Tag: Infrared Thermography

The first Kiln monitoring system that Yellotec installed is still in operation since 2013 which makes it a very reliable solution. The system detected faults and prevented catastrophic failures and saving our customers millions of Rands since the installation. The Kiln Monitoring system is inexpensive compared to possible failures and is very low in maintenance cost. The team at Yellotec are very proud to build and supply the complete solution for continuous kiln shell monitoring.

A recap of our previous article:

In the previous article that was written in 2014, we looked deeper into the world’s first Kiln Shell Monitoring System based on Microbolometer Infrared Camera Technology.

IRT KilnMonitor® is a full-featured computer system that allows you to monitor, process and trace data from rotary cement kilns. Unlike existing solutions, it is based on standard microbolometer radiometric infrared cameras, as used in a variety of different applications.

The system has major advantages over other methods. Including, reduced maintenance costs, high-resolution thermal profiles, and internal refractory profiling via 3D modelling, significantly reduced capital costs, and maximised up times – the revolution has finally started.

Key features of the Virtual 3D Kiln Display:

• Kiln “pipe” with infrared image on the surface.
• The kiln is rotating at a real speed.
• Rings and other shadow zones.
• Position of the top-kiln.
• Real coordinates ruler with the kiln refractory and shadow zone’s structure.
• And many more!

Staying up to date with Kiln Monitoring:

Kiln monitoring is important, and you must monitor the degradation of the material and detect damaged or fallen bricks. The easiest way to do this is to monitor the temperature of the kiln shell. Infrared technology has been favoured in the past to perform this task. Sophisticated user interfaces have been designed to make the data easier to analyse and understand. Recently, high demands have led to the development of more complex products that do a lot more than just measure temperature.

The Thermal Imaging Cameras of the Kiln monitoring system provide accurate temperature measurements in a visual format, with high detector resolution. This enables the user to extend equipment life and allow money-saving on maintenance programs. This infrared technology contributes to improving production in quality and quantity while reducing downtime and energy consumption.

Benefits of Kiln Monitoring:

• Higher field of view for new larger kilns (up to 4 thermal cameras with 110º view angle)
• Higher resolution (up to 3.200 measuring points per line) for refractory detail
• High sensitivity to identify even the smaller temperature changes and hot spots.
• Easy integration and communication of all data to Plant Control System.
• Pre-wired and pre-tested for an easy installation.
• Calibration checks are not required.
• Fibre optic communication
• Training and commissioning support by a highly qualified and experienced team.

What Yellotec offers in terms of Kiln Monitoring Technology:

Yellotec partnered with Grayess, who is an Infrared Thermography Software Developing Specialist with software that is:

• easy to use, 
• highly sophisticated, 
• high compatibility, 
• ease of data exchange and 
• has more than 3000 installations worldwide!

 

Today, it is impossible to imagine the building industry without cement. Cement is one of the most valuable and useful products in the world. It is an important part of mortar, concrete, manufacturing and more. Cement production is a complex process, in which one of the steps consists of blending limestone with other components in big rotary furnaces. These furnaces or kilns are a critical asset of a cement production plant, heating their contents to temperatures up to 1,500 °C. There is a risk of overheating, which can cause serious damage to the kiln shell. It is important to monitor this delicate heating process and prevent possible damage to the kiln. Thermal imaging cameras are great to use in this situation as they are used to measure temperatures on a 24/7 basis.

The IRT KilnMonitor® system is an advanced computer system that allows cement production operators to monitor, process and trace data from several kilns at once. IRT KilnMonitor® systems protect your plant and machinery constantly. Yellotec is proud to be able to provide this dependable turnkey solution. We have trust in the brands that we represent and the solutions we can create with our partners.
If you would are interested in Kiln Monitoring equipment. Please feel free to contact us by visiting, calling, emailing or filling in the contact form and one of our experienced team will get back to you with everything you need.

When it comes to the purchasing of any product, we often tend to focus on three major aspects; quality, cost and usability.

However, when it comes to purchasing a thermal camera, there are a few more things we need to take into account before we make our decision.  

Factors to consider when choosing your next thermal camera

To do this, we have put together a list of 6 factors to consider when purchasing your next thermal camera.

Factor 1: A thermal camera that fits your needs.

As the first factor, we thought we would start with the most important one. Purchasing one that fits your needs. Having a thermal camera is an important tool for a wide variety of tasks such as machine condition monitoring and plant safety and monitoring. 
This is why it is important to fully understand your needs for the thermal imaging camera.

Here are some questions to ask when picking your next thermal camera

1. What areas am I trying to monitor? 

2. Does it need to be fixed or portable? 

3. Do I need easy access to the images on hand?

Once the questions have been asked, it is easier to identify the thermal imaging camera that best suits your needs. 

