Furnace Monitoring Camera

About Furnace Monitoring Camera

Benefits / Advantages of Furnace Monitoring Camera

• Boosts efficiency: Operators can observe and modify the shape and position of the burner flame during the combustion process.
• Increases quality: The process that identifies and corrects flaws in the process early on, which can prevent condition that disrupts downtime.
• Boosts safety: With real-time observation from a safe distance, there is no need for manual verification within a toxic or high-temperature environment.
• Enhances product: A manufacturer can monitor the entire internal process closely to ensure both consistent product quality and throughput.

System Components

The improved design of the furnace monitoring camera allows it to operate safely and reliably in high-temperature environments. A typical system consists of several specialized components.

• Camera head: This includes specially designed thermal imaging sensors that are infrared, or visible light. It features a highly precise pinhole lens and is packaged inside a rugged, hermetically sealed, stainless-steel probe.
• Cooling system: To keep the camera safe from extremes of heat, a continuous cooling system is run to the probe. Most systems will utilize a vortex air cooler, a water-cooling jacket, or a combination of the two. To keep any debris such as ash and smoke off the lens, an air purge system blows air across the lens.
• Retraction system: A pneumatic or automatic retraction system features the camera retracting out of the furnace if there is a failure in the cooling system, or if the temperature exceeds safety limits.
• Control unit: The system is linked to a control cabinet that includes a PLC (programmable logic device). The PLC manages the camera movement and cooling system.
• Display and software: Live video feed is viewable, along with data analysis, on a remote monitor or computer system for the operator using standard and specialized software for thermal analysis, alerts, and trend charts. 

Types of furnace cameras

Depending on what it is you want to monitor there are various types of cameras.  

• Visible-light camera systems: These use high-definition colour CMOS sensors so you have a clear view in real-time of burner flames, material movement, and the process within the furnace chamber. These are suitable for monitoring flame behaviour, preventing impingement on furnace walls.
• Infrared (thermal) camera systems: Infrared cameras measure heat signatures and then convert them to thermal images. Infrared cameras are essential for non-contact temperature measurement and can detect hotspots, and temperature gradients and other thermal problems that are not visible to the naked eye.
• Combined visible and thermal systems: More advanced systems, such as the Tempsens TE series, combine visible and thermal images in the same camera system. This allows the operator to see the process visually while also analysing the thermal profile. 

Industries / Applications of Furnace Monitoring Camera

• Cement: For monitoring rotating kilns, clinker coolers, and general furnace conditions to ensure the health of equipment and quality of the product.
• Steel: Utilized in the production lines from smelting down to rolling. Cameras can inspect steel ladles, blast furnaces, and reheating furnaces.
• Power generation: Used to inspect boiler and burner flames with a view to optimal combustion as well as performing predictive maintenance on critical equipment.
• Glass: Utilized for melting furnace conditions and process flaws monitoring to offer high product quality.
• Waste-to-energy: Applied to improve the combustion process of incinerators with regards to maximum energy recovery and minimum emission. 

Operation

Improved operational safety and furnace availability

With the Furnace Camera, the conditions of the furnace are clearer, regardless of the fumes and dust contained in the field of view. This means that manual inspections would not require the need to open hatches or shut down the furnace for visual inspections – this not only improves operational safety but significantly increases the availability of the furnace. Proactive actions can be taken more quickly.

Improved response time

Operators can spot problems like water leaks, broken electrodes, or hot spots early on and fix them quickly and safely. This helps keep production running smoothly.

Installation is fast and simple

The complete solution is made to fit each customer’s needs. Along with the camera system, we also offer top-quality hatches and cooling systems for modern furnaces. The system is tested thoroughly before it’s sent out, and its design makes it easy to install and get up and running without stopping production.

The system is smart and easy to use

It has an automatic retraction feature that protects the camera if there’s a power cut, water loss, or no instrument air or nitrogen.

The system can record videos, take snapshots, and track trends in certain areas of the furnace for later review. This data can be sent to the plant’s control system or shown on a control room screen.

Tempsens offers full support to get the most out of the system

Our experts help during setup and train both operators and managers to make sure everyone uses the system to its full potential.

We can also offer technical help and system updates through an optional remote support service.