industrial observation & diagnostic systems - paptac · industrial observation & diagnostic...
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© Copyright 2004, Diamond Power International, Inc.
Industrial Observation & Diagnostic SystemsIndustrial Observation & Diagnostic Systems
© Copyright 2004, Diamond Power International, Inc.
Diamond Electronics History:Diamond Electronics History:
•• 1946 first closed circuit television 1946 first closed circuit television installationinstallation
•• Located in central Ohio since 1946Located in central Ohio since 1946
•• Started in electric utility, heavy Started in electric utility, heavy industrial, government, and industrial, government, and commercial venturescommercial ventures
•• Sold to Arvin Industries in 1972Sold to Arvin Industries in 1972
© Copyright 2004, Diamond Power International, Inc.
Acquisition:Acquisition:
•• DPII acquired Diamond Electronics DPII acquired Diamond Electronics industrial market CCTV business from industrial market CCTV business from Ultrak Inc (successor to Arvin) on July 27, Ultrak Inc (successor to Arvin) on July 27, 20012001
•• Relocated to DPII Lancaster facilityRelocated to DPII Lancaster facility
•• Merged CCTV business with DPII Merged CCTV business with DPII Diagnostics businessDiagnostics business
© Copyright 2004, Diamond Power International, Inc.
Applications:Applications:
•• Industrial CCTV WallIndustrial CCTV Wall--Eye CameraEye Camera
•• Solid State IR CamerasSolid State IR Cameras
•• Boiler Diagnostic SystemsBoiler Diagnostic Systems
•• Process Surveillance & Security Process Surveillance & Security SystemsSystems
© Copyright 2004, Diamond Power International, Inc.
System Features:System Features:
-- Operates in Furnace Temperatures up to +3000 Operates in Furnace Temperatures up to +3000 °°FF
-- Over 480 Lines ResolutionOver 480 Lines Resolution
-- Uses Dual Vortex Coolers for CoolingUses Dual Vortex Coolers for Cooling
-- Replaces Existing Wall Boxes and Water ShroudsReplaces Existing Wall Boxes and Water Shrouds
-- Minimal Maintenance Compared to LenstubesMinimal Maintenance Compared to Lenstubes
-- No Water Cooling RequiredNo Water Cooling Required
WallWall--Eye Camera System:Eye Camera System:
© Copyright 2004, Diamond Power International, Inc.
System Features ContSystem Features Cont’’dd:- Optional 4Optional 4--20mm Motorized Zoom Lens20mm Motorized Zoom Lens- Available In: NTSC, PAL, or Monochrome (EIA) Available In: NTSC, PAL, or Monochrome (EIA) - Lengths Vary from 18Lengths Vary from 18”” to 36to 36””- Optional Pneumatic Retract Available Optional Pneumatic Retract Available - Water Cooled Right Angle Configuration Available Water Cooled Right Angle Configuration Available - 2424”” and 36and 36”” F:8 Wall Box Replacement Systems F:8 Wall Box Replacement Systems
WallWall--Eye Camera System:Eye Camera System:
© Copyright 2004, Diamond Power International, Inc.
--SteelSteel--Reheat FurnacesReheat Furnaces
• Billet PositionBillet Position• Slab Position (Charging Furnace)Slab Position (Charging Furnace)
• Combustion and Flame PatternCombustion and Flame Pattern• Peel Bar Billet PositionPeel Bar Billet Position• Coiler Insert Position Coiler Insert Position
WallWall--Eye ApplicationsEye Applications
© Copyright 2004, Diamond Power International, Inc.
-GlassGlass-Melt TankMelt Tank
• Batch Feeder, Observation Flow StatusBatch Feeder, Observation Flow Status• Batch Melt Process, Ensure Proper Melting of GlassBatch Melt Process, Ensure Proper Melting of Glass• Burner CombustionBurner Combustion• General Observation of Refractory WallsGeneral Observation of Refractory Walls
Plate Glass Float TanksPlate Glass Float Tanks• Observation of Knurl Position (Tin Bath)Observation of Knurl Position (Tin Bath)
WallWall--Eye Applications ContEye Applications Cont’’ dd
© Copyright 2004, Diamond Power International, Inc.
