Carpenter Technology Corporation
Carpenter utilizes the SAVEWAY system on two vacuum induction furnaces. The first system was installed in 1996 on a conventional single chamber 15-ton furnace while the second system was installed as part of a 20-ton VIDP furnace that was commissioned in March of 1997. Both of these furnaces utilize a refractory working lining of MgO brick with a dry vibratable MgO backup lining. Grades melted in the furnaces include super alloys for critical rotating part applications, premium stainless steels, bearing steels, and electronic and magnetic alloys.
Distinct advantages we have observed with the SAVEWAY system are:
Elimination of metal damage to the induction coils due to early detection of metal penetration through the refractory lining.
Identification of problem regions in refractory linings that help to improve lining construction techniques.
The impact of raw material charging practices on refractory lining life can now be evaluated.
The impact of various refining practices on refractory lining life can be determined which allow improved melting practices to be developed.
Maximum refractory lining life can now be obtained without any risk to induction coil components.
Moisture elimination from the refractory lining at the beginning of the campaign can now be clearly determined.
Production operations can be managed much more efficiently since the completion of melting campaigns can now be estimated based upon SAVEWAY system data.
Dwight D. Wegman
Area Manager – VIM Process Technology
ThyssenKrupp VDM USA, Inc.
SAVEWAY was installed after a run-out that caused extensive damage to our VIM furnace. We had also experience a few less damaging run-outs prior to installing SAVEWAY. Faced with the cost of downtime and equipment repairs, we consulted with our sister facilities in Germany, who had already successfully been utilizing SAVEWAY since 1993. Our intent was to create a safer working environment and, at the same time, maintain furnace uptime by better predicting refractory wear.
Thyssen Krup VDM USA has not experienced any molten metal run-outs or contact with the induction coil since the inception of this system. After the initial learning and adjustment cycle, we trust SAVEWAY´s accuracy and the company´s commitment to service. During the initial start up, SAVEWAY worked with our OSHA advisor to create a plan that allowed us to take their advice, backed up with confirming emails, to handle any critical warnings. Along the way we were able to use the knowledge gained to improve our grouting, re-lining and drying practices.
SAVEWAY provides the level of operational safety we demand and we will not operate the furnace without it.
After a serious injury of an operator by metal run out, the SAVEWAY system was gradually installed on all of our eight coreless induction furnaces of our plant KSB AG in Pegnitz, starting in the year 2003. The furnace sizes are between 650 kg and 6 t. During a two or three shift operation we melt grey and ductile iron, various steel alloys as well as bronze in the furnaces. The iron alloys are melted in silica lined main frequency furnaces whereas the steel alloys are melted in medium frequency furnaces lined with alumina.
The installation of the SAVEWAY system absolutely ensures that an accident like that mentioned above will never happen again. An optimal and risk free operation of the furnaces is guaranteed. The efficient use of refractory lining is ensured as well as a true prediction of the relining, and the optimization of startup parameters after relining and furnace shut downs. As a consequence of those facts, unplanned production shut downs created by the atypical wear of the lining became minimized, and a continuously ongoing casting process is ensured. A big advantage of the system is the monitoring of the dry out of a new lining. This opportunity guarantees us safety during the start up procedure.
The wear history recorded by the SAVEWAY system allows conclusions regarding the quality of the refractory material, properly done lining work as well as the influence of the furnace operation to the lining life.
For our staff, the SAVEWAY technique is a basic prerequisite for operating a furnace.
Easy and clearly arranged screens on the system signal critical situations to the operational staff. Furthermore, the provided automatic power switch-off of the furnace ensures the quickest protection of human power and plant equipment in case of critical wear. Every check of the displayed wear by manual lining tear down confirmed the accuracy of the system. The SAVEWAY technique has helped us several times to avoid coil damages and heavy accidents. The service team of the Saveway Company provides competent and qualified answers for our questions at any time.
We are convinced of the reliability of the SAVEWAY technology and wouldn’t like to miss the safety provided in our everyday work routine.
Manager of Melting and Casting Department
Metso Paper Valkeakoski Oy /
Refiner Segments Finland
The main reason that the SAVEWAY system was installed in 1996 was to increase the number of heats from one lining. Before installing the system we were only able to achieve 25 heats for safety reasons. Now that the SAVEWAY system has been installed we achieve between 60 and 70 heats with every lining at a melt temperature of 1650 °C to 1770 °C.
Before installing the SAVEWAY system a ground leak detection system was used but this system did not continuously monitor lining wear. The GLD system warned of damage much later than the SAVEWAY system. The SAVEWAY system has prevented water access to melted metal on two occasions.
