NIR Borescope

NIR Borescope Thermal Imager Land InstrumentsThe NIR Borescope Thermal Imager can give the operator access to data which would have previously been either highly time consuming to collect or perhaps completely unknown. Through collecting this data the operator can begin to increase the efficiency of the furnace/melt tank, improving product quality and reducing process costs.

Using LIPS (Land Image Processing System) the operator has the ability to set points or areas of interest and measure live data points as well as storing and trending this data for future analysis.  By monitoring the live video, it can allow the operator to configure the correct, most efficient firing pattern and achieve optimum performance from the burners. This can save significant costs through reducing fuel usage and gaining the best possible performance from the furnace/melt tank

The NIR-b Thermal Imager offers the operator numerous advantages over the existing techniques:

  • The operator gets a high resolution radiometric image of the process meaning a live temperature value can be obtained from any point on the image.
  • Automated alarm outputs can instantly alert the user to any problems within the process
  • Any air leaks and glass leaks, which are detrimental to the efficiency of the furnace are clearly visible and simple to detect
  • A clear profile of the flame is easily visible
  • The operator has access to more than 324,000 live temperature data points
  • Thermocouple can alert to product overheating
  • Coverage 24 hours a day, 7 days a week
  • Improve plant safety by removing personnel from the dangerous environment of the application
  • Monitor all positions from the safety of the control room
  • Long term data trending
  • Fuel optimisation meaning significant savings on gas

Key Benefits of a Thermal Imager

  • Accurate, high resolution radiometric thermal imager camera provides high definition temperature maps enabling precise product control and monitoring
  • Short wavelength sensor provides low sensitivity to emissivity changes and can be used through existing glass or quartz view ports.
  •  Resolution of 656 x 494 pixels gives 324,000 live temperature data points.
  •  Dedicated software with data points, areas of interest, automated alarms and long term data trending
  • 24 hour, 7 day monitoring solution means accurate trending information with no missing data
  • Live data points mean measurements are taken from exactly the same point each time. This removes operator error from collected information
  •  Shutter less operation ensures 100%measurement availability (i.e. no blind times)
  • The thermocouple located at the tip of the NIR-b can alert the operator if the instrument temperature is rising to unsafe levels, it can be removed from the process and avoid damage
  • Auto-retraction means the instrument is removed from the process in the event damage could be caused.
  • 24 Month Warranty gives ownership piece of mind

Galery

Thermal Imager Thermal Imager inside reformer Tube Thermal Imager inside Induction Furnace Thermal Imager inside Reheat Furnace
Side View Inside Reformer Tube Furnace Induction Furnace Reheat Furnace

 

Technical Details

Available Ranges 600 – 1000 ºC / 800 – 1400 ºC / 1000 – 1800 ºC
Probe Lengths 305mm, 610mm, 915mm
Probe Diameter 54mm
Accuracy 1%
Repeatability <1°C
Detector Silicon focal plane array / 656 x 494 pixels
Frame Rate 30fps (Gigabit Ethernet)
Outputs Digital data over Gigabit Ethernet (M12)
Optical System 44° / 90°
Field of View 44° x  33° / 90° x 67.5°
IFOV 1.2mrad / 2.4mrad
Focusing Range 1000mm to infinity
Spectral Response 780 to 1100nm
Emissivity Adjustment 0.2 to 1.0 in 0.01 steps
Operating Temperature Range 0 to 60ºC (Operating)
Storage Temperature Range -20 to 80 °C (non-condensing)
Operating Humidity 0 to 90 % non-condensing
Power Requirement 24VDC (3 watts)
Sealing IP65 / NEMA 4
Vibration 3g between 10 and 300 Hz

Thermal Imager Applications

Glass Melt Tanks

It is desirable to monitor the conditions inside glass melt tanks for a number of reasons. The operator will always want to gather as much information as possible to improve his/her understanding of the process and the temperatures involved.

There are several aspects most operators would like to monitor within the tanks. One is the crown and wall temperatures of the furnace to help ensure that the refractory is not overheating and running at temperatures which could cause damage to the furnace. Another is to monitor the blanket (or melt line).

Monitoring the conditions inside glass melt tanks has traditionally utilized visual camera technology and manual inspections. Both of these techniques have inherent problems.

Visual cameras:

DO NOT give a true temperature reading. There is no guarantee of accuracy meaning aligning the process to run to optimum performance based on this information will not be successful and could result in overheating or inefficient combustion. The radiometric image can be presented to appear to simulate the visual camera view the operator may be accustomed to working with.

Manual inspections are also widely used. Manual inspections have a number of weaknesses:

  • They are labour intensive and time consuming.
  • Often taking hours to complete everyday and requiring multiple staff members.
  • Inherently possess a risk to the operator of having to spend extended periods of time within the application environment.
  • Different operators will naturally take the temperatures readings from slightly different points. Therefore the data collected will not necessarily be suitable for building trend information.

The NIR Borescope can give the operator access to data which would have previously been either highly time consuming to collect or perhaps completely unknown. Through collecting this data the operator can begin to increase the efficiency of the furnace, improving product quality and reducing process costs.

Using LIPS the operator has the ability to set points or areas of interest and measure live data points as well as storing and trending this data for future analysis.  By monitoring the blanket (or melt line), live video can allow the operator to configure the correct, most efficient firing pattern and achieve optimum performance from the burners. This can save significant costs through reducing fuel usage and gaining the best possible performance from the furnace.

