The Use of Thermal-Imaging Inspection at the Chelyabinsk Metallurgical Combine

The condition of production equipment and other facilities at factories, their readiness for continued use, or their need for repair can be evaluated based on observations of changes in the equipment’s temperature over time. Equipment problems can quite often be detected without having to make contact measurements. These objectives are accomplished through the use of thermal-imaging systems. A thermal-imaging system is a diagnostic tool used in detecting anomalies, performing preventive maintenance, and analyzing the condition of production equipment and building structures. Problems are quickly identified and corrected by measuring the surface temperature of the object being inspected [1]. A thermal-imaging system makes it possible to view the pattern of heat-energy radiation from the object without having to remove it from service. The time required for such inspection is minimal, which makes it possible to react quickly to any problems that are found. In addition, the costs associated with repairs and unplanned equipment downtime can be significantly reduced by using thermal-imaging systems to perform preventive maintenance [1]. The Chelyabinsk Metallurgical Combine (ChMK) has used thermal-imaging inspection since May 2001, after it acquired a thermal-imaging system that operates within a broad range of temperatures – from –40°C to 1600°C. The size of the system’s array is 640 × 480 pixels. Thermal-imaging inspection of electrical equipment. Thermal-imaging inspection of the condition of electrical systems is very convenient and safe, since it makes it possible to evaluate equipment without direct contact during measurement. Most inspections carried out by thermal imaging entail a simple comparison of the thermal images generated by similar elements [2]. Figure 1 shows the cable connections of the reactor of a synchronous motor. If the thermal anomalies visible on the thermogram cannot be attributed to the normal load balance, they could be indicative of possible faults in the electrical equipment. Thermal-imaging inspection of the refractory linings of production equipment. Thermal-imaging inspection has found broad application for analyzing the durability of the lining of arc steelmaking furnaces, converters, and steel-pouring ladles (SLs) and evaluating the heat-engineering characteristics of new refractories. Figures 2 and 3 show the thermograms of 140-ton steel-pouring ladles in electric steelmaking shop No. 6 during service under identical conditions with the same number of heats but different layers of insulation. It is apparent from a comparison of the thermograms that the temperature of the shell of the SLs with a DALHIN insulating layer is lower than that of the SL shells with insulation KAOH-1. This shows that the new insulating material has better heat-engineering properties. Metallurgist, Vol. 57, Nos. 3–4, July, 2013 (Russian Original Nos. 3–4, March–April, 2013)