Industrial Observation & Diagnostic Systems

© Copyright 2004, Diamond Power International, Inc.

Industrial Observation & Diagnostic SystemsIndustrial Observation & Diagnostic Systems


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


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


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


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:


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:


--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


-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


--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


Actual WallActual Wall--Eye Images:Eye Images:

-- Walking Beam ReheatWalking Beam Reheat

-- Push Bar ReheatPush Bar Reheat

-- Heat TreatHeat Treat

Steel IndustrySteel Industry


Actual WallActual Wall--Eye Images Eye Images ContCont’’d:d:

-- Peel BarPeel Bar

-- Slab ReheatSlab Reheat

Steel IndustrySteel Industry


Actual WallActual Wall--Eye Eye Images:Images:

-- Melt TankMelt Tank

-- Tin BathTin Bath(Right Angle Wall(Right Angle Wall--Eye)Eye)

Glass IndustryGlass Industry



-- Rotary KilnRotary Kiln

-- Clinker CoolerClinker Cooler

Cement IndustryCement Industry



-- Flame ViewingFlame Viewing

Power IndustryPower Industry


Actual WallActual Wall--Eye Eye Images:Images:

-- Ash PitAsh Pit

-- Cyclone ThroatCyclone Throat

-- Cyclone Slag tapCyclone Slag tap

Power IndustryPower Industry


Solid State IR CameraSolid State IR Camera

SmeltCamSmeltCamTMTM Infrared CameraInfrared Camera


•• 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


•• 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


BenefitsBenefits


•• 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


BenefitsBenefits


•• 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


BenefitsBenefits


•• 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


Key FeaturesKey Features


•• 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


Key FeaturesKey Features


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:


•• 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:


Quad Display Quad Display -- 4 cameras4 cameras Single Display Single Display -- 1 camera1 camera

Fireside AdvisorFireside Advisor


• 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:


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



Accuracy:Accuracy: +/-+/- 5050°°F recovery black liquorF recovery black liquornatural gas and fuel oil

GasTempGasTempTM TM RBRB



Accuracy:Accuracy: +/-+/- 5050°°F coal, biomass, refuse,F coal, biomass, refuse,natural gas and fuel oil

GasTempGasTempTM TM XRXR--SS


• 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


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


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


GasTempGasTempTMTM

Methods of Measuring Startup FEGT:Methods of Measuring Startup FEGT:

TPTP--500500


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


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


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


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


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


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””


•• 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


•• 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


Typical CMSTypical CMSInstallation Installation positioned at positioned at bull nose of bull nose of recovery boilerrecovery boiler

CMS Installation locationsCMS Installation locations


GasTempGasTempTMTM

CMSCMS

IR CamerasIR Cameras Fireside AdvisorFireside AdvisorControl RoomControl Room

Boiler Diagnostic Systems Boiler Diagnostic Systems -- RecoveryRecovery


BoilerBoiler Diagnostic Systems Diagnostic Systems -- UtilityUtility

GasTempGasTempTMTMIR CamerasIR Cameras

WallWall--EyeEye

Fireside AdvisorFireside AdvisorControl RoomControl Room


•• 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


•• HighHigh--speed pan speed pan & tilt systems& tilt systems

•• Fixed camerasFixed cameras

•• Camera controlsCamera controls

•• SwitchersSwitchers

•• Video recordersVideo recorders

•• MonitorsMonitors

Security Surveillance Security Surveillance


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


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

Industrial Observation & Diagnostic Systems

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