SAVEWAY ® system

Continuous measurement of remaining lining thickness

The SAVEWAY® system allows the continuous measurement of remaining lining thickness during furnace operation. It is the only technology used in security monitoring, which measures the actual remaining lining thickness. In addition to visible signs of wear, such as erosion and worn-out areas, covered wear conditions are detected reliably, like dangerous metal penetrations and metal fins.

Metal fins represent an enormous risk potential for coreless induction furnaces. They can cause short-circuited coil turns if they remain undetected. Contact between liquid metal and cooling water could lead to an explosive molten discharge – an immense and possibly fatal danger for workers and plant.

The system also offers the option to switch between “melting mode” and “drying mode”, so that the sinter charge can be monitored on metal penetration. The detection of coil leakage, such as those occurring on coreless induction furnaces, completes the service range of the SAVEWAY® Technology.

Hardware components of the SAVEWAY system Operator display SAVEWAY system (coreless induction furnace)
Hardware components of the SAVEWAY ® systems
Left: Control and visualization unit (C&V)
Right: Measuring unit
Operator display of the SAVEWAY ® system using the example of a coreless induction furnace

Application

Application

The SAVEWAY® system can be used wherever ceramic refractory material is used and a temperature gradient exists. The main application area is the measurement of remaining lining thickness on coreless induction furnaces.

Coreless induction furnace:

Placement of electrode Panels on a coreless induction furnace (animation) Animation of the wear display on a SAVEWAY® system using the example of a coreless induction furnace

 

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

Additional application examples:

+ RH degasser
+ AOD converter
+ Ladle
+ Glass melting tank

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

Targeted melting process improvement
by optimizing the sinter heat

Product attributes

Product attributes

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

Functionality

Functionality

To measure the wear condition, electrode panels (sensors) are installed on an insulating surface. On a coreless induction furnace, the sensors are used in place of the usual slip-plane on the coil grout.

The measurement is based on the distinctive temperature dependence of the electrical resistance of refractory materials. The 16-stage wear indicator shows each segment separately. Critical conditions are immediately displayed on the operators’ display screen.

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; for example, next to the furnace instead of in the control room.

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 of the SAVEWAY system

 Gradient analysis using the example of a coreless induction 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 of the SAVEWAY system

Peak level indicator using the example of a coreless induction furnace


Ineractive 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

Dual display

The dual display allows you to monitor the wear condition of two different furnaces on one screen.

Dual display of the SAVEWAY system

Dual display using the example of a coreless induction furnace

up

  • Installed electrode panels on a coreless induction furnace
  • Installation connecting studs on top ring
  • Safely spotted metal fin
  • Position of the electrode panels (green) on a coreless induction furnace