Furnace Monitoring System – Introduction
Such systems are necessary to see the internal conditions of any hot furnace. Conventionally speaking, this used to be done through peep holes inside the furnace, however with better protections and the advent of new-found technologies, to obtain this image, the control room provided a great benefit to the operators as well as plant management. Cameras for monitoring the furnaces are utilized in cement plants, steel plants, glass plants as well as power plants; to see in the boiler furnaces, rotary kilns, melting furnaces, clinker coolers, and etcetera. Such types of systems are flexible in nature and they are quite easy in installation on the furnace wall. They have a 68°horizontal & 50°vertical field of the view; providing a better overall picture. The conventional straight view lens tube is commonly utilized in most wall-mounted boilers. The offset angle-lens could be utilized in much smaller-sized tangentially-heated boilers that are corner-fired.
Cement Kilns & Coolers
To make the finest firing decision, the kiln user must have reliable information about the kiln. The camera of the furnace offers a view into the interior of the kiln directly in that of the control room. The camera of the furnace shows the flame, monitors its length, direction and any effect that it has on the feed. Better control helps in achieving the best conditions of operating for the flame and also improves efficiency of the fuel. The temperature of the flame could also be monitored while petroleum coke or burning coal; and this is done by observing the color changes or selecting a thermal camera. The camera selected for the coolers-section offers a view in the coolers, which is crucial for monitoring the condition of the cement clinker that is quite significant for the quality of the product.
Power Utility Boilers
Cameras have been utilized for decades for viewing the interiors of the boilers operating with coal & oil heating for facilitating start-up or shut down! There is a risk of an explosion inside the boiler if the fuel does not ignite as it should, so monitoring this process will help prevent this type of any unrequired reactions. Earlier, flame detectors had been utilized for assisting light-of, but this was not quite reliable as is needed. Black & white cameras had also been utilized for helping, but were often pulled when the boiler was under full load as such cameras rarely work well across the full dynamic ranges of these boilers. Now, with the help of certain new found systems, it’s now becoming increasingly possible to constantly monitor the various condition(s) of such furnaces.
The camera of the furnace gives a clear-cut view of steel-slab progress in batch or even continuous steel reheating of the furnace as well as the performance of the burner. The camera here is perfectly installed near the furnace exit, above the products on opposite sides. A collective view of the cameras gives a 360-degree view of this furnace. The camera is even quite useful if it is installed below the height of the slab traveling movement. This helps to see the scale accumulated under the steel.
The camera of the furnace offers a clear-cut view of the inside of the glass furnace. It controls the condition of the molten glass, the health of the refractory material and the activity inside the furnace. A thermal view is used in some of the specific cases wherein the need is of obtaining a thermal view of the furnace. With the help of data recording, it is possible to analyze the life of the refectory, etcetera. Such types of cameras are also being utilized in the applications of steel kilns to view the interior of those kilns & the burner flame. A furnace camera installed at the entrance of the rolling mill helps the users to monitor the slab from the plate to the rolling mill.
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