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High Temperature sensing proximity for Hot Rot Mills
Robust proximity to withstand harsh ambient condition of high ambient temperature and presence of water spray. High temperature electronics to withstand harsh ambient temperature. Higher sensing distance to counter any mechanical plays. Cable protection to withstand temperature cycling causing cable cracking/ hardening. Home Case Studies High Temperature hrm High Temperature sensing proximity for Hot Rolling Mills Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection High temperature / sensing proximity can withstand high ambient temperatures Higher sensing distance to counter mechanical plays Challenges Harsh ambient condition of high ambient temperature and presence of water spray Solution 120|1000C: High temperature electronics to withstand harsh ambient temperature 15-40mm: Higher sensing distance to counter any mechanical plays. Silicon Cable: 1800C to withstand temperature cycling causing cable cracking/ hardening Cable protection: Protect against cable damage from fire, scales, sparks, radiation heat Products and Accessories Hot rolling mill proximity with conduit Cable Protection conduits Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions in Hot Rolling Mills Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All
Tags: high radiant heat, Hot Rolling Mills, water spray
August 30, 2021
Condition based monitoring for Tuyeres
High-resolution infrared camera provided real-time thermographic images unaffected by noise from combustion gases to quickly detect hot spots in the tuyeres and optimize process conditions as needed Home Case Studies Temperature Measurement of the coke for fire safety in the coke wharf-2 Condition based monitoring for Tuyeres Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Increased efficiency: Scans the entire tuyeres to check for any refractory break. Improved safety level: Hot spot detection to avoid costly damage and subsequent downtime Challenges During the process of heating iron-ore to make iron, hot air is injected at high temperature at the bottom of the blast furnace by tuyeres. The heated air optimizes the process accelerating the burning of the coke and effectively reduces the coke consumption per ton of iron produced. As smelting temperatures of over 1600⁰C is produced, it becomes critical to carefully monitor refractory temperature for hot spots and blockages.Thermocouples do survive the high heat and high-pressure environment but lifespan of the thermocouple is significantly reduced due to damage to its metal sheath. Furthermore, sudden change in temperature readings due to snorting can result in unreliable thermocouple signals. Solution A high-resolution infrared camera from Optris is ideal for this application. It provides pin-sharp infrared pictures and videos unaffected by noise from combustion gases.The real-time thermographic images prove especially valuable to quickly detect hot spots and optimize process conditions as needed. System features include Temperature range of 50⁰-600⁰C Wide optic lens Alarm and alert PTZ Housing: Pan- Tilt housing Products and Accessories Thermal Imaging Camera Water Cooling Jacket Air Purge Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions in Hot Rolling Mills Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All
Tags: Blast Furnace, Condition Based Monitoring, Iron Making, Pi640, Temperature, Thermal Imaging, Tuyeres
Temperature measurement of the coke for fire safety in the coke wharf
Thermal imaging cameras can effectively detect any uncooled areas within the coke and identify potential hot spots. Continuous temperature monitoring of the coke on the conveyor ensures rapid response to hot spots thereby protecting the conveyor belt from damage and reduces fire risk from hot inclusions reigniting coke. Home Case Studies Temperature coke wharf Temperature measurement of the coke for fire safety in the coke wharf Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Increased confidence in safety with continuous monitoring and quick response alarm system Reduction in insurance costs and prevention of damage and downtime Challenges During transport in conveyors, hot spots can be created which increases risk of fires and damages the conveyer belt.Detection of these hot spots during the rail car transport or wharf quenching can reduce safety risks and prevent damage to equipment. Solution Thermal imaging cameras can effectively detect any uncooled areas within the coke and identify potential hot spots. For this application, a highly robust and compact IR camera was installed. This fast response camera has a 80 Hz frame rate and is especially suited to detect hot spots in the coke at an early stage.Continuous temperature monitoring of the coke on the conveyor ensures rapid response to hot spots thereby protecting the conveyor belt from damage and reduces fire risk from hot inclusions reigniting coke. Products and Accessories Thermal Imaging Camera Water Cooling Jacket Air Purge Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions in Hot Rolling Mills Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All
Tags: Coke Oven, coke temperature, Coke wharf, Fire safety
