Condition Based Monitoring of Kiln Shell
Thermal imaging camera provides real time temperature measurement and identifies hot spots in the kiln shell. Wide optic lens enabled continuous scanning of the entire kiln from 60-100mtrs relaying a thermal map to plant operations. Improved safety level: Automatic hot spot detection could be done hence avoiding costly damage and subsequent downtime. Reduced power: 3nos of analog/ digital output were available to activate the cooling fans. Shadow monitoring of Slip rings: Modular system approach that enabled additional thermal cameras to be installed for capturing hidden areas. |
Pilger mill in tube rolling mills - hot and cold pipe detection
- Increased efficiency: Scanning of the entire kiln from 60-100mtrs was now feasible.
- Improved safety level: Automatic hot spot detection could be done hence avoiding costly damage and subsequent downtime.
- Save power: 3nos of analog/ digital output were available to activate the cooling fans.
- Shadow monitoring of Slip rings: Modular system approach that enabled additional thermal cameras to be installed for capturing hidden areas.
Challenges
The refractory-lined lower part of the kiln reaches temperatures of up to 2,000 ⁰C making it prone to refractory damage. Localized hot spots of the kiln shell may occur, that can lead to extensive damage to the kiln and unexpected breakdowns
Solution
In order to enable real time temperature measurement and identify hot spots in the kiln shell, a thermal imaging camera was used.
With a very small measuring VGA and an optical resolution of 640×480 pixels, the PI 640 delivers pin-sharp radiometric pictures and videos in real time.
It has a compact design, with a body sized 45x56x90 mm and weight of 269 – 340 g making it ideal to be installed where space is limited.
The wide optic lens enabled continuous scanning of the entire kiln from 60-100mtrs relaying a thermal map to plant operations.
- 4-20Ma output signal
- Data logging
- Alarm and alert
- Temperature range of 50 °C to 600 °C
- Additional cameras were used for shadow monitoring
Products and Accessories
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
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