When the Heat is On, Control with Wireless


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Presented by Emerson's Michael Pearson and Roy Gueldenzoph at the 2011 Emerson Exchange in Nashville, TN USA.

Abstract: Many measurement challenges exist when monitoring high temperature assets such as Arc Furnaces, including high temperature, moving platforms, and high EMI. Northstar Bluescope Steel had all of these problems and more. They used these points for control, and their only solution was shutting the furnace down and replacing the wires often. By implementing an Emerson Smart Wireless technology, the customer was able to reduce or eliminate all of these measurement challenges, resulting in greatly reduced maintenance costs, and additional throughput.

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When the Heat is On, Control with Wireless

  1. 1. When the Heat is On, Control with Wireless
  2. 2. Presenters <ul><li>Mike Pearson </li></ul><ul><li>Marketing Engineer </li></ul><ul><li>Roy Gueldenzoph </li></ul><ul><li>Executive Sales Engineer </li></ul>
  3. 3. Agenda <ul><li>Summary of problems that occur with wired temperature measurements in high heat environments </li></ul><ul><li>Introduction to the Smart Wireless Solution </li></ul><ul><li>Case Study: North Star BlueScope Steel </li></ul><ul><ul><li>Measurement Challenges </li></ul></ul><ul><ul><li>Emerson Solution </li></ul></ul><ul><ul><li>Business Results Achieved </li></ul></ul><ul><li>Conclusion and Questions </li></ul>
  4. 4. Wires have problems! Especially in High Heat… Slag… Brittle Wires… Measurement Drift… EMI…
  5. 5. Wired Architecture Eight Sensor Wires Large Field Junction Box With Marshalling Bundled Sensor Cable Control Room Large Marshalling Cabinets and Many I/O Cards 100 Meters 20 Meters
  6. 6. Smart Wireless – Solving your high heat temperature problems <ul><li>Emerson Smart Wireless has the ability to reduce or eliminate all of these problems. </li></ul><ul><li>By mounting the transmitter close the process </li></ul><ul><ul><li>Sensor Wire is reduced </li></ul></ul><ul><ul><li>EMI is reduced </li></ul></ul><ul><ul><li>Heat Damage is Reduced </li></ul></ul><ul><ul><li>Marshalling and remote terminations are eliminated </li></ul></ul><ul><ul><li>Downtime is reduced </li></ul></ul>
  7. 7. Wireless Architecture Control Room
  8. 8. Wireless Transmitters Can be Used for Control <ul><li>Data Reliability </li></ul><ul><ul><li>99.9% Reliable IEC 62591 SmartWireless Technology </li></ul></ul><ul><ul><li>Self-Organizing Mesh Technology </li></ul></ul><ul><ul><li>Multiple Communication Paths </li></ul></ul><ul><li>Security </li></ul><ul><ul><li>Network IDs and Join Keys </li></ul></ul><ul><ul><li>Data Encryption </li></ul></ul><ul><li>Fast Update Rates </li></ul><ul><ul><li>1 and 2 second update rates </li></ul></ul><ul><li>Redundant Gateways </li></ul><ul><ul><li>Increase network reliability </li></ul></ul><ul><li>Discrete Output Coming Soon </li></ul>
  9. 9. Wireless Transmitters Work in the Harshest Environments Temperature Transmitters
  10. 10. North Star Bluescope Steel <ul><li>North Star BlueScope Steel operates a steel mill in Ohio. </li></ul><ul><li>The technology used at North Star BlueScope Steel allows a very rapid conversion of scrap steel into hot rolled coils. The Melt Shop and Caster converts scrap steel into slabs. The Rolling Mill converts the slabs produced into quality hot rolled steel coils. </li></ul><ul><li>The Melt Shop contains 2 twin-shell, twin shaft Electric Arc Furnace </li></ul>
  11. 11. The Electric Arc Furnace <ul><li>Liquid steel is produced by melting recycled scrap in the electric arc furnaces. </li></ul>
  12. 13. The Cooling Jacket <ul><li>The Electric Arc Furnace (EAF) is cooled using a water cooling jacket. </li></ul><ul><li>28 temperature control points are monitored to prevent runaway temperatures, hot spots, and panel failures </li></ul><ul><ul><li>Each panel failure is a significant maintenance cost </li></ul></ul><ul><li>Temperatures are also monitored on water cooled burners to control energy to the burner to help prevent burner failures. </li></ul><ul><li>These indications are utilized for alarming through PLCs and control through SmartArc™ transformer regulation and burner control. </li></ul>Water Jacket SmartArc™ is a registered trademark of AMI GE International
  13. 14. Measurement Challenges <ul><li>Each of the 28 measurement points had ten different wiring junction connections between the sensor and the control system that could fail in the wiring or create higher resistance. Wire runs were 10-50 feet. </li></ul><ul><li>Other sources of wire failure included moisture, vibration, heat, and molten slag ejected by the EAF. </li></ul><ul><li>Each time a measurement point failed, safety protocol required the furnace to be shut down for the point to be fixed. Generally once per week. </li></ul><ul><li>Typically, each furnace required 12 man hours of maintenance per week to repair wiring and conduit with the original system. </li></ul><ul><li>High Temperature sensor cable cost ~ $4.00/ft </li></ul><ul><li>http://www.youtube.com/watch?v=ijWwfcw0FOo </li></ul>
  14. 15. Wireless Solution <ul><li>7- four-input wireless temperature transmitters, and 7- single-input wireless transmitters are used to monitor 28 temperature points, most of which are used for control </li></ul><ul><li>By using SmartWireless, most of the wiring was eliminated </li></ul>
  15. 16. Installation Pictures 848T Protective Box, before operation 848T Protective Box, after operation
  16. 17. Other Wireless Applications Wireless Transmitter Monitoring Exhaust Hood @ > 800°C Heat-Mangled Transmitter – Still Functioning Perfectly
  17. 18. Wireless Transmitters in High Heat 648 near opening of Arc Furnace Close-up of 648 Protective Box
  18. 19. Business Results <ul><li>Nearly 100% of wiring and terminations have been eliminated. </li></ul><ul><li>Since installation, maintenance due to temperature monitoring has been reduced by 99% </li></ul><ul><li>Plant safety was improved due to effective cooling panel monitoring and reduced maintenance demands working on a hot furnace. </li></ul><ul><li>Better Temperature control has resulted in shorter batch times and as a result, additional throughput </li></ul>
  19. 20. Summary <ul><li>Wired sensors have many issues when installed in high heat environments </li></ul><ul><ul><li>Melting, multiple termination points, moisture, vibration </li></ul></ul><ul><li>SmartWireless technology, reduces or eliminates all of these problems </li></ul><ul><ul><li>They were able to monitor new points that were unable to monitor before, resulting in safer more efficient operation </li></ul></ul><ul><ul><li>NSBSS has added 8 wireless flow transmitters to monitor cooling panels and plans to add more. </li></ul></ul><ul><li>Wireless is being used for Control </li></ul><ul><ul><li>Safe, Reliable, Secure Wireless Technology </li></ul></ul>
  20. 21. Where To Get More Information <ul><li>Tradeshow </li></ul><ul><ul><li>Rosemount Temperature Booth </li></ul></ul><ul><ul><li>Emerson SmartWireless Booth </li></ul></ul><ul><li>SmartArc Website: </li></ul><ul><ul><li>http://www.amige.com/meltshops_technological_controls_smartarc.html </li></ul></ul><ul><li>Northstar Blue Scope Steel </li></ul><ul><ul><li>http://www.northstarbluescope.com/ </li></ul></ul>