Probe Assembly with ICPC Cleaning for Process Vessel Inspection
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Solution Overview
Problem
Existing camera systems for process vessels, such as melting furnaces, do not allow for in-situ observation and measurement of high-temperature and molten material processes, limiting process efficiency, safety, and the ability to evaluate equipment conditions without opening the vessel.
Innovation Solution
A probe assembly with a camera unit and ICPC (In-line Camera Port Cleaning) unit is mounted to the sidewall of the vessel, enabling inspection of sidewalls and providing a clear path through a thermal insulation sleeve, allowing for camera insertion and retraction despite slag or dross, with automated cleaning and water-cooled protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a camera system is installed to observe the interior of the process vessel, then operators can view conditions within the vessel, but the camera cannot withstand high temperatures and molten material exposure
Solution Approach 1:
The camera system is divided into separate functional components: the camera unit remains outside the vessel in a safe temperature zone, while a protective nozzle assembly with water cooling and air blasting functions is positioned inside the vessel to protect the camera from high temperatures and molten material exposure
Solution Approach 2:
A water-cooled protective nozzle assembly acts as an intermediary between the camera and the harsh vessel interior environment. The nozzle provides water cooling protection and air blasting cleaning functions, shielding the camera from direct exposure to high temperatures and molten material while enabling continuous observation
2Loss of information
If the camera is positioned to view the vessel interior, then operators can observe process conditions, but slag or dross blocks the camera view
Solution Approach 1:
The air blasting cleaning system operates continuously or periodically to remove slag and dross deposits from the camera lens and protective window, ensuring uninterrupted clear viewing of the vessel interior without requiring manual intervention or camera repositioning
Solution Approach 2:
The camera protection system is self-cleaning through automated air blasting that removes accumulated slag and dross from optical surfaces, eliminating the need for manual maintenance and ensuring continuous operational readiness without human intervention
3Loss of information
If operators remove the vessel roof to inspect conditions, then they can directly observe the interior, but operators are exposed to dangerous positions and high temperatures
Solution Approach 1:
Instead of direct human observation, a camera system creates a visual copy or representation of the vessel interior conditions, transmitting images to operators who remain in safe locations outside the vessel, eliminating direct exposure to dangerous environments while maintaining full observational capability
4Loss of information
If the camera is inserted into the vessel for better viewing, then operators can see sidewall conditions, but the camera cannot be retracted when temperatures exceed maximum allowable limits
Solution Approach 1:
The system separates the temperature-sensitive camera unit from the high-temperature zone by positioning it outside the vessel, while only the heat-resistant protective nozzle assembly is inserted into the vessel interior, allowing sidewall observation without exposing the entire camera system to excessive temperatures
Solution Approach 2:
The protective nozzle assembly is designed to be dynamically positionable within the vessel interior, allowing it to extend to optimal viewing positions for observing sidewall conditions and then retract when temperature limits are approached, while the camera remains stationary in a safe temperature zone
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables safe and efficient inspection of vessel sidewalls and molten material processes before, after, and between cycles without opening the vessel, improving safety and process efficiency by providing predictive maintenance and clear views of slag and heel conditions.
Implementation Method 1
cameras with protective cooled jackets
Implementation Method 2
thermal insulation sleeve
Data Source
AI summary
A probe assembly for a process vessel for viewing the inside of the vessel, the probe assembly includes an elongated bracket, an elongated frame, an ICPC unit, and a camera unit. The elongated bracket has a front face and a rear face, the elongated bracket having an upper portion and a lower portion, the lower portion has a first aperture. The elongated frame has a proximal end and a distal end, the distal end of the elongated frame is coupled to the upper portion of the front face of the bracket. The ICPC unit includes a housing that has a front wall, a rear wall, and side wall extended between the front wall and the rear wall, the front wall has a second aperture, the rear wall has a third aperture. The ICPC unit further includes an actuator enclosed in the housing and an elongated tube operably coupled to the actuator, the tube extends through the second aperture and the first aperture away from the rear face of the bracket, the actuator configured to reciprocate the tube between an extended position and a retracted position. The camera unit includes a camera enclosure housing a camera, wherein the actuation member is configured to reciprocate the camera unit between the engage mode and stand-by mode, in the engage mode, the lens' hood is within the tube of the ICPC unit, and in the stand-by mode, the camera unit is away from the ICPC unit towards the proximal end of the elongated frame.