Factor 2: A Thermal Camera with Easy Access to Data

There is nothing worse than collecting data and not being able to access it easily and painlessly. That is why we recommend choosing a camera that not only allows you to access your images easily but also saves them easily as well.

We even suggest looking at one with Wifi capabilities with access to software that all images are directly uploaded to. Looking for more information. The Yellotec team would be more than happy to help answer your questions and give you the best advice. 

Factor 3: The Battery Life & Type of Recharging

Once you have an understanding of your thermal image needs, it would give you an idea of the type of battery that you would need. This will determine the type of camera to look for.

When considering a camera based on battery type & life, these are some of the qualities to look at.

• Time: How long does the battery last and how long does it take to charge?
• How easy is it to charge? Is it a removable battery or a charging cable that goes straight into the camera? Which would be a good option when looking at a camera that will need to be fixed.
• Is battery replacement easy? If needed. Could the battery be replaced easily and accessible or would it have to be taken to a specialist and have to be opened to replace the battery?
• Does a battery icon show? There is nothing more frustrating than going to work and having to stop because the camera turned off due to a flat battery because there was no way to identify if the battery was fully charged.

Factor 4: The Specs of the Thermal Camera.

When deciding on a Thermal Imaging Camera, it is important to look at the capabilities of the camera. But sometimes this can be a bit overwhelming when we aren’t quite sure what to look for. This is why we have given a little breakdown of some of the capabilities that can be focused on when choosing your right camera. 

Range: When selecting a camera, we suggest looking at one with a controllable temperature range, perhaps one that automatically selects the range based on your scene. Being able to control the temperature range is a great way to monitor when something is not quite right.

Resolution: Having a camera with the best detail and image quality that suits your needs is important. And having a camera with a strong resolution is beneficial to this. This Resolution is made of pixels which are little blocks that are used to make an image. The higher the pixels, the higher the quality of the image.

Focus: This is a specification that will vary on your needs. When looking at the focus, you have three options.
Fixed: This means that we won’t have to make adjustments to obtain the focus.
Manual: Where the user adjust the focus of the camera
Auto-focus: Which focuses automatically based on what it can see for contrast on the scene.

Colour Palette: Having a Thermal Image Camera with multiple Palettes is highly beneficial for monitoring and finding obvious anomalies. This is why it should be easy to change the palettes either on the camera or on the software.

Field of View: Field of View determines the extent of a scene seen by the camera at any given moment. For work being done close-up, you need a lens with a wide-angle FOV (45° or higher). For long-distance work, you need a telephoto lens (12° or 6°). Some cameras may be available with multiple lenses for different applications. 

Factor 5: Technical Support & Training

And lastly, when choosing a Thermal Imaging Camera, it is so important to purchase from a reputable manufacturer or supplier who has a post-sale customer support service as well as training for when those moments occur where you just cannot get it to monitor exactly how you want.

Or when a production error occurs, which does happen, and you can contact the manufacturer and the problem can be rectified.

Wrapping it up.

We hope that you found this article about what you need to consider when choosing a thermal imaging camera helpful and informative. If you need to know any more information about thermal cameras, or you are still unsure which one to choose from. Why not give the yellotec team a shout and we will assist you in any way we can.

Yellotec strives to offer the most effective and efficient technology in all machine health and reliability monitoring equipment. As well as providing services and training that help plant and equipment managers to predict all failures as well as prevent major failures in the future.

Are you looking for more information, want to purchase a product or require our service? You can either visit us, call us, email us or save yourself the hassle and send us an enquiry and we will contact you instead. Visit our Contact Us page here.

These useful guidebooks from FLIR will introduce you to the world of thermal imaging and help you select the best tool for your application.

Is your company looking for a head start with a camera that offers unmatched power and flexibility? Then here is your answer!

From the industry’s first high definition handheld cooled optical gas imaging camera to an expended T-Series range, the following are the latest product releases from the thermal imaging experts at FLIR.

It is incredible to see the advances made in the field of infrared thermography since the first hand-held cameras hit the market, not only from the actual thermal detector technology, but also the overall functionality of the cameras.

Case in point, FLIR’s new Exx-Series cameras are much more than their impressive infrared capturing capabilities, but have become an all-in-one tool to enhance and improve your condition monitoring experience. From its quick start-up and intuitive interface you can operate with one hand to the ease with which you can annotate, save and organise your images.

In the video below, see how the new Exx Cameras tags the GPS location of the images taken.

Some other key features include:

• Interchangeable, auto-calibrating lenses
• Laser distance meter for measurement information and crisp, accurate focus
• Our best MSX® enhancement
• UltraMax® processing for 4x pixel resolution
• A larger, 4” display that’s 33% brighter
• A responsive new interface
• Improved organization and reporting options