--PowerPower--BoilersBoilers
• Furnace Flame ObservationFurnace Flame Observation• Superheater Observation for Slag BuildSuperheater Observation for Slag Build--UpUp• Ash Pit Observation, Slag DischargeAsh Pit Observation, Slag Discharge
--CementCement--
• Rotary Kiln ObservationRotary Kiln Observation• Clinker Cooler ObservationClinker Cooler Observation
• Cyclone throat & Slag Tap ObservationCyclone throat & Slag Tap Observation
WallWall--Eye Applications ContEye Applications Cont’’ dd
© Copyright 2004, Diamond Power International, Inc.
Actual WallActual Wall--Eye Images:Eye Images:
-- Walking Beam ReheatWalking Beam Reheat
-- Push Bar ReheatPush Bar Reheat
-- Heat TreatHeat Treat
Steel IndustrySteel Industry
© Copyright 2004, Diamond Power International, Inc.
Actual WallActual Wall--Eye Images Eye Images ContCont’’d:d:
-- Peel BarPeel Bar
-- Slab ReheatSlab Reheat
Steel IndustrySteel Industry
© Copyright 2004, Diamond Power International, Inc.
Actual WallActual Wall--Eye Eye Images:Images:
-- Melt TankMelt Tank
-- Tin BathTin Bath(Right Angle Wall(Right Angle Wall--Eye)Eye)
Glass IndustryGlass Industry
© Copyright 2004, Diamond Power International, Inc.
Actual WallActual Wall--Eye Images:Eye Images:
-- Rotary KilnRotary Kiln
-- Clinker CoolerClinker Cooler
Cement IndustryCement Industry
© Copyright 2004, Diamond Power International, Inc.
Actual WallActual Wall--Eye Images:Eye Images:
-- Flame ViewingFlame Viewing
Power IndustryPower Industry
© Copyright 2004, Diamond Power International, Inc.
Actual WallActual Wall--Eye Eye Images:Images:
-- Ash PitAsh Pit
-- Cyclone ThroatCyclone Throat
-- Cyclone Slag tapCyclone Slag tap
Power IndustryPower Industry
© Copyright 2004, Diamond Power International, Inc.
Solid State IR CameraSolid State IR Camera
SmeltCamSmeltCamTMTM Infrared CameraInfrared Camera
© Copyright 2004, Diamond Power International, Inc.
•• SolidSolid--state infrared camera with no vidicon tubesstate infrared camera with no vidicon tubes
•• Views combustion processes in coalViews combustion processes in coal--fired boilers:fired boilers:
−− monitors smelt bed;monitors smelt bed;−− detects slagging and/or pluggage in pendant tube area; detects slagging and/or pluggage in pendant tube area;
oror−− view liquor guns.view liquor guns.
•• Optimum wavelength penetrates fumingOptimum wavelength penetrates fuming
•• For negative or positive pressure furnacesFor negative or positive pressure furnaces
•• Compact camera, no operator controls or adjustmentsCompact camera, no operator controls or adjustments
SmeltCamSmeltCamTMTM
OverviewOverview
© Copyright 2004, Diamond Power International, Inc.
•• HighHigh--quality images for bed or pendant monitoringquality images for bed or pendant monitoring
•• Optimum wavelength for clearer picturesOptimum wavelength for clearer pictures
•• More accurate monitoringMore accurate monitoring
•• Two SmeltCamTwo SmeltCam™™ systems can provide systems can provide 91 91 percent coveragepercent coverage on a recovery boileron a recovery boiler
SmeltCamSmeltCamTMTM
BenefitsBenefits
© Copyright 2004, Diamond Power International, Inc.
•• Reduced operating costs (time and money)Reduced operating costs (time and money)
•• Dependable solidDependable solid--state microprocessors and chipsstate microprocessors and chips
•• No lens tubeNo lens tube; no disassembly or cleaning; no disassembly or cleaning
•• No vidicon tubeNo vidicon tube to change or maintainto change or maintain
SmeltCamSmeltCamTMTM
BenefitsBenefits
© Copyright 2004, Diamond Power International, Inc.
•• No camera calibrationNo camera calibration
•• Maintenance payback (no technicians needed to Maintenance payback (no technicians needed to make adjustments)make adjustments)
•• No image driftingNo image drifting
SmeltCamSmeltCamTMTM
BenefitsBenefits
© Copyright 2004, Diamond Power International, Inc.