The NIR-b offers the operator numerous advantages over the existing techniques:

  • The operator gets a high resolution radiometric image of the process meaning a live temperature value can be obtained from any point on the image.
  • Automated alarm outputs can instantly alert the user to any problems within the process
  • Any air leaks and glass leaks, which are detrimental to the efficiency of the furnace are clearly visible and simple to detect
  • A clear profile of the flame is easily visible
  • The operator has access to more than 324,000 live temperature data points
  • Thermocouple can alert to product overheating
  • Coverage 24 hours a day, 7 days a week
  • Improve plant safety by removing personnel from the application environment
  • Monitor all positions from the safety of the control room
  • Long term data trending
  • Fuel optimisation meaning significant savings on gas

Reformer Tube Furnaces

By viewing inside the furnace the operator can take temperature information from various points of each tube in order to monitor the tube condition. This information can be used to check for hot spots appearing and trended over time to identify potential problem areas.

maximise their knowledge of the temperatures involved within the process for several reasons:

Prolonging the life of the tube

  • The tubes used within the process are extremely expensive. Made specifically for the application the cost of a single tube can be £10,000 with each furnace using hundreds of tubes. Running the process over temperature will drastically reduce the lifetime of the tubes meaning the tubes will need replacing more often or faults can occur leading to super heated steam escaping into the process.

Reducing down time and tube replacement

  • Replacing the tubes requires the purchase of replacements and stopping the process for the work to be completed. This downtime is extremely expensive and can, on a large plant, cost up to £1m per day!

Running at maximum efficiency

  • Through improving their knowledge of the process the operator is able to ensure that the temperatures involved are correct for the most efficient use of the furnace. This has several benefits, first it will ensure the maximum level of reaction in the process and secondly, it can maximise fuel efficiency and so reduce costt.

Reduce risk of catastrophic failure

  • Closely monitoring the condition of the tubes within the furnace can allow early identification of any potential hot spot or weaknesses. This can allow preventative action to be taken before the problem becoming serious.

The NIR Borescope can give the operator access to data which would have previously been either highly time consuming to collect or perhaps completely unknown. Through collecting this data the operator can begin to increase the efficiency of the furnace, improving product quality and reducing process costs.  By setting data points in the software the operator can ensure that the data is taken from exactly the same point every measurement and remove human error.

Through better understanding the temperature the operator can monitor the tubes and ensure they are within the specified limits thus greatly increasing the life time of the tube and the period between expensive downtime periods. The operator will also be able to maximise combustion efficiency and so reduce fuel costs and maximise output.

The NIR-b offers the operator numerous advantages over the existing techniques:

  • The operator gets a high resolution radiometric image of the process meaning a live temperature value can be obtained from any point on the image.
  • Automated alarm outputs can instantly alert the user to any problems within the process
  • A clear profile of the flame is easily visible
  • The operator has access to more than 324,000 live temperature data points
  • Thermocouple can alert to product overheating
  • Coverage 24 hours a day, 7 days a week
  • Improve plant safety by removing personnel from the dangerous environment of the application
  • Monitor all positions from the safety of the control room
  • Long term data trending

Reheat Furnaces

By viewing inside the furnace the operator can take temperature information from relevant points and trend the data. The operator will need to know:

  • That the burners are working correctly and consistently.
  • The condition of the furnace walls
  • Temperature information of the product as it moves through the process

The operator will want to maximise their knowledge of the temperatures involved within the process for several reasons:

  • Reducing downtime
  • Running at maximum efficiency
  • Maximise combustion
  • Reduce fuel costs
  • Prolong furnace life

The NIR Borescope can give the operator access to data which would have previously been either highly time consuming to collect or perhaps completely unknown. Through collecting this data the operator can begin to increase the efficiency of their process, improving product quality and reducing costs.

By setting data points in the software the operator can ensure that the data is taken from exactly the same point every measurement and remove human error. The operator will also be able to maximise combustion efficiency and so reduce fuel costs and maximise output.

The NIR-b offers the operator numerous advantages over the existing techniques:

  • The operator gets a high resolution radiometric image of the process meaning a live temperature value can be obtained from any point on the image.
  • Automated alarm outputs can instantly alert the user to any problems within the process
  • A clear profile of the flame is easily visible
  • The operator has access to more than 324,000 live temperature data points
  • Thermocouple can alert to product overheating
  • Coverage 24 hours a day, 7 days a week
  • Improve plant safety by removing personnel from the dangerous environment of the application
  • Monitor all positions from the safety of the control room
  • Long term data trending

Cement Kiln – Burning Zone

The NIR Borescope can give the operator access to data which would have previously been either highly time consuming to collect or perhaps completely unknown. Through collecting this data the operator can begin to increase the efficiency of their process, improving product quality and reducing costs.

By setting data points in the software the operator can ensure that the data is taken from exactly the same point every measurement and remove human error. The operator will also be able to maximise efficiency and so reduce fuel costs and maximise output.

  • The operator gets a high resolution radiometric image of the process meaning a live temperature value can be obtained from any point on the image.
  • Automated alarm outputs can instantly alert the user to any problems within the process
  • A clear profile of the flame is easily visible
  • The operator has access to more than 324,000 live temperature data points
  • Coverage 24 hours a day, 7 days a week
  • Long term data trending

More Information

NIR Borescope – Product Datasheet

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