Measurement of Mandrel hydraulic expansion in Down Coiler
A compact inductive proximity sensor is used for the measurement of mandrel hydraulic expansion at the down coiler. The sensor provided reliable position signal irrespective of the environmental conditions. Benefits included repeat accuracy , optimal linearity and no interference from contaminants. Home Case Studies Measurement of Mandrel hydraulic expansion in Down Coiler Measurement of Mandrel hydraulic expansion in Down Coiler Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Analog Proximity (4-20mA) Reliable in harsh environment with heat radiation, water, grease, chemical High repeat accuracy, optimal linearity Easy parameterization for analysis; unaffected by contamination Robust with sturdy stainless steel casing Challenges The sensor needed to operate in a very harsh environment with water, heat radiation, grease, etc. The requirement was to provide reliable position signal irrespective of the environmental conditions Existing solution had a poor performance to price ratio and with long lead delivery time Solution A compact inductive proximity sensor in stainless steel casing was installed for this application. With a sensing range of 0-120 mm the object distance is transferred via the analogous output – 0-10Vdc giving a 4-20mA output signal. With a protection rating of IP65 it is highly robust with sturdy stainless-steel casing and entirely casted μ-processor-electronics enabling efficient operations under rough ambient conditions and temperature range of -20 to 700C. It is provided with a 2x2m POKT Therm cable connection Products and Accessories Analog Inductive Sensor Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions in Hot Rolling Mills Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All
Tags: Analog Inductive, Down Coiler, HRM Flat, Mandrel, MKZ
Slab Centering at Charging side
Home Case Studies Slab Centering at Charging side High ambient temperature IR Light Barrier / Photocell) is used for the detection of thin slabs inside the tunnel reheating furnace. The system with fiber optic cables (290⁰C ambient) and separate electronics is installed 2m away from the heat zone. This allowed the photocell to operate in ambient temperatures of 290⁰C without the need of any water cooling. Slab Centering at Charging side Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Accurate performance in high ambient temperature up to 290 ⁰C High operating reserves 290°C ambient temperature without any water-cooling Unaffected by water vapor, smoke, dust Safe from leaking flames Challenges Furnace refractory deteriorates and creates hot spots causing signal fluctuation. Burner flames directly cause disturbances, leading to false triggering. Flames can get out of the furnace through sitting tube and damage the lens of the sensor. Breakdown due to slab pile up inside the furnace caused by false triggering of the photocell. Solution Light Barrier with high operating reserves enables keeping the photocell 30-40cm away from glass window saving it from any leaking flames. Photocell can operate in ambient temperature of 290⁰C without any water cooling. Electronics can be kept safely 2m|5m|10m away. The powerful infrared transmitter diodes create a large beam diameter that penetrate through water vapour, smoke and dust. Products and Accessories Light Barriers Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions in Hot Rolling Mills -Reheating Furnance Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All
Tags: HRM Flat, Light Barrier, Reheating Furnace, Slab detection
August 27, 2021
Ensuring uniform cooling on Cooling Bed for Billet | Bloom Caster
Home Case Studies Ensuring Uniform Cooling on Cooling Bed for Billet | Bloom Caster Ultra-compact infrared camera is used to monitor temperature profile of the bar at the cooling bed. high-performance sensor electronics allow a short reaction time of 1ms for the displaying of the temperature information of the center pixel. Ensuring Uniform Cooling on Cooling Bed for Billet | Bloom Caster Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Non Contact Thermal Imaging Camera is used to increase yield and reduce maintainence costs Challenges In the cooling bed, it is critical that the entire length of the bar is cooled in a uniform manner. An optimized cooling rate ensures minimum distortion of the bars and results in high quality profiles and high throughput. High maintenance costs as it is not possible change wiring while furnace is in operation Solution In order to obtain the real time temperature profile of the billet/bloom, a thermal camera was installed. This ultra-compact infrared camera with its with high emissivity at the short measurement wavelength of 1μm is ideally suited for non-contact temperature measurements of metallic surfaces. System features Temperature range of 4500 C -18000C Resolution of 768*428 pixels Short measurement wavelength of 1µm 1Khz capture rate 4-20mA output signal Excel data logging and image capture (JPEG) In parallel with the visualization of a thermal process, the high-performance sensor electronics allow a short reaction time of 1ms for the displaying of the temperature information of the center pixel. Products and Accessories Thermal Imaging Camera Water Cooling Jacket Air Purge Unit Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions in Hot Rolling Mills Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All
