Land – NIR – Borescope – Temperature Profiles inside Furnaces

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The NIR Borescope can give the operator access to data which would have previously been either highly time consuming to collect or perhaps completely unknown. Through collecting this data the operator can begin to increase the efficiency of the furnace/melt tank, improving product quality and reducing process costs.

Using LIPS (Land Image Processing System) the operator has the ability to set points or areas of interest and measure live data points as well as storing and trending this data for future analysis.  By monitoring the live video, it can allow the operator to configure the correct, most efficient firing pattern and achieve optimum performance from the burners. This can save significant costs through reducing fuel usage and gaining the best possible performance from the furnace/melt tank

The NIR-b offers the operator numerous advantages over the existing techniques:

  • The operator gets a high resolution radiometric image of the process meaning a live temperature value can be obtained from any point on the image.
  • Automated alarm outputs can instantly alert the user to any problems within the process
  • Any air leaks and glass leaks, which are detrimental to the efficiency of the furnace are clearly visible and simple to detect
  • A clear profile of the flame is easily visible
  • The operator has access to more than 324,000 live temperature data points
  • Thermocouple can alert to product overheating
  • Coverage 24 hours a day, 7 days a week
  • Improve plant safety by removing personnel from the dangerous environment of the application
  • Monitor all positions from the safety of the control room
  • Long term data trending
  • Fuel optimisation meaning significant savings on gas

Key Benefits

  • Accurate, high resolution radiometric thermal imager camera provides high definition temperature maps enabling precise product control and monitoring
  • Short wavelength sensor provides low sensitivity to emissivity changes and can be used through existing glass or quartz view ports.
  •  Resolution of 656 x 494 pixels gives 324,000 live temperature data points.
  •  Dedicated software with data points, areas of interest, automated alarms and long term data trending
  • 24 hour, 7 day monitoring solution means accurate trending information with no missing data
  • Live data points mean measurements are taken from exactly the same point each time. This removes operator error from collected information
  •  Shutter less operation ensures 100%measurement availability (i.e. no blind times)
  • The thermocouple located at the tip of the NIR-b can alert the operator if the instrument temperature is rising to unsafe levels, it can be removed from the process and avoid damage
  • 24 Month Warranty gives ownership piece of mind

What advantages does the Borescope have?

Building on more than twenty years experience with infrared technology Land has continued to widen its range of temperature measurements solutions by launching the NIR Borescope. With the NIR Borescope it is possible to use the
proven technology of NIR Thermal Imager to accurately profile the temperature of the entire furnace with only a small opening in the wall.

Thermal imaging inside refractory lined furnaces, boilers and glass melt tanks normally requires the plant operator to cut large openings in the refractory to enable viewing of the critical area. This can cause significant wasted energy from heat
loss and can be difficult to keep the opening free from debris. The NIR-b has a 90° viewing angle, through a narrow opening to overcome this.

Why traditional methods of monitoring are highly limited?

The NIR-Borescope offers significant advantages over some of the traditional methods of furnace monitoring, including Visual Inspection (can take hours to comple and isn’t continuous), a Visual Camera (does not provide a termperature reading) or using Thermocouples (regular failure or loss of connections).

Temperatures
Low Temperature (C): 600 High Temperature (C): 1800
Low Temperature (F): 1112 High Temperature (F): 3272

Technical Details

  Measurement Range

Measurement Parameters

  Available Ranges

  (With respect to Blackbody)

600 – 1000 ºC/1112 – 1832 ºF

800 – 1400 ºC/1472 – 2552 ºF

1000 – 1800 ºC/1832 – 3632 ºF

  Probe Lengths

305mm / 12”, 610mm / 24”, 915mm / 36”

  Probe Diameter (of Water Cooled Tube)

54mm / 2.2”

  Accuracy

1%

  Repeatability

<1°C

  Detector

Silicon focal plane array

  Image Size (Detector Array Format)

656 x 494 pixels

  Frame Rate

30fps (Gigabit Ethernet)

  Outputs

Digital data over Gigabit Ethernet (M12)

