CS400 Kiln Shell Imaging System
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Brand: Fluke Process Instruments Vietnam
Category: Thiết bị đo lường & Kiểm tra
Supplier: ANS Vietnam
Origin:
Ứng dụng sản phẩm: Automotive
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0911472255Fluke Vietnam,CS400 Kiln Shell Imaging System
CS400 Kiln Shell Imaging System
CS400 Provides Complete Kiln Monitoring
Capability
Kiln shell temperatures are monitored along the entire length of the kiln,
providing an essential indication of the health of the refractory material.
Temperature data for areas “shadowed” from the main sensor can be
provided by individual point sensors and seamlessly integrated into
one complete thermal image. Optional burning zone sensor and tire slip
monitoring can be integrated into the system, so that all information is
displayed on one screen in the control room. All events, as well as kiln
and refractory data, can be viewed in an optional real time moving 3D
view. These events can be permanently linked in an extremely versatile
Refractory Management database.
Rugged & Reliable for
Continuous Kiln Shell Monitoring
Picture every brick in your kiln in real-time with continuous infrared
monitoring that can help prevent costly shutdowns and extend production
runs. Specifically designed for harsh kiln environments, the CS400
Process Imaging System is a fully integrated solution that continuously
monitors kilns for hot spots – helping your team avoid costly damage and
unscheduled downtime.
At the core of the CS400 System is the MP Linescanner, which provides
accurate, edge-to-edge and real-time thermal imaging and temperature
measurements for continuous processes so you can get a complete picture
of your application.
To ensure reliable operation in
hars kiln environments, the MP
linescanner is designed with rugged,
aluminum-cast housing, which in
turn is mounted in a robust stainless
steel protective housing with
provisions for air-purge and water
cooling.
The protective housing includes an
adjustable mounting bracket to aim
the scanner along the kiln axis, a
mounting rail permitting fast scanner
installation, quick-disconnect fittings
for air purge and water cooling and
an easily replaced viewing window |
Kiln Shell Scanning System
Specifically designed for kiln monitoring, the CS400
is a fully integrated solution that monitors rotary kilns
to detect hot spots while avoiding costly damage and
unscheduled downtime. Optional, yet fully-integrated,
accessories, extend the CS400’s capabilities to include
shadow sensing, burn zone monitoring, tire slip and
fan control.
At the core of the CS400 system is the MP150
linescanner , which can scan up to 1024 data points
in a single scan, and an integral heater that can
be configured specifically for users’ unique kiln
applications. As an option, the system profiles a fully
featured Refractory Management data base.
Rotary Kiln Applications
• Cement Kilns
• Lime Kilns
• Metals and Chemical Processing
Benefits
• Detect hot spots due to refractory loss,
damage or wear
• Detect abnormal operating conditions such as
faulty flame position and shape
• Optimize and manage kiln maintenance
• Extend operational life of kiln
and refractory
• Completely integrated monitoring
of key kiln parameters
Features
• Map entire kiln surface and display in real-time
thermogram format
• “One brick” resolution hot spot detection,
even in shadowed areas
• Fail-Safe “hot spot” alarm outputs
(PC independent)
• On board Ethernet TCP/IP communication
• Interface with other programs via OPC
• Refractory Management software
• Modular design simplifies installation and
service
• All data, alarms and errors stored and
accessible in one common database
• Multiple level security settings
• Multiple Scanner Support
• Real time 3D view of the kiln
• Refractory Management
Accessories
• Tire Slip Monitoring
• Fan Control
• Burning Zone Monitor Package
• Shadow Sensor Package
CS400 System Software
User Friendly Software Provides Easy
Configuration and Startup
The CS400 Kiln Shell Imaging System features specially designed
software, which relies on standard Ethernet and/or CPM ports.
Because the graphic user interface is designed specifically for
kiln applications, the software is easy to set up and use with
little operator training required. With a variety of options and
accessories, the CS400 system expands to become a comprehensive
kiln monitoring tool.
Rapid Set up
Using intuitive set up screens, operators can easily enter the kiln’s
physical dimensions and linescanner position. Once established,
the software displays the resulting configuration and manages
temperature profile calculations.
Integrated Shadow Monitoring
Point sensors can be quickly configured to cover any shadow areas
created by the tires or by physical obstructions, such as buildings or
utility poles. All sensors are configured from one screen and, since
the software senses any conflicts and notifies the operator, set up
errors are virtually eliminated.
Kiln Shell Thermal Image
The software provides a thermal image of the entire kiln shell
surface, with a zoom function that allows detailed examination of
areas of interest. Temperature range, color palettes and zone alarms
are easily configured within the user-friendly software. Other
useful information, such as burning zone temperature, lap time and
the scanner’s internal temperature, is displayed in the status bar to
provide a complete system status without changing screens
Historical Data Analysis
Kiln shell temperature snapshots are taken at user-defined intervals
and stored in both short-term and long-term databases for later
review. Data can be viewed as thermograms, histograms or as line
charts to monitor gradual refractory degradation or other changes.
Integrated Live Ring Migration
Proximity sensors measure the rotation of each tire and calculate
the tire slip at each location. Results are calculated and displayed
for each rotation as well as being stored for data analysis. Any
deviation beyond user-defined limits results in immediate alarms.
