00adty check at the state-run steel\u00adworks has been pre\u00adpared in advance by Andreas Birk in Regens\u00adburg. Copies of Hartmann\u2019s pass\u00adport and visa have already been sub\u00admit\u00adted in order to speed up his entry into the works.<\/p>\n<\/div>\n<\/div>\n

In trop\u00adi\u00adcal heat con\u00addi\u00adtions, Hart\u00admann starts the ini\u00adtial assess\u00adment. He inspects the steel\u00adworks and speaks to the per\u00adson respon\u00adsi\u00adble for the sys\u00adtem on site as well as the trans\u00adformer manufacturer\u2019s ser\u00advice tech\u00adni\u00adcian, who has also trav\u00adeled to Poma\u00adlaa. In cas\u00ades like this, the trans\u00adformer man\u00adu\u00adfac\u00adtur\u00ader and MR work hand in hand. He now inspects the trans\u00adformer and the VACUTAP\u00ae VM\u00ae on-load tap-chang\u00ader. The sys\u00adtem is still in the same con\u00addi\u00adtion as it was when it failed, which is the ide\u00adal sit\u00adu\u00ada\u00adtion for Hart\u00admann. Like a foren\u00adsics expert at the scene of a crime, he gath\u00aders facts in order to come up with a diag\u00adno\u00adsis. Every dis\u00adrup\u00adtion has its own cause and its own char\u00adac\u00adter\u00adis\u00adtics and he has to under\u00adstand what went wrong before he can ini\u00adti\u00adate the right steps to solve the prob\u00adlem.
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The recon\u00adstruc\u00adtion shows that, although there is no indi\u00adca\u00adtion of a mal\u00adfunc\u00adtion of the on-load tap-chang\u00ader, it has suf\u00adfered seri\u00adous con\u00adse\u00adquen\u00adtial dam\u00adage as a crit\u00adi\u00adcal com\u00adpo\u00adnent in the trans\u00adformer. The scale of the dam\u00adage quick\u00adly becomes clear \u2013 the on-load tap-chang\u00ader can\u00adnot be repaired. Although a new tap chang\u00ader needs to be fit\u00adted in the trans\u00adformer, by the time it arrives the molten steel in the fur\u00adnace will have solid\u00adi\u00adfied. Hart\u00admann there\u00adfore needs to find a cre\u00adative solu\u00adtion in order to save the cus\u00adtomer from immense down\u00adtime costs.<\/p>\n<\/div>\n

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In a ware\u00adhouse at the steel\u00adworks, Hart\u00admann and the cus\u00adtomer dig out a decom\u00admis\u00adsioned tap chang\u00ader with the same dimen\u00adsions as the VACUTAP\u00ae along with var\u00adi\u00adous old parts of anoth\u00ader tap chang\u00ader. Hart\u00admann can use these to impro\u00advise. His plan is to pre\u00adpare the on-load tap-chang\u00ader so it can con\u00adduct elec\u00adtric\u00adi\u00adty and there\u00adfore enable the trans\u00adformer to oper\u00adate. Admit\u00adted\u00adly, it will then be in a fixed oper\u00adat\u00ading posi\u00adtion and tap-change oper\u00ada\u00adtions will not be pos\u00adsi\u00adble under load, but at least the steel\u00adworks can oper\u00adate under restrict\u00aded con\u00addi\u00adtions.<\/p>\n<\/div>\n<\/div>\n

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After 10 hours, the makeshift on-load tap-chang\u00ader is ready for oper\u00ada\u00adtion. Hart\u00admann doc\u00adu\u00adments pre\u00adcise\u00adly which parts he has used. He also gives the cus\u00adtomer detailed instruc\u00adtions on how to oper\u00adate the sys\u00adtem safe\u00adly in this state.<\/p>\n<\/div>\n

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The spe\u00adcial\u00adist from the trans\u00adformer man\u00adu\u00adfac\u00adtur\u00ader now pre\u00adpares to put the trans\u00adformer into oper\u00ada\u00adtion. Hart\u00admann can head home.<\/p>\n

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\nWhen the trans\u00adformer is put into oper\u00ada\u00adtion, ser\u00advice tech\u00adni\u00adcian Hen\u00addra Kur\u00adni\u00adawan from Rein\u00adhausen Indone\u00adsia is on hand to assist the cus\u00adtomer with the final steps. After tak\u00ading a num\u00adber of mea\u00adsure\u00adments, the tech\u00adni\u00adcian from the trans\u00adformer man\u00adu\u00adfac\u00adtur\u00ader declares that the trans\u00adformer is fit for oper\u00ada\u00adtion. The solu\u00adtion has been imple\u00adment\u00aded in time \u2013 the molten steel has not solid\u00adi\u00adfied.<\/p>\n<\/div>\n

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24 Novem\u00adber 2016,<\/span> Mis\u00adsion accom\u00adplished. Thanks to the efforts of the MR ser\u00advice team, the trans\u00adformer can be put into oper\u00ada\u00adtion again. The steel is still molten; the fur\u00adnace is rum\u00adbling and vibrat\u00ading! Every\u00adthing is going accord\u00ading to plan. By this time, Andreas Hart\u00admann is already on the way to his next impor\u00adtant job. Around six weeks lat\u00ader, once the steel\u00adworks has made inter\u00adnal pro\u00advi\u00adsions for the changeover, the new tap chang\u00ader from Regens\u00adburg can be installed. The steel\u00adworks can now once again use the trans\u00adformer and on-load tap-chang\u00ader as nor\u00admal. With 107 taps, the sys\u00adtem enables excep\u00adtion\u00adal\u00adly pre\u00adcise volt\u00adage reg\u00adu\u00adla\u00adtion.<\/p>\n","protected":false},"excerpt":{"rendered":"

What hap\u00adpens when things go wrong.<\/p>\n","protected":false},"author":8,"featured_media":3772,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"wp_typography_post_enhancements_disabled":false,"footnotes":""},"categories":[5],"tags":[],"class_list":["post-3553","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-12-2018"],"acf":[],"_links":{"self":[{"href":"https:\/\/onload.reinhausen.com\/en\/wp-json\/wp\/v2\/posts\/3553","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/onload.reinhausen.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/onload.reinhausen.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/onload.reinhausen.com\/en\/wp-json\/wp\/v2\/users\/8"}],"replies":[{"embeddable":true,"href":"https:\/\/onload.reinhausen.com\/en\/wp-json\/wp\/v2\/comments?post=3553"}],"version-history":[{"count":2,"href":"https:\/\/onload.reinhausen.com\/en\/wp-json\/wp\/v2\/posts\/3553\/revisions"}],"predecessor-version":[{"id":8464,"href":"https:\/\/onload.reinhausen.com\/en\/wp-json\/wp\/v2\/posts\/3553\/revisions\/8464"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/onload.reinhausen.com\/en\/wp-json\/wp\/v2\/media\/3772"}],"wp:attachment":[{"href":"https:\/\/onload.reinhausen.com\/en\/wp-json\/wp\/v2\/media?parent=3553"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/onload.reinhausen.com\/en\/wp-json\/wp\/v2\/categories?post=3553"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/onload.reinhausen.com\/en\/wp-json\/wp\/v2\/tags?post=3553"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}