  Optical System

44°

90°

  Field of View

44° x  33°

90° x 67.5°

  IFOV

1.2mrad

2.4mrad

  Focusing Range

1000mm (3’) to infinity

  Spectral Response

780 to 1100nm

  Emissivity Adjustment

0.2 to 1.0 in 0.01 steps

  Operating Temperature Range

0 to 60ºC / 32 to 140 ºF (Operating)

  Storage Temperature Range

-20 to 80 °C / -4 to 176 °F (non-condensing)

  Operating Humidity

0 to 90 % non-condensing

  Power Requirement

24VDC (3 watts)

  Weight:

15kg (for 2’ variant)

  Sealing

IP65 / NEMA 4

  Vibration

3g between 10 and 300 Hz

  Mountings

Choice of  3in ANSI Flange & Gasket & PN16 DN80 Flange & Gasket with a 12” standpipe

  Probe Diameter

54.0mm / 2.125in.

  Software

Complete LIPS (Land Image Processing Software) package for PC

  Standard Accessories

Power supply, Cables, Software, Close-up Lenses, Water cooled/purged Mounting and Tube

Application

  • Glass Melt Tanks
  • Reformer Tube Furnaces
  • Reheat Furnaces
  • Cement Kilns

Glass Melt Tanks

It is desirable to monitor the conditions inside glass melt tanks for a number of reasons. The operator will always want to gather as much information as possible to improve his/her understanding of the process and the temperatures involved.

There are several aspects most operators would like to monitor within the tanks. One is the crown and wall temperatures of the furnace to help ensure that the refractory is not overheating and running at temperatures which could cause damage to the furnace. Another is to monitor the blanket (or melt line).

Monitoring the conditions inside glass melt tanks has traditionally utilized visual camera technology and manual inspections. Both of these techniques have inherent problems.Inside view Glass Melt  Tank

Visual cameras:

DO NOT give a true temperature reading. There is no guarantee of accuracy meaning aligning the process to run to optimum performance based on this information will not be successful and could result in overheating or inefficient combustion. The radiometric image can be presented to appear to simulate the visual camera view the operator may be accustomed to working with.

Manual inspections are also widely used. Manual inspections have a number of weaknesses:

  • They are labour intensive and time consuming.
  • Often taking hours to complete everyday and requiring multiple staff members.
  • Inherently possess a risk to the operator of having to spend extended periods of time within the application environment.
  • Different operators will naturally take the temperatures readings from slightly different points. Therefore the data collected will not necessarily be suitable for building trend information.

The NIR Borescope can give the operator access to data which would have previously been either highly time consuming to collect or perhaps completely unknown. Through collecting this data the operator can begin to increase the efficiency of the furnace, improving product quality and reducing process costs.

Using LIPS the operator has the ability to set points or areas of interest and measure live data points as well as storing and trending this data for future analysis.  By monitoring the blanket (or melt line), live video can allow the operator to configure the correct, most efficient firing pattern and achieve optimum performance from the burners. This can save significant costs through reducing fuel usage and gaining the best possible performance from the furnace.

The NIR-b offers the operator numerous advantages over the existing techniques:

  • The operator gets a high resolution radiometric image of the process meaning a live temperature value can be obtained from any point on the image.
  • Automated alarm outputs can instantly alert the user to any problems within the process
  • Any air leaks and glass leaks, which are detrimental to the efficiency of the furnace are clearly visible and simple to detect
  • A clear profile of the flame is easily visible
  • The operator has access to more than 324,000 live temperature data points
  • Thermocouple can alert to product overheating
  • Coverage 24 hours a day, 7 days a week
  • Improve plant safety by removing personnel from the application environment
  • Monitor all positions from the safety of the control room
  • Long term data trending
  • Fuel optimisation meaning significant savings on gas

Reformer Tube Furnaces

By viewing inside the furnace the operator can take temperature information from various points of each tube in order to monitor the tube condition. This information can be used to check for hot spots appearing and trended over time to identify potential problem areas.Reformer Tube Furnace with data points

maximise their knowledge of the temperatures involved within the process for several reasons:

Prolonging the life of the tube

  • The tubes used within the process are extremely expensive. Made specifically for the application the cost of a single tube can be £10,000 with each furnace using hundreds of tubes. Running the process over temperature will drastically reduce the lifetime of the tubes meaning the tubes will need replacing more often or faults can occur leading to super heated steam escaping into the process.

