HJKIR HomePage
Torpedo tank car is a large-scale molten iron transportation equipment, which has the advantages of small heat loss, long insulation time, energy conservation and so on. It can also store molten iron to coordinate the temporary imbalance between iron making and steel-making. At the same time, it can replace the steel-making mixer and ordinary molten iron tank car, and can also complete the desulfurization, dephosphorization and other operating procedures in the process of molten iron transportation.
Figure 1 torpedo tanker
There are 150t, 200t, 250t, 320t, 420t and other models of torpedo tank cars.
Figure 2 outline dimension drawing of torpedo tank car
Cracks, bulges and falls off of torpedo tank car lining caused by chemical erosion, mechanical scouring and rapid cooling and heating. When the refractory materials are partially damaged and not found, serious accidents will be caused.
Conventional detection method of torpedo tank car
The conventional detection method of torpedo tank cars is that the detection workers use ordinary point temperature measuring instruments, combined with their detection experience, to measure the temperature of possible damaged torpedo tank cars, and then record and repair the torpedo tank cars with abnormal temperature. This method mainly relies on the experience of testing workers to measure the temperature at limited points, rather than the whole tank car. Therefore, it has certain limitations, randomness and easy to miss inspection. The torpedo tank car has a large volume, the inspection workload of maintenance workers is large, and the time of one inspection is also relatively long.
The thickness of the lining of the torpedo tank is 300~400mm, and the thickness of the part directly washed by molten iron is 500~600mm. Each time the torpedo tanker is loaded with molten iron, the inner lining of the tank is eroded by about 0.5mm. After delivering several cans of molten iron (the regulations of manufacturers with different delivery times are different), the torpedo tank must be removed and replaced with a new refractory lining.
Figure 3 torpedo tanker filling and lining
2, Detection of torpedo tank car by infrared thermal imager
2.1Operation mode
Figure 4 infrared analysis of torpedo tank car
The infrared camera detects the surface of the torpedo tank, obtains the thermal image of the whole torpedo tank, and uploads the data to the microcomputer system. The infrared analysis software on the microcomputer system analyzes the temperature distribution of the obtained thermal image. The infrared analysis software not only displays the shell temperature of the torpedo tank, but also marks the abnormal part of the temperature. Through the different changes of torpedo tank surface temperature, we can directly judge whether there is lining defect.
The infrared analysis system of torpedo tank car can select one or more inputs to observe the temperature data of the roof, side and bottom of the torpedo tank. The image data obtained by the analysis software can be viewed, analyzed in real time, played back, or directly stored in the database. The thermal analysis of points, lines, surfaces or designated areas can be carried out for each obtained thermal image, especially the temperature measurement and recording of areas prone to lining damage.
Through the database, the temperature information can be played through the Internet or transmitted to the offline torpedo tanker software for further analysis.
2.2Characteristic
Comprehensive real-time infrared imaging:
The infrared camera adopts advanced uncooled focal plane imaging, automatic image adjustment, and clear and stable image. The infrared cameras installed at the dump, top, side and bottom can fully monitor the surface of the torpedo tanker, and no hot spots can be ignored.
Figure 5 Comparison of infrared and visible images of torpedo tank car
High temperature resolution:
High sensitivity infrared detector, its temperature resolution can reach <0.08 ℃ (30 ℃ target). In this way, the subtle changes of the hot metal torpedo tank car can be reflected in time. Combined with the infrared analysis software, it can predict the trend, avoid accidents and reduce consumption.
Not affected by environmental changes:
Wind, rain and snow will affect the surface temperature of the car body, but will not affect the temperature distribution of the tank surface. Therefore, even if the absolute temperature of the defective part of the lining changes, it will not affect the analysis results.
Intuitive analysis results：
The monitoring system adopts a lot of computer technology, and the measurement data is completely digitized. The digitized signal and various calculation results are intuitively displayed on the monitor in the form of graphics. The displayed color temperature distribution image intuitively shows the temperature distribution of the torpedo tank car.
Trend line algorithm:
Combined with the number of torpedo tank cars, comprehensive and accurate temperature records and trend data can be provided for each car for a long time and all-weather.
History:
The operation condition of the torpedo tank car can be recorded regularly. The calculation result of each thermal image and the image itself can be recorded in the computer, and the existing records can be called out at any time for playback. This facilitates the storage, transfer and management of data. In addition, the use of rich software will make historical records a powerful scientific basis for future analysis, demonstration and decision-making.
Detect other mechanical faults：
The bearing and clutch will be overheated locally due to friction, poor lubrication and other faults. The infrared detection system can be used to detect the mechanical fault, so as to avoid accidents such as molten steel splashing.
Convenient for torpedo tank maintenance
After delivering molten iron for a certain number of times, the torpedo tank must be removed and replaced with a new refractory lining. However, in most cases, the refractory lining has not been locally thinned. The state and when to maintain the ladle will be determined by using the thermal imager. The cost of manpower and material resources is greatly reduced, and the spare number of torpedo tanks is reduced.
The image collected by the infrared camera not only shows the high temperature of the shell, but also marks the high temperature part, which can help find abnormal parts such as refractory blocks during maintenance.
