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. |
Online Condition based Monitoring of EAF for Preventative Maintenance
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
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
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