과제들
The plant encounters a significant technical issue during routine maintenance periods of the rotary kiln, which is a critical piece of equipment to produce steel and cement. Over time, iron and other process residues have accumulated on the inside of the kiln causing an extremely thick hardened layer. For the viability of the kiln, the hardened iron deposit needs to be drilled and removed to minimize operational losses and damage to the refractory lining.
To perform this drilling operation, the maintenance team uses heavy-duty drilling machines which require rugged, high-temperature rated power cables that are also robust enough to withstand the rigors of the kiln environment.
The plant is faced with a recurring issue:
- The cables used in conjunction with the drilling machines continuously fail because of the extreme heat from process conditions, mechanical stress, and abrasion risk.
- There is a high failure rate of cables even when multiple cable brands were tested.
- Cables are being damaged or short-circuited either during or shortly after the drill shut down operation, thus delaying the process in the restart of kiln operations.
- The implications are significant, with increased maintenance costs, the risk of electrical hazards and downtime within a tightly scheduled process.
A solution for this situation was needed in the short-term to create a durable and application-specific item that would work and outperform standard industrial cables in high-heat and high-abrasion applications.
OUR SOLUTION
Tempsens was asked to review the problem and make recommendations. Our team visited the site when one of the kilns was shut down to gain an understanding of the real world in which the cables were being used.
Key Observations
- The ambient temperature near the kiln wall was extremely high, especially in the initial cooldown of the kiln.
- The drilling machine cables were exposed to metallic iron dust, vibration, and direct friction.
- The way the cables were routed often led to dragging on rough surfaces and subjecting the cables to high wear during vibration and mechanical action.
Engineering a Custom Power Cable
Using our study and input from the plant engineers, we produced a purpose-built cable specifically to address all the failure points of the cables previously used.
LT Power Cable – High-Temperature Grade (10 Sqmm / 3 Core)
This Low Tension (LT) Power Cable is designed for high-performance applications in extreme thermal environments such as kilns, furnaces, and process industries. Built to withstand continuous and short-term thermal stresses, the cable delivers both electrical reliability and mechanical durability.
Technical Description:
● 지휘자:
10 Sqmm, Multistrand, Annealed Bare Copper
– Ensures high flexibility and low electrical resistance, ideal for dynamic industrial environments.
● No. of Cores:
3 Core – Suitable for balanced three-phase power distribution.
● 격리:
Multi-layered High-Temperature Construction
– Kapton + Teflon + Fiberglass (FG) + Mica, reinforced with high-temperature varnish for superior dielectric and thermal stability.
● 내부 덮개:
Teflon – Offers excellent chemical and thermal resistance.
● Protective Layers:
- Double Mica Taping – Exceptional fire resistance
- Double FG Braiding – Mechanical strength and insulation integrity
- Stainless Steel Braiding – Abrasion resistance, mechanical protection, and electromagnetic shielding
● Core Colour Coding:
Red, Yellow, Blue (for easy phase identification)
● Inner Sheath Colour:
검은색
Thermal Ratings:
- Continuous Operating Temperature: Up to 500 °C
- Short-Term Exposure: Up to 600 °C
This LT cable is ideally suited for low-voltage power distribution in high-temperature and mechanically demanding settings. Its robust construction ensures long service life, safety, and reliability, even under thermal shock or mechanical stress.
This multilayered construction provided 3 layers of protection and exceptional mechanical strength for a longer life under extreme shutdown conditions. The stainless-steel braiding acted as armor to minimize mechanical damage of the cable core during defect movement within the kiln zone.
Why It Worked
- High Flexibility: Copper conductors offered unrestrained movement even when handled manually in tight-fitting conditions.
- Thermal Resistance: The multi-layer insulation—comprising Kapton, Teflon, Fiberglass, and Mica protected the conductors against thermal distortion and damage.
- Abrasion Protection: SS braiding acted like a bullet proof vest and prevented cable core damage when being pulled or laid over harsh metallic surfaces.
- Electrical Integrity: Maintained safe insulation resistance and dielectric strength after repeated cycles of use.
RESULTS
The redesigned 템센스 cable was used for real-time service during the shutdown of the kiln and exceeded all our expectations.
Operational Impact
- Zero cable failures during the first cycle of usage, a huge improvement over previous experience.
- Maintenance crews could complete the drilling and cleaning job unscheduled and return the kiln into service on time.
- No damage to insulation or broken conductors noted post-operation.
- The customer was happy and confirmed that cables were re-used during the next shutdown without visible degradation or change in performance.
This improved cable life, reduced procurement cycles, and improved operational safety by reducing the risk of short circuits and electric failure.
결론
In industrial applications such as the steel industry’s continuous caster production of plates in steel mills, typical cables could not withstand the combination of intense heat, mechanical abuse, and metal dust. What was required here was not just a better cable; it was a cable that was engineered for the job.
Tempsens’ custom power cable is an example of how application-specific engineering relevant to the site conditions can alleviate long-standing reliability challenges. By combining materials science, thermal engineering, and site knowledge, we helped our customer convert an ongoing headache into a resolved issue. We did not just deliver a product; our accomplishment was in properly identifying the issue, engineering the right solution, and providing consistent performance under extreme conditions.
Tempsens continues to empower industries by creating temperature systems and cables that exceed tolerance and provide assurance.
ABOUT TEMPSENS
Tempsens Instruments is a global brand known for industrial thermal engineering and sensor technology, supporting effective solutions and technologies to over 75 countries. With over forty years of history, we manufacture high quality cables, temperature sensors, infrared pyrometers, heating systems, and calibration devices. Our solutions are developed based on real-world operational challenges, ensuring that every product is designed for durability, function, and success for its application.