Reducing down time and tube replacement

  • Replacing the tubes requires the purchase of replacements and stopping the process for the work to be completed. This downtime is extremely expensive and can, on a large plant, cost up to £1m per day!

Running at maximum efficiency

  • Through improving their knowledge of the process the operator is able to ensure that the temperatures involved are correct for the most efficient use of the furnace. This has several benefits, first it will ensure the maximum level of reaction in the process and secondly, it can maximise fuel efficiency and so reduce costt.

Reduce risk of catastrophic failure

  • Closely monitoring the condition of the tubes within the furnace can allow early identification of any potential hot spot or weaknesses. This can allow preventative action to be taken before the problem becoming serious.

The NIR Borescope can give the operator access to data which would have previously been either highly time consuming to collect or perhaps completely unknown. Through collecting this data the operator can begin to increase the efficiency of the furnace, improving product quality and reducing process costs.  By setting data points in the software the operator can ensure that the data is taken from exactly the same point every measurement and remove human error.

Through better understanding the temperature the operator can monitor the tubes and ensure they are within the specified limits thus greatly increasing the life time of the tube and the period between expensive downtime periods. The operator will also be able to maximise combustion efficiency and so reduce fuel costs and maximise output.

The NIR-b offers the operator numerous advantages over the existing techniques:

  • The operator gets a high resolution radiometric image of the process meaning a live temperature value can be obtained from any point on the image.
  • Automated alarm outputs can instantly alert the user to any problems within the process
  • A clear profile of the flame is easily visible
  • The operator has access to more than 324,000 live temperature data points
  • Thermocouple can alert to product overheating
  • Coverage 24 hours a day, 7 days a week
  • Improve plant safety by removing personnel from the dangerous environment of the application
  • Monitor all positions from the safety of the control room
  • Long term data trending

Reheat Furnaces

By viewing inside the furnace the operator can take temperature information from relevant points and trend the data. The operator will need to know:Thermal view inside a Reheat Furnace

  • That the burners are working correctly and consistently.
  • The condition of the furnace walls
  • Temperature information of the product as it moves through the process

The operator will want to maximise their knowledge of the temperatures involved within the process for several reasons:

  • Reducing downtime
  • Running at maximum efficiency
  • Maximise combustion
  • Reduce fuel costs
  • Prolong furnace life

The NIR Borescope can give the operator access to data which would have previously been either highly time consuming to collect or perhaps completely unknown. Through collecting this data the operator can begin to increase the efficiency of their process, improving product quality and reducing costs.

By setting data points in the software the operator can ensure that the data is taken from exactly the same point every measurement and remove human error. The operator will also be able to maximise combustion efficiency and so reduce fuel costs and maximise output.

The NIR-b offers the operator numerous advantages over the existing techniques:

  • The operator gets a high resolution radiometric image of the process meaning a live temperature value can be obtained from any point on the image.
  • Automated alarm outputs can instantly alert the user to any problems within the process
  • A clear profile of the flame is easily visible
  • The operator has access to more than 324,000 live temperature data points
  • Thermocouple can alert to product overheating
  • Coverage 24 hours a day, 7 days a week
  • Improve plant safety by removing personnel from the dangerous environment of the application
  • Monitor all positions from the safety of the control room
  • Long term data trending

Cement Kiln – Burning Zone

The NIR Borescope can give the operator access to data which would have previously been either highly time consuming to collect or perhaps completely unknown. Through collecting this data the operator can begin to increase the efficiency of their process, improving product quality and reducing costs.

Resource & Download

Flag-gb Manual 807427 – LIPS NIR_b Software User Guide application/pdf Download File
(3.24 MB)
Flag-es MANUAL NIR Boroscopica application/pdf Download File
(1.09 MB)
Flag-gb Datasheet 807346 NIR BoreScope – Installation Guide Issue 4 application/pdf Download File
(6.89 MB)
Flag-gb Datasheet NIR-Borescope sales presentation application/vnd.ms-powerpoint Download File
(3.94 MB)
Flag-gb Datasheet NIR_BoreScope July 2012 application/pdf Download File
(1.13 MB)
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