"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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化工
化工厂依靠连续和批量的生产过程，每个生产过程对控制系统都有不同的要求。连续的过程需要一个强大而稳定的控制系统，该系统不能因为自身失效而导致生产线关闭；批量过程的重点在于拥有一个可以灵活调整地公式和程序的控制系统。两种系统都需要在产品质量记录中进行管理，并且能够执行非常规操作。横河电机凭借广泛的产品组合、经验丰富的系统工程师、遍及全球的销售和服务网络，为每个工厂流程提供解决方案。
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油气下游
近年来，油气下游产业面临着越来越多的挑战。这些挑战包括待加工原料的特性变化、工艺设施及设备的老化、能源成本的上升、缺乏能够使炼油厂安全有效运行的熟练技术工人，以及市场和客户的需求不断变化。
多年来，横河与许多下游公司合作，致力于提供应对这些挑战和问题的工业解决方案。横河的VigilantPlant解决方案帮助工厂投资者尽可能实现最大的盈利能力和工厂内可持续的安全。
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石油和天然气
石油和天然气
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钢铁
在钢铁工业中，不仅要提高产品质量，而且要提高制造和运营技术，解决环境问题、提高能源效率。横河帮助客户创造理想的工厂，并与客户共同成长。
相关产品&解决方案
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DTSX200 分布式温度传感器
DTSX200是一种标准版本，非常适合对中型区域，以及光纤传感器电缆距离较短的区域进行温度测量。它具有优异的耐环境性，因为它消耗的功率更小，对温度测量环境的依赖更小。
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DTSX3000 [长距离]
DTSX3000可以用于传统和非传统的油/气井下应用、LNG和炼油厂、管道和油罐泄漏检测以及其他需要监控温度的应用。
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DTSX™1光纤热检测器
DTSX1将热检测所需要的功能存储在一个盒子中。DTSX1通过光纤传感器电缆进行测量，并执行高温热检测，从而以高精度分析温度数据。
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光纤温度传感器DTSX
我们采用的技术是使用光纤本身作为温度传感器。
由于它可以测量长距离和宽范围的温度分布，所以能够无遗漏地监测沿线温度。因此，它不仅在工厂中有效使用，而且在需要温度监测的领域也能发挥作用。
