SAVELINE ® system

Comprehensive measurement of hot spots

The SAVELINE® system can comprehensively monitor refractory linings for local overheating (hot spots), during operation. This is achieved with the help of encapsulated linear sensors, which are not sensitive to electrically conductive deposits (metal condensates, moisture, carbonaceous refractory materials) Special sensor ceramics enable measurement in the temperature range between 150°C (302°F) and 1350°C (2462°F).

Operator display SAVELINE system
Hardware components of the SAVELINE ® system
Left: Control and visualisation unit (C&V)
Right: Measuring unit
Operator display of the SAVELINE ® System using the example of a channel furnace

Application

Application

The extraordinary flexibility of the technology enables the adaption to many customized tasks.

SAVELINE® installation on a channel furnace inductor (animation)

 

Application examples:

+ Coreless induction furnace
+ Coreless inductor
+ Channel furnace
+ Cupola
+ RH-Degasser
+ AOD-Converter
+ Ladle
+ Arc furnace
+ Submerged arc furnace
+ Blast furnace
+ Imperial smelter

Benefits

Benefits

Significantly improves safety
for operating staff and plant, because furnace damage and molten breakouts can be safely avoided

Optimize operating costs
by reducing the costs of maintenance and production losses

Increase equipment up-time
based on the risk-free increase of Service life and predictability of relining

Product attributes

Product attributes

  • Simple and safe handling
  • Robust equipment for working in harsh environments
  • Multifunctional application on various furnaces
  • Easy integration in existing networks
  • Automatic self-diagnosis of all SAVELINE® devices
  • Electrically autonomous measuring system
  • Fast remote service via TeamViewer
  • Continuous data storage
  • Easy integration into furnace controls
  • Combinable with SAVEWAY® and SAVEDRY®

SAVELINE ® sensor:

  • Operating range: 150 °C (302 °F) to 1350 °C (2462 °F)
  • Outside diameter: 3 bis 6 mm (0.12 to 0.24 inch)
  • Lenght: variable
  • Insensitive to moisture and conductive deposits
  • Flexible

Functionality

Functionality

SAVELINE® measures not simply at one point, but always the highest temperature over the entire sensor length, compared to other methods of temperature measurement. The measurement is based on the strong temperature dependence of the resistivity of certain ceramic materials which are contained in the SAVELINE® sensors. It is displayed in form of a bar graph or chart, separately for each segment. Critical conditions are immediately displayed on the operators‘ display screen.

At relining, the sensors can be arranged in prefabricated segments or directly on the inside of the steel or shell wall. To comprehensively monitor distinct areas, the sensors can be arranged in a serpentine fashion easily due to their flexibility. The partition of critical areas into separate segments allows localized hot spot detection.

Features

Features


Additional external dual display

This separate parallel display always shows the same screen as on the control and visualization unit, without time delay. Longer distances can be reached, with a maximum distance of 100 m (328 ft) to the control and visualization unit.

There are two different variants:

External opti panel External TFT display
External opti panel External TFT display


Furnace shell identification

With the help of this feature, the system automatically identifies which furnace shells are currently connected to the system. The identified furnace shell will be monitored in the wear and history display.


Gradient analysis

With the aid of the gradient analysis, a critical increase of penetration for each segment will be displayed separately. That means metal is penetrating the lining at an unsafe rate. A critical increase of wear levels can be set differently for each segment.

Gradient analysis using the example of a cannel furnace

Gradient analysis using the example of a cannel furnace


Peak level indicator

The peak level indicator refers to the temporary display and storage of the maximum wear level per segment until manually reset. Quick and easy view of the maximum wear is possible. This quick overview is an enormous benefit, for example at, shift changes.

Peak level indicator using the example of a channel furnace

Peak level indicator using the example of a channel furnace


Interactive readout of the operator displays

This feature allows the automatic switching between operator displays of all furnaces connected to the system. Activation and deactivation is done manually. This display is advantageous; especially at greater distances between furnace and the control and visualization unit.


External LED status display

The three-step status stack (ANDON lights), which is designed for floor and wall installation, shows the current wear condition of the furnace as Green, Yellow or Red.

External LED status display

External LED status display

 

up

  • Installation of the SAVELINE sensor directly on the steel shell
  • SAVELINE sensor on a cupula
  • Equipped bushing
  • SAVELINE sensor in a ladle