•• Pneumatic retract system:Pneumatic retract system:
•• Automatic activation by lowAutomatic activation by low--pressure switch on air supply,pressure switch on air supply,thermal sensor near camera, or AC power failurethermal sensor near camera, or AC power failure
•• Can also be operatorCan also be operator--controlled by using the control unitcontrolled by using the control unit
•• Mounts in upright or inverted positionMounts in upright or inverted position
•• Withdraws in case of air system failure, camera high Withdraws in case of air system failure, camera high temperature, or electrical system failuretemperature, or electrical system failure
SmeltCamSmeltCamTMTM
Key FeaturesKey Features
© Copyright 2004, Diamond Power International, Inc.
•• Alarm/character generator board in camera Alarm/character generator board in camera control box with temperature sensor unit: control box with temperature sensor unit: temperature sensor input:
•• 4 alarm inputs/4 contact outputs4 alarm inputs/4 contact outputs
•• Monitors voltage level and changes of stateMonitors voltage level and changes of state
•• Can add alarm messages to video signalCan add alarm messages to video signal
•• Optional 20Optional 20--character programmable camera character programmable camera title title and onand on--screen messagesscreen messages
SmeltCamSmeltCamTMTM
Key FeaturesKey Features
© Copyright 2004, Diamond Power International, Inc.
Images taken from the same port at same timeImages taken from the same port at same time
SmeltCam SmeltCam
DE SmeltCamDE SmeltCamTMTM imageimage DE Vidicon IR imageDE Vidicon IR image
Actual SmeltCamActual SmeltCamTMTM Image:Image:
© Copyright 2004, Diamond Power International, Inc.
•• Pentium4 3.0 GHz based PCPentium4 3.0 GHz based PC•• Windows XP P, W 98, NT, and 2000Windows XP P, W 98, NT, and 2000•• Up to 4 camera inputsUp to 4 camera inputs•• Quad display capabilityQuad display capability•• 10 movable temperature cells per camera10 movable temperature cells per camera•• Top (10) different colorization schemeTop (10) different colorization scheme•• Displays a single camera view to 2/3 of the CRTDisplays a single camera view to 2/3 of the CRT•• Trending done internally in Excel spreadsheetsTrending done internally in Excel spreadsheets
Boiler Diagnostic SystemsBoiler Diagnostic Systems
Fireside Advisor:Fireside Advisor:
© Copyright 2004, Diamond Power International, Inc.
Quad Display Quad Display -- 4 cameras4 cameras Single Display Single Display -- 1 camera1 camera
Fireside AdvisorFireside Advisor
© Copyright 2004, Diamond Power International, Inc.
• HVT Probe
• Infrared PyrometersGasTempTM
• HVT ProbeHVT Probe
•• Infrared PyrometersInfrared PyrometersGasTempGasTempTMTM
Optical Pyrometers Optical Pyrometers -- GasTempGasTempTMTM
Methods of Measuring OnMethods of Measuring On--Line FEGT:Line FEGT:
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Range:Range: 575575 °° - 2800- 2800 °°F (standard calibration)F (standard calibration)
Accuracy:Accuracy: +/-+/- 5050°°F regardless of coal typeF regardless of coal typenatural gas and fuel oil
GasTempGasTempTM TM XRXR
© Copyright 2004, Diamond Power International, Inc.
Range:Range: 575575 °° - 2800- 2800 °°F (standard calibration)F (standard calibration)
Accuracy:Accuracy: +/-+/- 5050°°F recovery black liquorF recovery black liquornatural gas and fuel oil
GasTempGasTempTM TM RBRB
© Copyright 2004, Diamond Power International, Inc.
Range:Range: 575575 °° - 2800- 2800 °°F (standard calibration)F (standard calibration)
Accuracy:Accuracy: +/-+/- 5050°°F coal, biomass, refuse,F coal, biomass, refuse,natural gas and fuel oil
GasTempGasTempTM TM XRXR--SS
© Copyright 2004, Diamond Power International, Inc.
• Optical pyrometerOptical pyrometer•• Based on PlanckBased on Planck’’s Law for spectral emittances Law for spectral emittance•• 575 to 2800 degrees Fahrenheit575 to 2800 degrees Fahrenheit•• +/+/-- 50 degrees accuracy50 degrees accuracy•• OnOn--line or startline or start--up measurement up measurement •• Digital display and 4Digital display and 4--20mA output20mA output•• PrePre--calibrated to boiler widthcalibrated to boiler width•• NonNon--intrusive intrusive --““point and shootpoint and shoot”” Isolation Valve MountIsolation Valve Mount
Advantages with GasTempAdvantages with GasTempTMTM XRXR
© Copyright 2004, Diamond Power International, Inc.
