Monitoring Solutions from Viper Imaging provide an accurate, reliable temperature measurement solution to ensure plant safety and increase efficiency.
Viper’s Steel Mill Monitoring Solutions use thermal imaging cameras to monitor in real time and alarm for temperature anomalies. System solutions combine advanced thermal imaging, condition monitoring sensors, and intelligent software to deliver real-time insights so you can keep operations running with confidence. Scroll down for use case examples!
Steel Mill Application Areas
Continuous thermal and visual monitoring sees through steam and smoke to effectively detect hot spots early.
Use thermal imaging cameras to monitor the shell temperature of process vessels to assess refractory wear. Continuous thermal monitoring can also identify potential water leaks. (See below for more info)
A multi-camera system will monitor the shell temperature of the AOD (Argon Oxygen Decarburization) and VOD (Vacuum Oxygen Decarburization) vessels. A key area of interest is often the shell directly behind the AOD tuyeres.
The cooling water system is an inherent part of every EAF, and there is an industry need for effective and reliable water leak prevention as well as leak detection. When water is trapped beneath molten steel, it often leads to one of two explosions.
- Steam ejects from below the surface – projecting molten metal and slag
- More severe explosion from the rapid ignition of H2 and CO gas inside the EAF
Viper’s monitoring system, using thermal cameras easily detect water and determine the source. Scroll to the bottom of the page to see thermal images of discovered leaks.
The Viper Ladle Refractory Monitoring system uses thermal imaging to monitor the health of a ladle through its lifecycle.
Steel mills worldwide use refractory-lined ladles to store and transport molten steel. A key benefit of the Viper monitoring system is that it allows users to input a ladle ID, and ViperVision Max software will monitor the health of the ladle through its lifecycle.
Over time, the refractory linings degrade or develop cracks that allow the ladle’s outer shell to be exposed to excessive temperatures. If not caught in time, a molten metal breakout can occur, threatening the lives of plant personnel and causing unnecessary downtime and significant damage to equipment. Viper’s Ladle Refractory Monitoring System uses thermal imaging cameras to monitor the ladle in real-time and warn of excessive shell temperature resulting from refractory degradation – ultimately preventing a breakout. Scroll down to the bottom of this page for images of discovered hotspots.
Continuous casting monitoring tracks tundish shells, casters, spray chambers, & cut zones— detecting hot spots, temperature inconsistencies, cooling issues, & missed cuts.
In keeping with the industry trend to remotely monitor furnace operations, the Viper Furnace Monitoring Systems provide data previously obtained through visual observation from the pulpit and dangerous, hands-on testing.
Continuous monitoring of equipment tracks temperature, vibration, & acoustic signals, giving operators early warning of anomalies to prevent failures & downtime.
Continuous thermal and visual monitoring leverages advanced sensors and intelligent software to detect anomalies early, provide real-time insights, and improve safety and reliability in substations and vault rooms.
Click here for more details about substation monitoring.
Monitor the sanding process to identify when the tap hole has been properly sanded so that the vessel can be refilled safely. Scroll down to our featured case studies and videos to see actual footage from a thermal sanding camera.
Viper's System Solutions
Predator Kit
This illustration portrays a typical installation for Viper’s Ladle Refractory Monitoring system using the Viper Predator Kit. Viper’s design places three thermal imaging cameras around the ladle and a fourth camera to monitor from underneath. The camera’s digital data stream is connected via Ethernet to the ViperVision control system. ViperVision software controls all camera functions, collects temperature data, displays thermal images, and analyzes data.
The Included ViperVision Max Software will view, analyze, record, and trend critical data for key assets. This package includes a Control Communication module and a Database/Reporting module. The ViperVision Ultra package provides integration with your company’s VMS using RTSP output. (Refer to the Gerdau customer case study to learn more about this feature!)
eM Saver
Advanced Integrated Multisensor Device
Engineered for harsh industrial environments, The eM Saver helps to reduce downtime, extend asset life, and support condition-based maintenance strategies. It’s OEM-agnostic and ideal for manufacturing, utilities, processing, and more.
A compact, plug-and-play sensor designed for continuous condition monitoring of motors, pumps, gearboxes, and bearings. Each device integrates tri-axial vibration, ultrasound, temperature, and magnetic field sensors to detect faults before failure occurs.
With built-in Wi-Fi and optional RS-485 connectivity, the sensors connect to a cloud-based dashboard for real-time alerts, diagnostics, and predictive analytics. No field configuration is required, and installation is quick with magnetic mounting.
White Paper: Improving Safety & Productivity - Why the Steel Industry Needs Continuous Thermal Monitoring
Electric Arc Furnaces have changed the way steel is produced.
But they also create unique risks and operational challenges that require specialized expertise. Continuous Thermal Monitoring solutions leverage advanced thermal and visual cameras to provide steel plants with 24/7 coverage of ladles, electric arc furnaces, and other critical equipment.
Case Study: How a leading global steel producer's commitment to safety led to incorporating a thermal monitoring system
Watch this webinar recording to learn more about continuous thermal monitoring for automating and optimizing processes in the steel industry.
Featured examples include EAF Water Wall Leak Detection and Steel Ladle Refractory Monitoring.
This Milestone XProtect Smart Client screen recording shows the sanding process.
This is used to identify when the tap hole (EAF) has been properly sanded to begin the next heat. This video was captured by the Viper Predator System and processed with ViperVision Ultra software integrated with Milestone VMS.
Key Benefits
System Solution Components
Using the Predator Kits, thermal cameras are integrated with the ViperVision software, which directly communicates with most industrial platform controllers. Every thermal imaging camera is mounted in an industrial camera enclosure that uses the appropriate purge and pressurization to protect the camera equipment. Viper Imaging provides solutions for Class I and Class II environments (Division 1 or 2).
For vibration monitoring, Viper is the exclusive distributor of Enertics’ asset performance and condition-based monitoring systems. The eM Saver is an advanced integration multisensor that offers wireless monitoring.
Some Images of Viper's System Solution
