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Client Profile
This client is one of Asia’s most respected integrated steel producers, with an annual capacity of 4 million tonnes. The plant caters to demanding global sectors, producing plates, pipes, and coils that are used in applications ranging from pipelines and pressure vessels to shipbuilding and structural steel. The company maintains a reputation for delivering high-quality steel that meets strict international specifications, and its customers include some of the world’s most quality-sensitive industries.
Client Requirement
To support its global commitments, the client’s internal quality requirements are stringent. The lab team is expected to deliver:
- Accurate elemental readings, including light and gaseous elements like Carbon, Sulphur, Phosphorus, Nitrogen, and Oxygen, some at sub-ppm levels.
- Consistent results across three shifts, with multiple teams and operators handling testing duties.
- Rapid turnaround time to avoid delays in dispatch, ladle processing, or casting.
- An OES that can run 24×7 with minimal intervention, without frequent recalibration or maintenance.
Traditional OES systems struggled in this environment, especially in terms of calibration downtime and long-term stability.
The MPA Solution: Metavision-10008X
To address the above, Metal Power Analytical supplied its flagship Metavision-10008X system. The instrument was chosen specifically for its proven ability to combine lab-grade analytical accuracy with the ruggedness and efficiency needed in a high-volume steel plant.
Some of the key features that met the client’s expectations included:
- Single-Sample Smart Standardisation: Enabled quick recalibration in less than 5 minutes using just one certified reference material, reducing shift disruptions.
- High Spark Endurance: Handled up to 1,500 sparks per day without performance degradation.
- Extended Uptime: The unit has operated continuously for months at a time without requiring service intervention.
- Thermal and Plasma Stability Controls: Delivered low drift over time, even in changing ambient conditions across shifts.
Repeatability and Stability Test: Verified Using CRM BCS/SS-CRM 404/2
To verify performance under plant conditions, the client conducted a repeatability test over three shifts using certified reference material BCS/SS-CRM 404/2 (Low Alloy Steel). Measurements were taken without re-standardising between shifts.
Repeatability Results – Based on CRM BCS/SS-CRM 404/2
| Element | Certified (%) | Measured Avg. (%) | Std Dev | RSD (%) | Sparks |
| C | 0.696 | 0.694 | ±0.0011 | 0.16% | 30 |
| Si | 1.121 | 1.117 | ±0.0050 | 0.45% | 30 |
| Mn | 0.532 | 0.530 | ±0.0025 | 0.47% | 30 |
| P | 0.0479 | 0.0476 | ±0.0004 | 0.84% | 30 |
| S | 0.0228 | 0.0225 | ±0.0003 | 1.33% | 30 |
| Cr | 0.774 | 0.770 | ±0.0050 | 0.65% | 30 |
| Mo | 0.307 | 0.305 | ±0.0022 | 0.72% | 30 |
| Ni | 0.393 | 0.391 | ±0.0025 | 0.64% | 30 |
| Al | 0.017 | 0.0167 | ±0.0002 | 1.20% | 30 |
| Cu | 0.427 | 0.424 | ±0.0030 | 0.71% | 30 |
| N | 0.0089 | 0.0087 | ±0.0002 | 2.30% | 30 |
| V | 0.107 | 0.106 | ±0.0006 | 0.57% | 30 |
| O | – | 29.7 ppm | ±0.4 ppm | 1.33% | 30 |
The readings showed tight grouping around the certified values, with excellent control across the test duration. This confirmed the system’s ability to perform reliably across shifts and operators without any measurable loss in precision.
Benefits Realised
| Performance Area | Result |
| Calibration Time | Reduced from ~30 mins to <5 mins |
| Daily Analytical Load | 1,200–1,500 samples |
| Calibration Frequency | Once per shift or less |
| Service Requirement | >6 months MTBF |
| Data Trustworthiness | Consistently aligned with CRMs |
Final Outcome
The Metavision-10008X has now become a cornerstone of the plant’s quality control setup. It supports their round-the-clock operations, helps them meet tight dispatch deadlines, and ensures that every heat meets the chemistry specs demanded by their global customers. Importantly, the lab team now operates with higher confidence and less downtime, leading to improved productivity and fewer production bottlenecks.
