Trped Car Mnitring Thermal Imaging System fr a Reliable Cnditin Mnitring f the Refractry Lining Increased Safety fr Steel Prductin Preventin f Liquid Metal Breakuts Early Identificatin f Excessive Wear Maximizatin f the Refractry Lining Service Life Optimized Refractry Maintenance Autmatin Technlgy Visin Sensrs and Systems
Trped Car Mnitring The Trped Car Mnitring System f Autmatin Technlgy is a turn-key slutin fr autmatic Breakut-Early-Warning t guarantee plant safety, while ptimizing peratinal csts. The system cmprises infrared cameras t cver the cmplete uter surface f the trped cars, an infrared imaging sftware fr data acquisitin and system cntrl, a database fr the strage f all measured data, a web based user-friendly interface and devices t indicate the status f the inspected trped. Imprved Safety fr Steel Plants Liquid metal breakuts frm a defective refractry lining are a cmmn danger in steel prductin. The well knwn cnsequences are damages f the surrunding equipment, high repair csts and lss f revenue due t prductin delays. Besides this ecnmical impact, there is always a high risk f persnnel injuries r even the lss f life. The trped car mnitring system is designed t effectively prevent ht breakuts, by cntinuusly mnitring the trped cars during peratin. This way, areas with defects r depletins in the refractry lining are autmatically detected lng befre they becme critical. Cst Reductin The system als helps t reduce the prductin csts by extending the service life f trped refractries. Each time the fireprf lining gets in cntact with liquid metal, its cnditin deterirates until finally the trped must be relined. Generally, the maintenance intervals fr refractry material are determined based n experience. Fr safety reasns, these time intervals are cmmnly quite cnservative. The mnitring system allws a reliable assessment f the remaining lifetime f the refractry lining. The number f heats can thus be maximized withut any safety issues and the re-lining can be scheduled mre precisely. Cnsidering the high csts fr the refractry maintenance, the system can significantly cntribute t a reductin f the prductin csts f steel. Hw it Wrks The external surface temperature f a trped car is a reliable indicatr f the cnditin f its refractry lining. Therefre, infrared cameras are the perfect slutin fr a cntact-free mnitring f the refractry material during peratin. Once a temperature measurement is perfrmed, the thermal data is analyzed and the status f the trped is displayed thrugh the web interface f the system. All thermal images, the temperature infrmatin and ther prcess related data is stred in the systems database, enabling dedicated analyses f the refractry lining status.
System Setup RFID Thermal Camera Trped Car DB Server PC with Database Plant Intranet Thermal Camera Signal Light Operatr Operatr Typical Trped Car Inspectin Statin: Tw infrared cameras in prtective enclsures fr mnitring the cmplete uter surface f the trped cars RFID r visual camera fr autmatic recgnitin f the trped car identifier Server cmputer with the mnitring sftware, database and web server Indicating device fr displaying the status f the trped, e.g. digital utput mdule with signal light Key Advantages : Increased transprtatin safety Preventin f liquid metal breakuts Early identificatin f areas with increased wear Cst savings: maximizatin f refractry lining service life withut safety risks Optimized refractry maintenance planning Efficiency cmparisn f refractry linings Key Features : Fully autmated measurement sequence; n peratr interactin required Shape recgnitin functin fr mnitring the cmplete surface n tped cars in mtin with very high measurement accuracy 100% Traceability: Autmatic strage f images, measured temperatures and prcess related data Advanced data management and analysis with database and web server Varius interfaces fr cnnecting t yur prcess cntrl, data management and visualizatin
