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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.

  BELGIUM  

  ADI INDUSTRIAL SERVICES  

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.

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.

ASSET INTEGRITY MANAGEMENT & INDUSTRIAL SOLUTIONS

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