GasTemp™GasTemp™
Instrument Installed at this Wall Boiler Width
Incr
easi
ng T
empe
ratu
re
Average Temperature Profile
Gas Temperature
GasTempGasTempTMTM Temperature MeasurementTemperature Measurement
© Copyright 2004, Diamond Power International, Inc.
Gastemp V.S. HVT Probe Oklahoma Power & Electric
2000
20502100
21502200
22502300
23502400
24502500
2550
2 4 6 8 10 12 14 16 18 20
Insertion in boiler (FT)
Tem
pera
ture
(°F)
GASTEMP TEMP. HVT TEMP
Field Trial, GasTempField Trial, GasTempTM TM Online TestOnline Test
© Copyright 2004, Diamond Power International, Inc.
GasTempGasTempTMTM
Methods of Measuring Startup FEGT:Methods of Measuring Startup FEGT:
TPTP--500500
© Copyright 2004, Diamond Power International, Inc.
SCE&G Wateree Unit 1 Startup Plant's Gastemp Sidewall
0
200
400
600
800
1000
1200
1400
3:39
:18
PM
4:02
:18
PM
4:25
:18
PM
4:48
:18
PM
5:11
:18
PM
5:34
:17
PM
5:58
:57
PM
6:30
:16
PM
6:53
:16
PM
7:16
:16
PM
7:40
:09
PM
8:03
:09
PM
8:26
:09
PM
8:49
:09
PM
9:13
:17
PM
9:36
:17
PM
9:59
:17
PM
10:2
2:37
PM
10:4
6:01
PM
11:0
9:01
PM
11:3
2:01
PM
11:5
5:00
PM
12:1
8:36
AM
12:4
1:36
AM
Time
Tem
pera
ture
(Deg
. F)
Gastemp-XR TC CORREC.
Field Trial, GasTempField Trial, GasTempTMTM Startup TestStartup Test
© Copyright 2004, Diamond Power International, Inc.
Advantages of GasTempAdvantages of GasTempTMTM RBRB
•• Detect pluggage,Detect pluggage,improper airimproper air--delivery and elevationdelivery and elevationof combustion zoneof combustion zone
•• For black liquor, oil, or natural gas firingFor black liquor, oil, or natural gas firing•• Used in forced, induced, or balanced draft boilers Used in forced, induced, or balanced draft boilers
© Copyright 2004, Diamond Power International, Inc.
GasTempGasTempTMTM RB SpecificationsRB Specifications
•• Digital display andDigital display and44--20 mA output20 mA output
•• PrePre--calibrated tocalibrated toboiler widthboiler width
•• NonNon--intrusiveintrusive--““point and shootpoint and shoot””
•• AutoAuto--Retract and port cleaning deviceRetract and port cleaning device
© Copyright 2004, Diamond Power International, Inc.
GasTempGasTempTMTM Port Cleaning DevicePort Cleaning Device
Penetrating PipePenetrating PipeFlangeFlange
Twin 2 inch AirTwin 2 inch AirCylindersCylinders
Mounting RailMounting Rail
Universal Universal Mounting PlateMounting Plate
GasTempGasTempTMTM Port Cleaning Device Port Cleaning Device
© Copyright 2004, Diamond Power International, Inc.
Carryover Monitoring System (CMS) Carryover Monitoring System (CMS)
•• An apparatus for detecting carryover of unburned An apparatus for detecting carryover of unburned fuel particlefuel particle
•• Hot unburned particles appear as streaksHot unburned particles appear as streaks•• Signals indicative of carryover compared to a Signals indicative of carryover compared to a
threshold levelthreshold level•• Particle signals above threshold counted over a Particle signals above threshold counted over a
measured time interval measured time interval •• Dividing particle count by the measured time Dividing particle count by the measured time
interval produces a count rateinterval produces a count rate
CMSCMS
© Copyright 2004, Diamond Power International, Inc.
Carryover Monitoring System FeaturesCarryover Monitoring System Features
•• Optical Device Optical Device -- single point single point detectordetector
•• Near IR sensitivityNear IR sensitivity•• Device operation independent of Device operation independent of
rotational variationsrotational variations•• 0 0 –– 100 counts/sec100 counts/sec•• Digital display and 4Digital display and 4--20 mA 20 mA
outputoutput•• NonNon--intrusive intrusive –– ““point and shootpoint and shoot””
© Copyright 2004, Diamond Power International, Inc.
