Process Imaging - Glassman Events Imaging Mark Bennett – Glass Sector Lead Mark Bennett – Glass...

Process Imaging Mark Bennett – Glass Sector Lead

Mark Bennett – Glass Sector Manager [email protected]

17th January 2017


Land Instruments - History • Established 1947 in Sheffield by Tom Land

• Industry Firsts – Commercial infrared thermometer using silicon photodiode – Portable single lens reflex infrared thermometer – ISO9000 certified infrared thermometer manufacturer – Radiometric potable thermal camera – Gas turbine infrared thermometer

• 2006 Acquired by Ametek Inc

- Transformed from traditional, family run business into modern, global enterprise


The Facilities • LAND UK Facility

- R+D, manufacture, calibration and repair all under one roof

- Internationally renowned and accredited UKAS calibration laboratory

- ISO 9001 Accredited quality management systems

- IEC-Ex certified factory

- Annual factory audits by SIRA and Lloyds

- Design capabilities in software and hardware

- Specialist on-site machining centre


Introduction to AMETEK • AMETEK,

– annualized sales of more than $4.0 billion.

– approximately 15,000 employees.

– more than 120 manufacturing facilities.

– over 100 sales and service operations.

– In more than 30 other countries.

• AMETEK consists of two operating groups:

– Electronic Instruments - a leading manufacturer of advanced monitoring, testing, calibrating, and display instruments for the process, aerospace, power and industrial markets worldwide.

– Electromechanical – a differentiated supplier of electrical interconnects, technical motors and systems, and electric motors for floor care and other specialty applications.

Process Imaging Mark Bennett – Glass Sector Lead Mark Bennett

Ametek Land Instruments – Glass Melt Tank Monitoring Solutions


The Cyclops 100L is great if you measure at the same time after the reversal starts. The refractory will cool rapidly during the reversal which makes it important to always choose exactly the same time after the reversal starts – NIR-b can record up to and after this time – freeze frame at the exact moment the burners stop


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http://www.landinst.com/software-downloads




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Mark Bennett


Melt Tank / Furnace control • Shoot an optical profiles every reversal. • Capture image files and data for trending and setup / recipe comparisons. • Validation of CFD model for design and predictive control. • Automatic regenerator reversal optimised on temperature.

Campaign Life Asset Protection and Extension • Crown, Walls, Port Arch & Regenerator Temperature.

• High and Low temperature alarms. • long term temperature trending. • Movement and degradation of refractories.

Glass Production Efficiency and Throughput • Temperature of the blanket (melt line). • batch transit time recording and comparison.

Energy Efficiency & Emissions Reduction • Optimizing the flame pattern and burn efficiency. • Enhanced temperature “visualisation” of cold spots in refractory wall indicating air leaks caused

by structural issues. • Potential flame temperature / NOx correlation.

Benefits of accurate real time temperature measurement in a glass melt tank / furnace:


Single point Temperature monitoring Real Time Temperature data from the NIR-b thermal image being used to monitor crown temperature, crown thermocouples for drift and port arch temperatures. Note; alarms set to monitor for over temperature. Note; Emissivity set to 0.96 software allows for each point to be set independently.

Emissivity can be Set globally or each point

Single point Temperature monitoring.


Temperature measured relative to measurement point 1 i.e. cross referenced to a crown thermocouple.

Single point Temperature monitoring.


Continuous real time Temperature data. Areas used to monitor Highest, Average or Lowest Temperature. Crown and port arch over/under temperature monitoring.

Polygon Areas of Interest.


End Fired Furnace Continuous real time Temperature data. Areas used to monitor Highest or Average or Lowest Temperature. Crown, Regenerator and Side Wall temperature monitoring for over temperature (Flame impingement) under temperature (air ingress / refractory ware)

Polygon Area of Interest.


Thermal Image with polygon areas of interest defining areas of the melt to detect batch carryover. As batch moves into the area of interest the lowest temperature detected falls below a pre-set alarm threshold.

