Hermann-Bössow-Str. 6-8, 23843 Bad Oldesloe, Germany
+49 4531/88011-0
+49 4531/88011-20

Condition Monitoring of Steel Ladles with IR Cameras

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Thermal Monitoring of the Refractory Lining

The LadleCheck Refractory Monitoring System serves as a key solution to increase safety in steel making and to support the ladle maintenance schedules. It minimizes the risk of liquid steel breakouts while maximizing the lifetime of the refractory lining. The whole system is designed for reliable 7/24 operation in the harsh environment of a steel plant.

System Tasks

The system also helps to reduce the production costs by extending
the service life of the ladle refractories. LadleCheck allows a reliable assessment of the remaining lifetime of the refractory lining. The number of heats can thus be maximized without any safety issues and the re-lining can be scheduled more precisely. Considering the high costs for the refractory maintenance, the system can significantly contribute to a reduction of the production costs of steel.

Key Features
  • Fully automated measurement sequence;
    no operator interaction required
  • Modular and scaleable: 1 to 5 thermal cameras to cover the whole ladle surface
  • 100% Traceability: Automatic storage of images, measured temperatures and process related data
  • Advanced data management and analysis with database and web server
  • Various interfaces for connecting to your process control, data management and visualization

Key Advantages
  • Increased Safety for Steel Production
  • Prevention of liquid steel breakouts
  • Early identification of areas with increased wear
  • Cost savings: Maximization of the refractory lining
    service life without safety risks
  • Optimized refractory maintenance schedule and
    strategy
  • Efficiency comparison of refractory linings

While the ladles are transported by the overhead crane, several
thermal imaging cameras automatically measure the temperature
distribution on their external surface. The measurements are
performed in full movement; there is no need to stop the crane.
Due to the completely modular concept of the LadleCheck system,
an inspection station can comprise a varying number of cameras.
For covering the complete outer surface of the ladle including the
bottom, generally 4 – 5 cameras are required.
Once a measurement is performed, the thermal data are analyzed
and the status of the ladle is indicated to the crane operator. All
thermal images, the temperature data and process related data
are stored in a database enabling dedicated analyses of the
refractory lining status. Based on stored data of previous measurements LadleCheck analyzes the temperature as a function of the ladle service time. A sudden increase in the temperature trend implies a potential breakdown of the refractory and will trigger an alarm. Moreover, the temperature trend also provides a clear information for the progression of refractory wear, allowing to schedule maintenance activities more precisely.

Infrared Camera
Typ: IRSX-I
Temperature Measurement Range: -40°C to +600°C
Temperature Measurement Accuracy: ±2°C or ±2% of Reading
Thermal Resolution: 0,1°C
Image Pixels: 336 x 256 640 x 512
Field of View: 25° x 19° 45° x 35°
Other Lenses available on Request
Frame Rate: 9 Hz oder 60 Hz
Detector: Uncooled Microbolometer
Interface: Gigabit Ethernet
Ambient Temperature Range: -40°C to +60°C
Weight: 310 g
Dimensions: 55mm x 55mm x 87mm
Protection Class: IP67

Camera Enclosures
Type: IRCamSafe AIW 168
Enclosure Material: Stainless Steel
Coolant: Air or Water
Germanium Window: Ø 70mm x 3mm, DLC coated
Air Barrier: Adjustable Air Flow, Supply Pressure 1 – 3 bar
Cable Protection: Heat Resistant Hose, Configurable Length, Resistance to Thermal Load: up to +1640oC
Ambient Temperature Range: -40°C to +350°C
Weight: 10,5 kg
Dimensions: Ø 168mm x 505mm
Protection Class: IP67
Mounting Bracket: Heavy Duty Bracket with Joint, Made from Stainless Steel, Load Rating 45 kg

Other Components
Server-PC: – Industry Standard Server Computer, 19″ Metal Case for Rack Installation
– The Server Computer hosts the LadleCheck Measurement Software, the
Database and the Web-Server.
IRCamSafe-Controller Integrated inside the camera enclosure. The board gives a significantly reduced installation effort, allowing a direct connection to mains power and
Ethernet without any additional connection cabinet. It features various sensors to continuously monitor the ambient conditions in the enclosure, thus
ensuring a safe operation of the camera.
  • 4 Port Switch with 2x LWL-LC 100Base-FX or 2x RJ45(10/100) Up-Links
  • 2 internal sensors for temperature; sensors for pressure and humidity
  • Supports a ring structure of the network for lower cabling complexity
  • Switchable camera power and heater via Modbus-TCP/IP (controlled by the monitoring software)

Interfaces
Web-Server
Ethernet Link
ODBC
OPC
Modbus-TCP
SQL Database
Digital I/O, 24V Input/Output, Potential-Free (Fieldbus Module)

Data Link of Cameras and Computer
Gigabit Ethernet
Up to 90m with Industrial Ethernet Cable
Up to 500m with Multi-Mode Glass Fiber Cable
Up to several km with Single Mode Glass Fiber Cable

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