Infrared (IR) thermometry company Raytek® has extended the capabilities of its CS210 process imaging system for cement kilns with optional, fully integrated 3D view and refractory management database modules. The enhanced kiln shell scanning system enables cement manufacturers to avoid costly damage and unscheduled downtime by continuously monitoring rotary kilns to detect hot spots due to refractory loss, damage and wear.
Using the CS210 infrared (IR) linescanning solution, which now supports up to four scanners, cement plant operators can determine the effectiveness of kiln refractory material. Fallen bricks can be quickly detected and appropriate action may be taken to prevent further damage. Scheduled maintenance can also be planned to replace the refractory with a minimum of downtime.
The 3D view module can help users to easily understand all of the data provided regarding the kiln and its environment, including the live view of the rotating kiln, life rings and zone (with optional hardware) – even for the non-refractory related real-time view, which is part of the standard CS system. The refractory management module can help users determine when to change the refractory of a cement kiln. Its database is based on an enhanced data management system that can monitor the installed brick, including gathering, storing and analysing all necessary data to indicate refractory wear during use. The system software features a user interface for entering standard data with predefined dropdown lists, as well as history tracking that includes all related refractory and kiln data, maintenance data, date, time and record of changes made by the user.
With the CS210, temperature is monitored along the entire length of the kiln shell with one brick resolution. The system also provides hot spot alarm outputs. Operators can detect abnormal conditions, such as faulty flame position and shape. Temperature data for areas shadowed from the main sensor are provided by individual point sensors and integrated into a complete, real-time thermal image. At the core of the CS210 system is a specially built MP150 HR linescanner with 1024 data points per scan line and an integral heater, configured for the user’s kiln applications. Featuring state-of-the-art optics, advanced microprocessor electronics and a high-reliability motor, the MP150 combines signal processing, data storage and data communications into one integral unit. To insure reliable operation in even the harshest kiln environments, the linescanner is designed with a rugged cast aluminum housing, which, in turn, is mounted in a stainless steel protective housing with provisions for air-purge and water-cooling.
The CS210 process imaging system employs onboard Ethernet TCP/IP communications and interfaces with other programmes via OPC. The system's DataTemp® CS Software is fully compatible with Windows® 7 and provides easy configuration/startup, as well as multiple security settings. The graphical user interface is designed specifically for kiln applications, allowing for easy scanner setup and use with little operator training. Installation of the CS210 process imaging system has been simplified with the addition of a single fiber-optic communication channel to carry all system data from the scanning system located at the kiln to the host computer imaging system in the control room. With DataTemp software accessories, the CS210 system expands to become a comprehensive kiln-monitoring tool. For example, optional burning zone sensor and live ring migration (LRM) tyre slip monitoring can be integrated into the system so that complete information is displayed on a single screen in the control room, and all data, events and alarms are stored and accessible in a common database.
Adapted from press release by Rosalie Starling
Read the article online at: https://www.worldcement.com/the-americas/10022014/new_features_expand_capabilities_of_rayteks_process_imaging_system_22/