Trped Car Mnitring - Features Temperature Trend Analysis Based n stred data f previus measurements n a trped car, the mnitring system analyzes the temperature as a functin f the trped service time. A sudden increase in the temperature trend implies a ptential breakdwn f the refractry and will trigger an alarm. Mrever, the temperature trend als prvides a clear infrmatin fr the prgressin f refractry wear, allwing t schedule maintenance activities mre precisely. Alarm Clrs Areas f the trped, where the temperatures indicate excessive wear r a defect are highlighted with alarm clrs in the webbased user interface. This way, the peratr gets a clear impressin abut the lcatin and severeness f a ptential prblem with the refractry. Ladle status indicatin Depending n the cnfiguratin f the system, the trped car status is displayed t the peratrs in multiple different ways: A signal light r sund alarm can infrm abut a critical cnditin (e.g. htspt detected) in the cntrl rm immediately after a measurement has been released. Persnnel in the cntrl rm r the trped maintenance persnnel may use the pages f the web applicatin, fr either viewing the data f the current measurement r t perfrm a dedicated analysis. Other persnnel, fr example frm the maintenance r prductin department, can access the Pages f the web applicatin frm their cmputer and s get detailed infrmatin abut all trped cars checked by the system. Varius Interfaces The trped car system features varius interfaces fr cnnecting t yur prcess cntrl, data management and visualizatin. This cmprises ODBC fr cnnecting t a database as well as a datatelegram server fr the exchange f prcess related data via LAN. With its COM/DCOM autmatin interface the system can be easily cnnected t a PLC, a prcess-visualizatin, r ther cmputers. Designed fr steel plants: Rbust and Fail-Safe The whle system is designed fr reliable 7/24 peratin in the harsh envirnment f a steel plant. Integrated self-diagnstic functins cntinuusly mnitr all cmpnents. Any pssible functinal impairment will be immediately detected and indicated. All system states are displayed and stred in a lg file in the database which grants fr a full traceability. With its intelligent recnfiguratin-functins the system is able t eliminate mst malfunctins withut any user interactin. Alarm clrs highlight ptentially prblematic areas in the thermal images Inspectin Sequence Autmatic recgnitin f the Trped-Car ID (RFID r visual camera) Start f inspectin sequence. Autmatic detectin Trped Car in Inspectin Psitin fr each camera individually Capture f the thermal images Analysis f thermal images and presentatin f results Measurement stred in database Temperatures BELOW the pre-defined alarm threshlds: Indicatin Trped OK Temperatures ABOVE the pre-defined alarm threshlds: Indicatin ALARM
Trped Car Mnitring - Features The mnitring system cmprises the cmplete functinality fr perfrming the trped car inspectins, as well as fr string and analyzing the data. Cmpletely autmated Inspectin Prcedure Inspectins are perfrmed fully autmatically in the backgrund withut any peratr actins. An RFID r a visual camera system read the trped identifier, starting the measurement sequence. The thermal imaging sftware utilizes highly accurate shape recgnitin functins and bject tracking rutines which determine fr each camera individually, if the trped is in the ptimum psitin fr perfrming a measurement. The measurement is then released autmatically. Thermal mnitring sftware fr data acquisitin and system cntrl Custmizable Inspectin All settings fr temperature measurement and evaluatin are cmpletely adjustable with an easy-t-use fully graphical peratr interface. This allws an ptimum adaptatin t the trped cars and prductin cnditins f the steel plant. Temperatures are evaluated in individual areas, frming a Measurement-Grid which is matched t the shape f the trped within the infrared image. The Measurement-Grid can cmprise an unlimited number f these s called Regins f Interest (RI), t get an arbitrarily fine subdivisin fr the temperature evaluatins n the trped surface. During an inspectin, the measured temperature data are cmpared with preset alarm threshlds. Each exceeding f a threshld will trigger an alarm. Temperature data utside the Regins f Interest will nt be cnsidered fr the evaluatin, thus effectively preventing false alerts due t ther ht pjects in the image. Advanced Data Management The Trped Car Mnitring system includes a pwerful database fr autmatically string the temperature data, the thermal images and the prcess parameters (trped identifier, heat number, trped type, measurement lcatin etc ). This allws a lng-term analysis fr all trped cars. The database may als be cnnected t the intranet f the plant in rder t allw data exchange and t pass the data t ther data prcessing systems. Web applicatin fr data display and data mining A cnfigurable web-applicatin serves fr displaying the inspectin results and fr perfrming extensive analyzes. With this cncept an unlimited number f users can get simultaneus access by just using a standard web-brwser. The web-applicatin includes several pages: A Status page gives a cmplete verview f the currently perfrmed inspectin, shwing all temperature data, threshlds, thermal images and prcess-related data. With the Research page the user can perfrm detailed analyzes fr all trped cars, based n the cntent in the database. The SystemLg page lists all status messages, ensuring a cmplete traceability f all system functins. Web-based User-Interface f the mnitring system
Trped Car Mnitring - Technical Data Thermal Cameras Tw maintenance-free thermal cameras with un-cled detectr, lcated n ppsite sides f the rail-track t cver the cmplete uter surface f the trped. The cameras are cnsistently designed fr industrial applicatins, featuring intelligent prcessing functins and a Standard-GigE-Interface fr data exchange. They are calibrated with an extended measurement range f up t 600 C fr measuring abslute temperatures with high accuracy. Camera Enclsures Prtective enclsure, manufactured frm stainless steel. An air barrier installed at the frnt side effectively prevents dust frmatins at the durable Germanium windw. All cnnectin cables are guided thrugh a high-temperature-resistant hse and enter the enclsure at the rear thrugh ne cable gland. Equipped with a wall munt with manually adjustable jint, the enclsure can be easily installed in any required psitin. Type IRSX-I Industrial Infrared Camera Temperature Measurement Range Temperature Measurement Accuracy Thermal Reslutin -40 C t +600 C ± 2 C r ± 2% f reading 0.1 C Image Pixels 336 x 256 640 x 512 Field f View Frame Rate Detectr Interface Ambient Temperature Range Weight Dimensins Prtectin Class 51 x 40 85 x 72 ther lenses available n request 9 Hz r 60 Hz Uncled Micrblmeter Gigabit Ethernet -40 C t +60 C 310 g 55mm x 55mm x 87mm IP67 Type IRCamSafe AI 168 Enclsure Material Germanium Windw Air Barrier Stainless Steel Ø70mm x 3mm, DLC cated Adjustable air flw, supply pressure 1-3 bar Cable Prtectin Heat resistant hse, cnfigurable length. Resistance t thermal lad: up t +1640 C Ambient Temperature Range Weight Dimensins Prtectin Class Munting Bracket -40 C t +60 C 6 kg Ø168mm x 505mm IP67 Heavy duty bracket with jint, made frm stainless steel. Lad rating 45 kg. Other Cmpnents Server Cmputer IRCamSafe Cntrller Industry standard server cmputer, 19"metal case fr rack installatin. The server cmputer hsts the infrared mnitring sftware, the database and the web-server Integrated inside the camera enclsure. The bard gives a significantly reduced installatin effrt, allwing a direct cnnectin t mains pwer and Ethernet withut any additinal cnnectin cabinet. It features varius sensrs t cntinuusly mnitr the ambient cnditins in the enclsure, thus ensuring a safe peratin f the camera. 4 Prt Switch with 2x LWL-LC 100Base-FX r 2x RJ45(10/100) Up-Links 2 internal sensrs fr temperature; sensrs fr pressure and humidity Supprts a ring structure f the netwrk fr lwer cabling cmplexity Switchable camera pwer and heater via Mdbus-TCP/IP (cntrlled by the mnitring sftware) Interfaces Data Link f Cameras and Cmputer Web-Server ODBC Mdbus-TCP Digital I/O, 24V Input/Output, Ptential-Free (Fieldbus Mdule) Ethernet Link OPC SQL Database Gigabit Ethernet Up t 90m with Industrial Ethernet Cable Up t 500m with Multi-Mde Glass Fiber Cable Up t several km with Single Mde Glass Fiber Cable Other Slutins fr Steel Industry Temperature Mnitring fr Cntinuus Casting EAF Transfrmer Mnitring Slag Detectin Ladle Refractry Mnitring Autmatin Technlgy GmbH Hermann-Bössw-Straße 6-8 D-23843 Bad Oldesle Cntact: Autmatin Technlgy Visin Sensrs and Systems Phne: +49-(0) 45 31 / 88011-0 Fax: +49-(0) 45 31 / 88011-20 E-mail: inf@autmatintechnlgy.de Internet: www.autmatintechnlgy.de