High-resolution infrared camera was used to create a colour palette visualization to easily identify hot spots. Scanning of full bottom shell was possible multiple areas /ROI were defined to get a 4-20mA output |
Condition Based Monitoring of bottom shell on BOF/EAF convertor
Pilger mill in tube rolling mills - hot and cold pipe detection
- No wiring required due to non-contact temperature measurement
- Scanning of full bottom shell. It was possible to define multiple areas /ROI to get a 4-20mA output
- Intuitive identification of hot spot. Software could automatically identify hot spots
- Increased the safety level by mitigating unforeseen events
Challenges
Effectively maintaining temperature of the heating chambers in the coke oven battery is essential for high yield and optimum quality of the coke. The narrow width of the flue makes it challenging for the accurate measurement of the flue temperature using a portable pyrometer inside the pusher arm as the hot coke is pushed out of the oven.Customer problem Maintaining optimal temperature in the convertor is critical for the efficient production process. Higher temperatures result in cost savings as less quantity of coke is needed but can also potentially damage the brickwork and reduce the life of the stove.
- Temperature monitoring using thermocouple was unreliable and had limitations –
- Point measurement thermocouples: On average only 9 thermocouple point measurements were possible.
High maintenance cost: it was not possible to change damaged wiring while furnace was in operation thereby increasing unplanned downtime.
Solution
Colour palette visualization was offered to the operator to easily identify hot spots.
The operator could make informed data driven decision of when to replace the refractory lining / gunning.
Alarms were configured to be interlocked with their safety systems.
Products and Accessories
Protective Housing
High Temperature Cables
USB to LAN
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
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