Our experience shows that the SAVEWAY system is reliable and that every alarm has indicated the correct location of the fault.
We were also able to increase production as a direct result of introducing the system. The system also benefits is not requiring extensive training or highly skilled operators.
We would install a SAVEWAY system in any new furnace.
BÖHLER Edelstahl GmbH & Co KG (now: voestalpine BÖHLER Edelstahl GmbH & Co KG)
Since 2003 we have been using the Saveway system successfully on our 8-ton, 14-ton and 17-ton vacuum induction furnaces. As the only safety monitoring technology which measures the remaining lining thickness between the approaching melt and coil grout, the SAVEWAY® system constantly and accurately determines the remaining refractory lining thickness. This gives us the opportunity to use the maximum life of the refractory effectively and risk-free. Besides visual wear like erosion and molten leaks, hidden wear conditions like dangerous metal fins and defects in the lining are reliably detected. In 2009 and 2012 the original SAVEWAY® Systems were upgraded to the latest generation of equipment, and another induction furnace was equipped with the SAVEWAY® System. Due to our success with the system, we requested that Saveway solve our problem of “detecting cooling water leaks on an electric arc furnace”. In 2007 we installed the SAVEDRY® system. Together with Saveway we customized it for our purposes. It constantly analyzes and displays the moisture content of the refractory lining. The electric arc furnace was equipped with the latest generation of SAVEDRY® sensors in 2015. Thanks to our close partnership with Saveway we have achieved a high degree of safety in our melting equipment. We can count on the Saveway measuring equipment and the personal service of the Saveway team any time. BÖHLER Edelstahl GmbH & Co KG Division manager steelworks- DI Dr. Hans-Peter Fauland
VACUUMSCHMELZE GmbH & Co. KG
In summer 1993 VAC Hanau installed a SAVEWAY system on a 4-ton vacuum induction furnace (VIM) for the first time. The main reason for that decision was the fact that there was a potential risk of explosions and serious injuries to employees caused by run outs. Our experiences proved that only the SAVEWAY system provides appropriate and reliable safety concerning run outs.
In addition only the SAVEWAY system offers the following advantages:
Elimination of damage to the furnace plant & equipment
Improving lining life in a range between 10 – 20% depending on the melted alloys
During the sintering process the elimination of moisture can be clearly determined
Trials for new dry ramming materials and prefabricated crucibles can be accomplished without any risk
Due to these positive experiences and our safety philosophy, all our furnaces have been equipped with a SAVEWAY system. This includes VIM, VID and open induction furnaces with a melting capacity between 0.2 and 6.0-ton. Consequently, we currently have 11 SAVEWAY systems in operation.
Regarding the structure of the furnace lining we either use a spinel forming dry ramming mix or a ceramic prefabricated crucible. The grades melted include mostly NI, Fe, Co and Cr as alloys used for different applications in a wide spectrum of products.
Since 1993 when a SAVEWAY system was applied to a vacuum furnace for the first time in history, the relationship between us VAC and Saveway is absolutely positive. Solutions to technical questions are solved jointly and in a very proficient and prompt manner.
Dipl.-Ing. Timm Scheidig
Manager Technical Investment
Doncasters Precision Castings Bochum GmbH
We have been using the Saveway system successfully on our 4t coreless induction furnace since 1993.
The vacuum induction furnace is used for the production of super alloys, i.e. alloys based on Ni and Co. These are then used for the manufacturing of aircraft turbine blades and blades for stationary gas turbines by lost-wax moulding.
Since using the SAVEWAY system there have not been any coil damages or metal run outs caused by undetected penetration of melt. We have increased the life of the coreless induction furnace linings on average from 18 to 25 heats. That is an increase of about 38 %.
Besides the easy handling of the SAVEWAY system we especially want to mention the excellent cooperation with the Saveway Company. The service team provides quick and competent help.
The handling of the refractory lining, which is the main wear component, became easier and it is possible to predict when to reline. The operation safety was increased considerably.
As part of the continuous improvement process and operational safety any potential source of failure has to be identified and eliminated. Therefore SAVESEARCH, a system for monitoring the shunts, was installed. The SAVESEARCH system localizes developing insulation faults and makes them visible to us. Quick and accurate repair of insulation faults can be carried out. Thus it becomes possible to guarantee preventive maintenance and to optimize the service life of the coil and shunt system. The SAVESEARCH system eliminated sending out the furnace box for expensive insulation inspections. Those checks are now done automatically and continuously. By using SAVEWAY and SAVESEARCH it is now possible to identify the source and the location of ground faults.
Dr. –Ing. Roman Ritzenhoff
Department leader Vacuum Melting