Manufacturing Maelstrom: Monitoring Mishaps Menace Metal Operations

Hot-rolling steel operations at Ternium's Monterrey facility faced perpetual challenges monitoring bearing temperatures amid cascading cooling water that resembled industrial waterfalls. Oliver Rodriguez, key account manager at Emerson, explained during his presentation at Emerson Exchange 2025 in San Antonio that "lube oil for bearings & cooling water are the blood of a hot-rolling system." The company's unique vertical integration, spanning from iron ore mining to steel manufacturing & distribution, couldn't shield it from traditional operational headaches including bearing failures & costly roller replacements.

Thermal Tribulations: Traditional Techniques Prove Tremendously Troublesome

Manual temperature monitoring using thermal guns proved inadequate due to excessive cooling water interference, making accurate measurements nearly impossible. Staff struggled to obtain reliable readings of lubrication oil outflow temperatures even using resistance temperature detectors. These measurement difficulties led to preventive roller replacements that were often unnecessary, consuming valuable time & resources while disrupting production schedules. Rodriguez noted that bearing over-temperature conditions caused by poor monitoring increased product scrap, reduced revenue, & triggered process shutdowns requiring full days to rectify.

Wireless Wizardry: WirelessHART's Wondrous Waterproof Wares

Emerson's solution centered on deploying WirelessHART technology's self-organizing, self-healing network capabilities to overcome Ternium's harsh environmental conditions. The system utilizes multiple communication pathways to reach gateways, ensuring robust & reliable data transmission despite constant water exposure. Rodriguez emphasized that the wireless network's resilience was crucial for maintaining connectivity in an environment where traditional wired systems would struggle to survive the perpetual deluge of cooling water.

Precision Parameters: Particular Prerequisites Prompt Prudent Procurement

Ternium's wireless network required components meeting stringent accuracy specifications of ±0.225°C alongside two-year stability & Callendar-Van-Dusen sensor matching for enhanced precision. The installation featured Rosemount 248 & 648 temperature transmitters housed in sealed enclosures preventing water intrusion, complemented by Rosemount 214C Temperature Sensors & Rosemount 1410 wireless gateways. External antennas provided standard & extended communication ranges, while field-replaceable Emerson SmartPower modules offered up to 10 years of maintenance-free operation.

Installation Innovation: Ingenious Implementation Improves Industrial Infrastructure

The wireless solution eliminated complex wiring requirements, enabling maintenance technicians to replace entire assemblies without cable concerns. This streamlined approach reduced replacement time to purely mechanical installation procedures, significantly improving maintenance efficiency. Temperature data from the transmitters flows seamlessly to Ternium's distributed control system, where bearing temperatures exceeding 85°C trigger immediate replacement alarms, preventing bearing melting or seizure incidents that would cause extended production interruptions.

Systematic Scaling: Strategic Expansion Sustains Substantial Savings

Ternium initially established its WirelessHART network using 24 input/output points monitoring two dozen bearings but recently expanded to 48 I/O points covering additional critical monitoring locations. The gradual expansion demonstrates the system's scalability & the company's confidence in the technology's reliability. This phased approach allowed operators to gain experience alongside the wireless monitoring system while progressively expanding coverage across their hot-rolling operations.

Economic Excellence: Exemplary Earnings Exceed Expectations Exponentially

The wireless monitoring implementation has eliminated unnecessary process shutdowns across six production lines while removing manual temperature measurement rounds entirely. Improved operator performance & eliminated rework have contributed to substantial cost reductions totaling approximately $650,000 monthly. These savings stem from reduced scrap rates, minimized unplanned downtime, optimized maintenance schedules, & enhanced overall equipment effectiveness across Ternium's steel production operations.

Technological Trajectory: Transformative Tools Transcend Traditional Techniques

The success at Ternium demonstrates how wireless sensor networks can revolutionize heavy industrial operations previously dependent on manual monitoring methods. The self-healing network architecture proves particularly valuable in harsh environments where traditional wired systems face significant reliability challenges. This implementation serves as a model for other steel manufacturers seeking to modernize their monitoring systems while achieving substantial operational cost reductions through improved process reliability & maintenance optimization.

Key Takeaways:

• Ternium Steel saves $650,000 monthly using Emerson's WirelessHART temperature transmitters to monitor bearing oil temperatures on hot-steel rollers, eliminating manual rounds & preventing costly shutdowns

• System expanded from 24 to 48 input/output points across six production lines, featuring Rosemount 248 & 648 transmitters housed in waterproof enclosures to handle constant cooling water exposure

• Wireless network's self-organizing, self-healing capabilities provide reliable communication despite harsh industrial conditions, triggering alarms when bearing temperatures exceed 85°C to prevent equipment damage