When the Heat is On, Control with

Wireless

When the Heat is On, Control with

Wireless

PresentersPresenters

Mike PearsonMarketing Engineer

Roy GueldenzophExecutive Sales Engineer

AgendaAgenda

Summary of problems that occur with wired temperature measurements in high heat environments

Introduction to the Smart Wireless Solution Case Study: North Star BlueScope Steel

– Measurement Challenges– Emerson Solution– Business Results Achieved

Conclusion and Questions

Wires have problems! Especially in High Heat…Wires have problems! Especially in High Heat…

Slag…

Brittle Wires…

Measurement Drift…

EMI…

Wired ArchitectureWired 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

Smart Wireless – Solving your high heat temperature problemsSmart Wireless – Solving your high heat temperature problems

Emerson Smart Wireless has the ability to reduce or eliminate all of these problems.

By mounting the transmitter close the process

– Sensor Wire is reduced– EMI is reduced– Heat Damage is Reduced– Marshalling and remote

terminations are eliminated– Downtime is reduced

Wireless ArchitectureWireless Architecture

Control Room

Wireless Transmitters Can be Used for ControlWireless Transmitters Can be Used for Control

Data Reliability– 99.9% Reliable IEC 62591

SmartWireless Technology– Self-Organizing Mesh

Technology– Multiple Communication Paths

Security– Network IDs and Join Keys– Data Encryption

Fast Update Rates– 1 and 2 second update rates

Redundant Gateways– Increase network reliability

Discrete Output Coming Soon

Wireless Transmitters Work in the Harshest EnvironmentsWireless Transmitters Work in the Harshest Environments

Temperature

Transmitters

North Star Bluescope SteelNorth Star Bluescope Steel

North Star BlueScope Steel operates a steel mill in Ohio. 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.

The Melt Shop contains 2 twin-shell, twin shaft Electric Arc Furnace

The Electric Arc FurnaceThe Electric Arc Furnace

Liquid steel is produced by melting recycled scrap in the electric arc furnaces.

The Cooling JacketThe Cooling Jacket

The Electric Arc Furnace (EAF) is cooled using a water cooling jacket. 28 temperature control points are monitored to prevent runaway

temperatures, hot spots, and panel failures– Each panel failure is a significant maintenance cost

Temperatures are also monitored on water cooled burners to control energy to the burner to help prevent burner failures.

These indications are utilized for alarming through PLCs and control through SmartArc™ transformer regulation and burner control.

Water JacketSmartArc™ is a registered

trademark of AMI GE

International

Measurement ChallengesMeasurement Challenges

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.

Other sources of wire failure included moisture, vibration, heat, and molten slag ejected by the EAF.

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.

Typically, each furnace required 12 man hours of maintenance per week to repair wiring and conduit with the original system.

High Temperature sensor cable cost ~ $4.00/ft http://www.youtube.com/watch?v=ijWwfcw0FOo

Wireless SolutionWireless Solution

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

By using SmartWireless, most of the wiring was eliminated

Installation PicturesInstallation Pictures

848T Protective Box,

before operation

848T Protective Box,

before operation

848T Protective Box, after

operation

848T Protective Box, after

operation

Other Wireless ApplicationsOther Wireless Applications

Wireless Transmitter

Monitoring Exhaust Hood

@ > 800°C

Wireless Transmitter

Monitoring Exhaust Hood

@ > 800°C

Heat-Mangled Transmitter

– Still Functioning

Perfectly

Heat-Mangled Transmitter

– Still Functioning

Perfectly

Wireless Transmitters in High HeatWireless Transmitters in High Heat

648 near opening of Arc

Furnace

648 near opening of Arc

Furnace

Close-up of 648 Protective

Box

Close-up of 648 Protective

Box

Business Results Business Results

Nearly 100% of wiring and terminations have been eliminated.

Since installation, maintenance due to temperature monitoring has been reduced by 99%

Plant safety was improved due to effective cooling panel monitoring and reduced maintenance demands working on a hot furnace.

Better Temperature control has resulted in shorter batch times and as a result, additional throughput

SummarySummary

Wired sensors have many issues when installed in high heat environments– Melting, multiple termination points, moisture, vibration

SmartWireless technology, reduces or eliminates all of these problems– They were able to monitor new points that were unable to

monitor before, resulting in safer more efficient operation– NSBSS has added 8 wireless flow transmitters to monitor

cooling panels and plans to add more.

Wireless is being used for Control– Safe, Reliable, Secure Wireless Technology

Where To Get More InformationWhere To Get More Information

Tradeshow– Rosemount Temperature Booth– Emerson SmartWireless Booth

SmartArc Website:– http://www.amige.com/meltshops_technological_controls_s

martarc.html

Northstar Blue Scope Steel– http://www.northstarbluescope.com/