CS400 System Accessories
Tire Slip Monitoring (TSM)
The TSM sensors and connection boxes required to activate
the system can be purchased as an accessory. This system
records tire slip and can be configured to generate alarms
at user-defined limits. The TSM is fully integrated with the
system software and is capable of extensive historical data
analysis.
Fan Control
Fan control software is included with the CS software to control
up to 48 discrete zones. The optional fan control hardware allows
the user to provide outputs to up to 16 fans per module.
Burning Zone Monitor Kit
When the optional Burning Zone Monitor Kit is installed,
operators can monitor the condition of the critical burning
zone area directly using the CS software. Temperature is
displayed alongside the kiln shell temperature and all data
is recorded and date stamped for later analysis. The kit
consists of a two-color ratio point sensor to “see through”
the combustion gases, a protective housing and all of the
hardware needed to complete the installation.
Shadow Monitoring Kit
The CS software can accommodate select pyrometers from
Fluke Process Instruments to monitor areas of the kiln
shadowed from the main linescanner. The data is seamlessly
integrated into a single thermogram, both for real-time
display and for later data analysis. For convenience, the most
commonly used sensor and all of the necessary accessories
are provided as a kit.
Refractory Management Kit
The Refractory Management Module Database is based on
an enhanced data management system that can monitor the
installed brick, including gathering, storing and analyzing all
necessary data to indicate refractory wear during use.
The content of the database will be related to the kiln
and refractory. Examples of this input data are: time of last
maintenance, brick types and properties, brick/refractory
zone names and positions, as well as flame/burning zone
temperature (with optional hardware).
The software features easy user interface for entering
standard data with predefined dropdown lists, as well as easy
to use history tracking that includes all related refractory and
kiln data, maintenance data, date, time and record of changes
made by user name.
The Refractory Management Module will help cement
manufacturers and rotary kiln operators decide
when to change the refractory of a cement kiln.
3D View
The 3D view module will help to easily understand all the
data from the kiln and its environment, including life view
of the rotating kiln, life rings and zones (with optional
hardware), even for the non-refractory related “real-time
view”, which is part of the standard CS System
Specifications
Temperature range 100 to 650 °C
Temperature resolution 0.1 K
Accuracy ± 0.5% of reading or ± 3 °C
Spot detection 450 : 1 ( 2.2 mradians )
(50% of energy)
Sampling rate 1024 pixel per scan line
(2048 for CS402)
Scan motor MTBF: 40,000 hours
Ambient operating temp. -40 to 45 °C ( no direct sunlight )
Position indicator temp. -25 to 230ºC
Zone alarms 48 software, 3 hardware (PC
independant)
Kiln rotation rate Up to 10 rpm
LRM accessory Supports up to 6 tires
Fan Control accessory Supports up to 16 fans per
module (48 total)
Burning Zone Accessory MR Ratio Pyrometer 700 to
1800 °C, connection box, 15 m
high temp. cable, Thermojacket,
blast gate, sighting tube, adj.
pipe adapter, adj. mounting base,
air flow/press. regulator
Shadow Monitor Accessory MIH Sensor (-40 to 600 °C) with
8 m high temp. cable, air purge
jacket and adj. mounting
CS400 System Details
Linescanner MP150 linescanner (2 for
CS400)
(includes all required cables
and connectors)
Protective Housing Rugged Stainless Steel
Housing (2 for CS402)
System Connection Box 2 for CS402
Position Indicator High-temperature kiln
rotation sensor
Software CS400 System Software
Documentation Documentation Binder with
Operators Manual and MP
Manual
Startup Service On-site startup
commissioning/training
available
CS400 Part Numbers
CS401-MP150-KIT CS400 Kiln Shell Monitoring System
CS402-MP150-KIT-2 Dual scanner system for longer kilns
CS403-MP150-KIT-3 CS403 Rotating Kiln System (3 scanner system)
CS404-MP150-KIT-4 CS404 Rotating Kiln System (4 scanner system)
A-CS-CONV-ETH485 Serial RS485 / RJ45 Ethernet Converter
(req’d for accessories)
A-CS-TSM-KIT-485 Tire Slip Monitoring (TSM) Hardware Kit
A-CS-BZ-EN-KIT-485 Burning Zone Monitor Kit
A-CS-SM-KIT-485 Shadow Monitor Kit
CS400-SW-CS210-UPG Basic upgrade from old CS210
Easy Installation & Maintenance
The MP150 linescanner (1) is installed to view the desired portion of the
kiln. The Position Indicator (2) is a high-temperature inductive sensor that
synchronizes thermal imaging with kiln rotation. The System Connection
Box (3) provides for local cable/wire termination. The Interface Box (4)
connects the scanner to the PC (5) and contains fibre-optics to Ethernet
conversion. The scanner communicates to a PC via fibre-optics for
distances up to 2000 m.
CS400 System components are easy to install and are field-replaceable.
When installing two linescanners, they may each mount at different
angles so that each has a clear view of the kiln shell. CS software
combines the data from each scanner providing a single thermal image for
display and analysis.
The CS400 System installs in a standard PC (local operating system) without
need to add expansion cards or open the computer.
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