Aperam, a leading stainless-steel manufacturer, faced the challenge of monitoring the thermal insulation on their furnace roof, which was difficult to access with traditional tools. In response, Fluves implemented a fiber optic-based Distributed Temperature Sensor (DTS) system to provide precise, real-time monitoring. This innovative solution allowed Aperam to efficiently identify and address insulation issues, resulting in significant cost savings and enhanced operational efficiency.
- Challenge: Aperam needed to monitor the furnace roof’s thermal insulation, which was inaccessible to traditional inspection tools, to control temperatures and reduce energy costs.
- Solution: Fluves installed a fiber optic-based Distributed Temperature Sensor (DTS) system, providing real-time monitoring and heat maps of the furnace roof.
- Results: Aperam saved on maintenance costs by targeting only the areas with insulation failure, while also benefiting from prioritized repair insights and exceeded expectations.
Challenge
Aperam needed to monitor the condition of the thermal insulation on their furnace roof to maintain optimal operating temperatures, reduce energy costs, and avoid shutdowns. However, the roof was inaccessible to traditional inspection tools like thermal cameras, making it difficult to identify areas needing repair.
Solution
Fluves Thermo installed a heat-resistant fiber optic cable in a grid pattern over the furnace roof, connected to a Distributed Temperature Sensor (DTS). This allowed Aperam to identify areas where the thermal insulation was compromised. Fluves also upgraded the system to provide constant monitoring of temperature hotspots. The DTS system generated user-friendly heat maps accessible through a web portal, allowing Aperam’s staff to track the furnace's condition in real-time.
Results
The DTS system accurately monitored temperature fluctuations during operational heat cycles, pinpointing the exact locations of insulation failure. This allowed Aperam to focus repairs on a small, targeted area, leading to significant maintenance cost savings. Fluves also prioritized repairs based on the insulation’s remaining lifespan, exceeding Aperam’s expectations with its precision and efficiency.
“The expectations we had of the Fluves Thermo monitoring system were largely exceeded.”
Erik Indesteege - Supervisor Repairables and Instrumentation at APERAM
More information
Visit Fluves Thermo or let’s have a chat via sales@fluves.com.
