dickinson-furnace-inspection-services.jp

FURNACE  

INSPECTION SERVICES

DGC offers a comprehensive range of Furnace Inspection Services to the metals smelting, mineral processing, thermal energy and industrial furnace industries. The services include:

 

  • High Temperature Endoscopy

  • Infrared Thermography

  • Image Processing & Laser Technologies

 

Dickinson Group of Companies has established strategic alliances with leading technology partners from countries around the globe.

  ADI INDUSTRIAL SERVICES    BELGIUM  

ADI Industrial Services is a Belgium based service company that has been performing endoscopic surveys and infrared thermography for furnaces in different industries for more than 25 years. Both methods are real time diagnostic tools that aim to providing status of the integrity of refractory linings within a furnace; with infrared thermography providing an external representation of the unit while endoscopy provides on the internal representation of the unit.

  SAPOTECH    FINLAND  

Sapotech is based in Finland offers breakthrough solutions to the metals industry, combining unique image processing and laser technologies to inspect the production of metals at all temperatures. All our solutions are designed to be compact, easy to maintain and customize, and with a short payback time. Our IoT-based Reveal platform enables real-time visualization, acquisition and storing of large amounts of production data. The company is a market leader in the real time visualization, monitoring and tracking of all the manufacturing processes in the metallurgical industry. The company’s technology is widely used in the steel, aluminium, ferrochromium, nickel and copper industries.

ENDOSCOPY  

Endoscopy at working temperature allows for the real time, remote visualisation of the interior of a furnace during normal operations, enabling the assessment of the state of the refractories inside the unit. The robust, purpose designed endoscopy devices are capable of operating within the extremely harsh conditions inside furnaces. Probes are designed to have small diameters thereby only requiring small openings (as small as 50mm).

ADI-IS designs and manufactures its own endoscopic devices enabling an appropriate technical answer to specific needs. Suitable endoscope lengths and various vision angles enable enhanced flexibility during inspection. Endoscopy can also be particularly helpful during Hot Repairs (e.g. for ceramic welding operations).

Furnace endoscopy is a proactive measure that permits for the timeous identification of a number of issues that are linked to the state of the furnace, typically before the onset of the orthodox, speculative and lagging performance indicators.

APPLICATIONS

Amongst other possibilities, employing the services allows plant owners the following feasibilities: 

  • Furnace bottom and sidewall monitoring to prevent catastrophic furnace runouts

  • Efficient scheduling of furnace maintenance or furnace rebuilds

  • Closely monitoring of the critical stages of the furnace in its later stages of operation as to balance the risk of safety concerns with the goal to maximize production

  • Guiding of strategic decisions about furnace operations, e.g. choice of production operations depending on their impact on the health of furnace

  • Objective investment optimisation

BENEFITS

Endoscopy drastically reduces the number of non-scheduled refractory maintenance stoppages as potential problems can be identified and remedied much earlier, as such; endoscopy contributes immensely to maximising equipment throughputs.

Some of the benefits of our endoscopic studies are summarized below:

  • Harmless non-destructive testing technology

  • Allows for objective audits from a neutral point of view

  • Guide continuous improvement and operational excellence initiatives

  • Cost / benefit ratio is always positive

  • Images are recorded at working temperature; no shut down required

  • Full range of support services, from audits to repairs for smooth operations

  • Improved energy efficiency thereby lowering emissions

INFRARED THERMOGRAPHY

Infrared thermography involves the real time, visualisation of the thermal status of furnace equipment from the outside, without any contact. Priority is on HOT SPOTS detection and temperature measurements which should help to monitor the evolution of damages on refractory lining, measuring the remaining thickness of the said lining.

The adoption of infrared thermography enables operators to constantly monitor the metallic shell status, identify / localise damaged areas (internal/external) as well as to estimate the remaining refractory lining thickness. The technique ultimately allows for the early detection of HOT SPOTS which could lead to the following:

  • Safety risks for staff

  • Mitigating major damage to the furnace

  • Impacts on ancillary

  • Production losses

  • Expensive repair costs

  • Poor energy efficiency

BENEFITS

The benefits of Furnace Endoscopy and Infrared Thermography include the following:

  • Compilation of comprehensive records of wear for refractory lining.

  • Reduced unplanned stoppages.

  • Maximising of furnace equipment availability, increasing yields and reducing operating costs.

  • Efficient planning for scheduled shutdowns and refractory materials supplies.

  • Confident budget planning for purchase of very expensive items such as refractories.

  • Knowledge sharing with plant maintenance staff.

REVEAL TAP

Reveal TAP Molten Metal Monitoring technology is the complete solution for monitoring, documenting and analysing processes involving molten metals. The hardware consists of different sensors and imaging technologies combined, such as high-speed monochrome, infrared and spectral sensors. Our software combines data from all sensors, performs algorithmic process analysis and provides real time numeric and visual feedback to the operators to solve their specific challenges.

Reveal TAP solution can be flexibly customized to specific issues such as:

  • Monitoring of tapping, de-slagging, gas flow purging, material feeding, foaming.

  • Installation at electric arc furnaces, converters, ladles, ladle stations, skimming stations.

  EVERYTHING IS VISUALIZED IN REAL TIME    AND IN EXTREME DETAIL  

APPLICATIONS

  • Molten metal (e.g. steel, nickel, copper, ferrochrome) tapping

  • EAF, AOD, ladle

FEATURES

  • Accurate imaging of molten metal flow

  • Real time control room display

  • Video storage to cloud service

  • Value added features like automatic reaction index

  • Metal and slag detection

  • Integration to Level 2 and 3 systems

  • Extremely easy-to-use web browser interface

BENEFITS

  • Immediate feedback to the operator about quality of tapping

  • Systematic and full documentation for later tracking,

       process development or quality problem solving

  • Work safety improved

  1   IMAGING UNITS

  2   CONTROL CABINETS

REVEAL 360

Reveal 360 Refractory Condition Monitoring technology is the complete solution for monitoring inner surfaces of ladles, converters and furnaces in high temperature conditions. Visual data of target surface condition is available online in unprecedented detail and presented utilizing an intuitive user interface.

The technology has the following:

BENEFITS

  HOT SURFACE    VISUALIZATION  

  • Unprecedented details revealed

  • Laser illuminated, online imaging and measurement of inner surfaces

  • Visual defect, slag accumulation and wear detection

  FEAUTURES    

  • Image data storage

  • Defect marking tools

  • Up-to-date process listing

  • Reporting and searching tools

APPLICATIONS

  • Accurate imaging of molten metal flow

  • Real time control room display

  • Video storage to cloud service

  • Value added features like automatic reaction index

  • Metal and slag detection

  • Integration to Level 2 and 3 systems

  • Extremely easy-to-use web browser interface

  GREAT USER    EXPERIENCE  

  • User friendly design

  • Intuitive web user interface

  • Tablet support

  CUSTOMER    SUPPORT  

  • Online customer support

  • Customer Collaboration Programme

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