Batch Line Monitoring


Optical Profile Thermal image showing profile lines. Using temperature data to continuously monitor the “hotspot” or “optical profile”. Note; to eliminate the effects of direct heat radiation from the flames data is captured for trending purposes during the reversal cycle. Note; on Oxy fuelled furnaces the flame is normally invisible to the thermal camera due to the unique filters used in the NIR-b borescope.

Optical Profiles


Air ingress Sodium Hydroxide Three different coloured isotherms (areas of the same temperature) used to highlight 1) Flame Intensity 2) Hotspot 3) Cold areas

Monochrome Thermal Image with Isotherms


Continuous real time Temperature data. Areas used to monitor Highest or Average or Lowest Temperature. Crown, Regenerator and Side Wall temperature monitoring. Monochrome pallet used to enhance clarity of image for identifying leakage and damaged refactory.

Thermal Image monochrome colour pallet


Highlights flame shape and areas of high intensity for combustion and emissions optimisation. Continuous real time Temperature data. Areas used to monitor Highest or Average or Lowest Temperature. Crown, Regenerator and Side Wall temperature monitoring.

Thermal Image – “NOx” colour pallet


Air ingress / leakage & monitoring of damaged refractory Monochrome Thermal Image with 3x zoom. Rectangle areas of interest Low alarm warning

Air ingress / leakage & monitoring of damaged refractory


Thermal Image 4x zoom Rectangle areas of interest Temperature differential measured against average crown temperature Low alarm warning

Air Ingress / Refractory Repair Monitoring


Temperature data monitoring / recording options

Real time image recorder (ERF files) • Captures real time data for offline analysis (up to 30 frames/s)

• Recording can be triggered by external input or alarm • Time lapse video recording for batch pattern and flow analysis. Single image recorder (IMG files) • Captures a “snapshot” image for offline analysis

• Recording can be triggered by external input or alarm • Compare 324,000 temperature data points for changes in temperature

and refractory movement / condition - daily / weekly / monthly / quarterly and annually.

Points or Areas of interest can be user defined and logged • LIPS software can generate a CSV file logger time base user defined. • 12 x Analogue and 24 x Digital outputs (via optional I/O modules). • 100 x data points via Ethernet TCP/IP or OPC.

Process Imaging Mark Bennett – Glass Sector Lead Control Room


Typical Installation – Holophane Case Study


Typical Installation


Extract from Installation Guide


Fibroptic Model FG

Range FG 9.8/13C 980 to 1300°C FG18/24F 1800 to 2400°F

FG 10/14C 1000 to 1400°C FG 22/30F 2200 to 3000°F

FG 12/16.5C 1200 to 1650°C

Wavelength 0.7 to 1.0mm

Optical Fixed focus. Target size 20mm / 0.8 inches at 1000mm / 39.4 inches

Lightguide : 6.1 metres / 20 feet

Output Current loop 4-20mA linear

Power Requirements Current loop 18 to 40V dc (nominal 24V dc)

Emissivity Adjustment Factory set at 1.0 but user adjustable 0.10 to 1.00

Ambient Temperature Lightgiude 175°C / 350°F Optic head 200°C / 400°F

Amplifier 10 to 60°C / 50 to 140°F

The use of Fibroptic thermometers is very effective where ambient temperatures are

high, targets are difficult to access, or the use of cooling water at the application is not

appropriate. The model FG is very suitable for glass forehearth applications.

•Loop powered linear 4-20mA output

•Adjustable emissivity.

•Rugged design with a choice of mounting options

•Optic head quickly demountable from air purge for maintenance.


Temperature Measurement of Glass Gob

Cross sectional view of a representation of the Forehearth showing glass gob measurement


Glass Gob Measurement under the Forehearth

using a Cyclops C100L Portable


Glass Gob Measurement under the Forehearth

using a Fibreoptic Model FG / System 5 Ratio


Glass Gob Measurement Using Thermal Imager


Mold Temperature Measurement


Linescanner – Bottles Entering/Leaving Lehr


Glass Bottle Lehr Exit – Temperature Profiles


Any Questions?

For further information and reference material Visit the Landinst website Publicity material See articles in glass magazines Case studies If in doubt …. ASK!

Process Imaging - Glassman Events Imaging Mark Bennett – Glass Sector Lead Mark Bennett – Glass...

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