"Early detection of failures in refractory materials"
Customer Concerns
Early detection of failures in refractory materials
Temperatures inside a harsh condition reactor such as synthesis gas reactor that produces carbon monoxide can reach as high as 1,600 degrees Celsius, and the outer surface of the reactor vessel can get as hot as 300 degrees Celsius. To protect their iron walls and enhance combustion efficiency, these facilities are lined on the inside with refractory bricks. As these bricks age and deteriorate, a variety of problems such as a drop in combustion efficiency and breaks in the iron wall can occur and result in the initiation of an emergency shutdown by the plant control system. In addition to being a safety issue, such unplanned shutdowns result in lost production and financial losses.
The Solutions and the Benefits
Quick detection of hot spots
Hot spots on the outer surface of a reactor or furnace occur wherever there are breaks in the refractory brick lining. With its optical fiber sensor cable, the Yokogawa DTSX distributed temperature sensor is able to constantly monitor for changes in the temperature of the outer wall and quickly spot problems early on, before they have a chance to grow into big problems and result in plant shutdowns or worse.
Proper maintenance period according to the conditions
Any reactor or furnace with a refractory brick lining needs to be shut down more frequently than other industrial facilities so that personnel can look inside and check the condition of the bricks. With the DTSX’s ability to monitor surface temperature 24/7/365, maintenance can be performed as soon as any signs are detected that indicate deterioration in the refractory liner. This switch to condition-based maintenance ensures that problems are caught early on and corrected.
How DTSX Works
Measuring the intensity of Raman scattered light
Using pulses of laser light beamed through an optical fiber cable, the DTSX is able to detect temperature-dependent variations in signal frequency that are the result of a phenomenon known as Raman scattering that occurs along the entire length of the optical fiber cable, and it also can determine the locations of those temperature readings using light that is bounced back (backscattering) to the source.
Example: Along a 6,000 meter optical fiber cable, nearly 6,000 measurement points
By measuring how long it takes light to make a round trip back to the source (backscattering), the DTSX is able to calculate the location for each temperature reading. Abnormalities can be located with a spatial resolution of just one meter.
Installation of the Optical Fiber Sensor Cable
There is no need to install a large number of temperature sensors. A single length of optical fiber sensor cable can be affixed to the surface of the reactor or furnace using aluminum tape or something similar. Figure 5 shows the layout of the optical fiber sensor cable on a reactor outer wall.
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Chimie
Les usines chimiques s'appuient sur des processus de production continus et discontinus, chacun posant des exigences différentes en matière de système de contrôle. Un processus continu nécessite un système de contrôle robuste et stable qui ne tombera pas en panne et n'entraînera pas l'arrêt d'une ligne de production, alors que dans le cas d'un processus discontinu, l'accent est mis sur un système de contrôle qui permet une grande flexibilité dans les ajustements des formules, des procédures, etc. Les deux types de systèmes doivent être gérés en fonction de l'historique de la qualité du produit et être en mesure d'exécuter des opérations non routinières. Avec son large portefeuille de produits, ses ingénieurs systèmes expérimentés et son réseau mondial de vente et de service, Yokogawa a une solution pour chaque processus d'usine.
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Fer et Acier
Dans l'industrie du fer et de l'acier, il est crucial d'améliorer la qualité non seulement des produits mais aussi des technologies de fabrication et d'exploitation, ainsi que d'aborder les questions d'environnement et d'efficacité énergétique. Yokogawa aide ses clients à créer l'usine idéale et évolue avec eux pour une croissance mutuelle.
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Pétrole et Gaz (exploration et production)
Yokogawa possède une grande expérience dans tous les domaines du pétrole et du gaz, des installations offshore et onshore aux pipelines, terminaux et opérations en eaux profondes. Nous fournissons des solutions qui améliorent la sécurité, garantissent un fonctionnement précis et fiable et augmentent l'efficacité des installations.
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Pétrole et Gaz (raffinage et distribution)
Ces dernières années, l'industrie pétrolière et gazière en aval a été confrontée à un nombre croissant de défis. Ceux-ci comprennent les caractéristiques changeantes des matières premières à traiter, le vieillissement des installations et des équipements de traitement, l'augmentation du coût de l'énergie, le manque d'opérateurs d'usine qualifiés capables de faire fonctionner une raffinerie de manière sûre et efficace, et les exigences en constante évolution du marché et du client.
Au fil des ans, Yokogawa s'est associé à de nombreuses sociétés en aval pour fournir des solutions industrielles axées sur la résolution de ces défis et problèmes. Les solutions de Yokogawa ont aidé les propriétaires d'usines à atteindre une rentabilité maximale et une sécurité durable dans leurs usines.
Les produits et solutions liés
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DTSX1 Fiber Optic Heat Detector
DTSX1 stores the functions required for heat detection in one box. DTSX1 analyzes the temperature data with high accuracy by measuring with fiber optic sensor cable and perform high temperature heat detection.
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DTSX200 Distributed Temperature Sensor
The DTSX200 is a standard version that is ideal for temperature measurement, for medium-sized areas, and for areas where the distance of fiber optic sensor cables is short. It has excellent environmental resistance because it consumes less power and is less dependent on the temperature measurement environment.
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DTSX3000 Distributed Temperature Sensor
The DTSX3000 is a distributed temperature sensor developed in response to the demand that “one unit be used to monitor temperature distribution a longer distance and a wider area”. A flagship model that meets the expectations for long-distance temperature measurement and high temperature resolution.
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Fiber Optic Temperature Sensor DTSX
The DTSX fiber optic temperature sensor, which uses optical fiber for the temperature sensor, quickly detects and locates abnormalities in equipment by monitoring temperatures at production facilities located far away and across wide areas 24 hours a day, without omission. Highly accurate predictive maintenance avoids downtime and ensures stable plant operation.