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Steel Mill Refractory Monitoring

Monitoring Solutions from Viper Imaging provide an accurate, reliable measurement solution to ensure plant safety and increase efficiency.

ARC Furnace – BOF Furnace – Torpedo Cars – Ladles

Use Case Example: 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.

Viper's System Solution

This illustration portrays a typical installation for Viper’s Ladle Refractory Monitoring system using FLIR A-series cameras. Viper’s design places three 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, collect temperature data, displays thermal images, and analyzes data.

Add the ViperVision Max Software package for the ability to view, analyze, record and trend critical data for key assets. This package includes a Control Communication module and a Database/Reporting module.

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a factory with smoke and fire

Case Study: Designing the Future of Steel Ladle Refractory Monitoring

The Refractory Engineer says he relies on the alarm system within the [ViperVision] software for protection from breakouts. He begins every day by reviewing a thermal image of each ladle looking for abnormalities.

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Key Benefits

  • Increased efficiency of ladle lifetime with early detection allowing for selective repairs as opposed to full lining replacement
  • Improved safety for plant personnel and reduced risk of damage to plant equipment
  • Prevention of metal breakouts by detection of abnormal temperature increases
  • Increased revenue with consistent production

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For your equipment

System Solution Components

FLIR 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).

Some Images of Viper's System Solution

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