Water Detection Technology
Tenova offers two Water Detection Systems: an Off-Gas based system and an Acoustic Panel Monitoring.
Overview
The Off-Gas system provides EAF optimization and cost savings together with proprietary software to track %H2O & %H2 analysis, enabling a global alert whenever actual EAF off-gas water levels exceed expected levels. The patented Acoustic System detects panel leaks directly by monitoring a specific acoustic signal emitted in the water-cooling circuit to detect signal changes that are indicative of a leak. These two technologies together provide the most comprehensive alert for EAF water leaks while minimizing false alarms.
Tenova’s Water Detection Technology is suitable for all EAF designs including Consteel®. The off-gas based technology typically provides an alert for water leaks greater than ~15 gpm (~55 lpm) while the Acoustic System provides a specific panel alert at ~5 gpm (~ 20 lpm). Both systems are Industry 4.0 ready and maintain a false alarm rate of less than 5%.
Technical Data
Tenova’s Off-Gas based Water Detection System provides both an excellent ROI from EAF optimization together with software to detect abnormal levels of H2O in the EAF off-gas. The proprietary “Alarming Model” is a combination of algorithms that dynamically compares the actual off-gas composition to the chemistry behavior expected for normal operations. The real-time calculations use NextGen® full spectrum off-gas analysis (including measured H2O and H2) plus Level 1/2 input data. Tenova’s Off-Gas based system provides accurate global water detection abnormal water levels in the EAF freeboard coming from all sources including the panels, electrode spray malfunctions, the cooling circuit on electrical control systems and the scrap charge with minimal false alarms.
The System’s analysis of both H2O vapor & H2 ensures the most comprehensive coverage for both oxidizing & reducing EAF freeboard chemistries.
Tenova’s patented Acoustic System monitors the panel cooling circuit directly and provides the most precise detection capability for specific panels.
The system continuously emits an acoustic signal in a specific frequency range directly in the water-cooling circuit and monitors for signal disturbances that are indicative of a water leak. Monitoring individual panels enables pin-point determination of the location of even small leaks a small as ~5 gpm (~20 lpm). Both Systems are designed to maintain a false alarm rate of less than 5%.
Innovation
The Off-Gas based water detection system uses Tenova’s patented, industry leading NextGen® hybrid laser/extractive off-gas analysis technology which is the only laser-based system to analyze both H2O vapor and H2 thereby ensuring the most comprehensive detection coverage in both oxidizing and reducing EAF freeboard chemistries.
The Acoustic detection system is a patented, novel technology for detecting cooling circuit water leaks in all EAF, Consteel & BOF steelmaking situations.
Digital
Both the Off-Gas based and Acoustic detection systems are fully digitalized and Industry 4.0 ready. Tenova’s Service 4.0 is a remote access/monitoring aftermarket service & support program utilizing KPI driven dashboards to monitor hardware & detection performance. Remote access service & support is provided to quickly & economically diagnosis System issues and to keep the System operating at peak performance. Service 4.0 is also designed to enable rapid retraining of detection software thereby ensuring precise water detection even when operating conditions change.
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