Tags: Cooling Bed, HRM Long, Pi1M, Temperature, Thermal Imaging
WRM:4-Strand Temperature & Detection with single thermal camera
Home Case Studies WRM: 4-Strand Temperature & Detection with single thermal camera WRM: 4-Strand Temperature Measurement & Detection with Thermal Imaging Camera High speed measurement: Infrared Camera at very fast speed of 1000hz frame rate Multiple strand measurement: One Thermal camera for all 4 strands Dual use: Temperature measurement and Hot Metal Detection Challenges The customer was facing the challenge of not being able to mount 4 HMDs in a single row. Additionally, the cost was prohibitive as one sensor was required for each strand of the hot wire. Solution One thermal imaging camera was used for the detection of all four strands This made it cost effective and allowed for ease of maintenance and no alignment issue Thermal Camera features included 4nos of Analog 4-20mA Excel data logging 315 C of ambient temperature 450-1800C 768*428 pixels1µm wavelength 1Khz capture rate Products and Accessories Thermal Imaging Camera Water Cooling Jacket for IR Camera Air Purge Unit Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions in Hot Rolling Mills Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All Home Case Studies WRM: 4-Strand Temperature & Detection with single thermal camera
Tags: HRM Long, Intermediate Stand, Pi1M, Temperature, Work Roll Mill
Online Condition Based Monitoring of EAF / Converter for Preventative Maintenance
Compact IR thermal imaging camera was installed to provide a temperature map of the bottom shell. The cameral scans the full bottom of the shell giving options to define multiple areas /ROI to get 4-20mA output. Software automatically finds hot spots enable timely preventative maintenance. Home Case Studies Online Condition based Monitoring of EAF for Preventative Maintenance Online Condition based Monitoring of EAF for Preventative Maintenance Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection No wiring: Non-contact temperature measurement. Scans full bottom shell. Multiple area /ROI possible to define to get 4-20mA output Intuitive identification of hot spot. Software automatically finds hot spots Challenges High temperatures cause wires to melt leading to loss of thermocouple readings. Plant operators need to wait until the next planned shutdown to carry out change in wires and undertake repairs. Furthermore, thermocouples only provide point temperature readings and therefore it becomes difficult to identify where the hot spots are being developed. Point measurement thermocouples: Average only 9 point measurements possible with thermocouples. High maintenance cost: Not possible to change wiring while furnace in operations Solution Compact IR thermal imaging camera was installed to provide a temperature map of the complete bottom shell Products and Accessories Thermal Imaging Camera Water Cooling Jacket Air Purge Unit Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other applications in Steel Making Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All
Tags: BOF, Condition Based Monitoring, EAF, Preventive Maintainence, Steel Making, Temperature, Thermal Imaging
Online condition-based Monitoring / Predictive Maintenance of LHF
Compact infrared thermal imaging camera was used for the continuous temperature monitoring of each zone. Alarm generated if zone temperature exceeds set points. Hot spot detector scans the entire critical asset and easily identifies the spot with maximum refractory erosion. Home Case Studies Online condition-based Monitoring / Predictive Maintenance of LHF Online condition-based Monitoring / Predictive Maintenance of LHF Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Increased efficiency: Ladle lifetime improvement with early detection allowing for selective repairs as opposed to full lining Improve safety level: Prevent breakouts and reduce risk of damage to personnel & plant equipment Avoid unscheduled downtime: Avoids costly machinery damage and days to clean-up Challenges The customer faced the challenge of measuring the temperature of ladle shell when the hot metal is inside so that any punctures can be identified in time Solution Compact infrared thermal imaging camera provided the ideal solution Zones Monitoring: Each zone temperature was continuously monitored.If zone temperature exceeded above 300⁰C, an alarm was generated. Hot Spot Detection: Hot spot detector scanned the entire critical asset and easily identified the spot with maximum refractory erosion. Predictive Maintenance: Real time system running 365 / 24/ 7 days, warning of excessive shell temperature from refractory degradation. Products and Accessories Thermal Imaging Camera Water Cooling Jacket Air Purge Unit Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Applications in Steel Making View All Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE
Tags: Condition Based Monitoring, Predictive Maintainence, Steel Making
August 24, 2021
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