•• Air FilterAir FilterReplace air filter cartridges every 6 monthsReplace air filter cartridges every 6 months
•• Objective Front CoverObjective Front CoverInspect & clean every 2Inspect & clean every 2--3 months3 months
CMS MaintenanceCMS Maintenance
AIR SHROUDNOSE CAP
LENS TUBE
© Copyright 2004, Diamond Power International, Inc.
•• Panel MountedPanel Mounted•• Available in multiple inputs Available in multiple inputs •• Vertical and Horizontal barVertical and Horizontal bar
graphsgraphs•• Allows digital readings and Allows digital readings and alarm statuses on all channelsalarm statuses on all channels
•• Optional removable storage mediaOptional removable storage media•• Available in desktop Available in desktop and portableand portable
DX 100/200DX 100/200
MV 100/200MV 100/200
CMS Data Logging EquipmentCMS Data Logging Equipment
© Copyright 2004, Diamond Power International, Inc.
Typical CMSTypical CMSInstallation Installation positioned at positioned at bull nose of bull nose of recovery boilerrecovery boiler
CMS Installation locationsCMS Installation locations
© Copyright 2004, Diamond Power International, Inc.
GasTempGasTempTMTM
CMSCMS
IR CamerasIR Cameras Fireside AdvisorFireside AdvisorControl RoomControl Room
Boiler Diagnostic Systems Boiler Diagnostic Systems -- RecoveryRecovery
© Copyright 2004, Diamond Power International, Inc.
BoilerBoiler Diagnostic Systems Diagnostic Systems -- UtilityUtility
GasTempGasTempTMTMIR CamerasIR Cameras
WallWall--EyeEye
Fireside AdvisorFireside AdvisorControl RoomControl Room
© Copyright 2004, Diamond Power International, Inc.
•• High temperature fixed camera systemsHigh temperature fixed camera systems•• Air cooled / water cooled housings Air cooled / water cooled housings
(HTH(HTH--8)8)
•• Camera housings with heater & blower Camera housings with heater & blower for extreme environments (CH112)for extreme environments (CH112)
Demon III CoolerDemon III Cooler
HTHHTH--8 Housing8 Housing
Process Viewing CamerasProcess Viewing Cameras
Process Surveillance & Security SystemsProcess Surveillance & Security Systems
© Copyright 2004, Diamond Power International, Inc.
•• HighHigh--speed pan speed pan & tilt systems& tilt systems
•• Fixed camerasFixed cameras
•• Camera controlsCamera controls
•• SwitchersSwitchers
•• Video recordersVideo recorders
•• MonitorsMonitors
Security Surveillance Security Surveillance
© Copyright 2004, Diamond Power International, Inc.
System Features:System Features:
- 100 Programmable Pre100 Programmable Pre--ShotsShots- 10 Programmable Vectorscans
- High Resolution Color Camera w/18x Zoom LensHigh Resolution Color Camera w/18x Zoom Lens
- Variable Speed: .1Variable Speed: .1°° to 400to 400°° Per SecondPer Second- 360360°° Continuous Pan RotationContinuous Pan Rotation
- Night Shot FeatureNight Shot Feature- BuiltBuilt--In Heater/BlowerIn Heater/Blower- Optional Nitrogen Pressurized HousingOptional Nitrogen Pressurized Housing- Outdoor Weatherproof Configuration Outdoor Weatherproof Configuration - Heavy Duty Ruggedized Configuration Heavy Duty Ruggedized Configuration
Pan & Tilt Camera SystemsPan & Tilt Camera Systems
© Copyright 2004, Diamond Power International, Inc.
Digital Video RecordersDigital Video Recorders
• 4, 8, 12, and 16-channel digital recorder •• Continuous (24/7) recordingContinuous (24/7) recording•• Frame rate default at up to 15 frames/secFrame rate default at up to 15 frames/secon all 16 cameras on all 16 cameras
•• Data stored on two internal highData stored on two internal high--capacity hard drivescapacity hard drives•• All cameras expandable to 640x480All cameras expandable to 640x480•• Play back/search by time, date and alarmPlay back/search by time, date and alarm•• Remote access via LAN/WAN/InternetRemote access via LAN/WAN/Internet•• Programmable recording/alarm modesProgrammable recording/alarm modes•• Intelligent, realIntelligent, real--time motion detection time motion detection •• FrontFront--end USB connection and CDend USB connection and CD--RW for quickRW for quickdata removaldata removal