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DETAILS & APPLICATIONS
Go the safe waMeasuring technology for melting & holding equipment
y
2 3
Your qualified partner for furnace safety and lining diagnostics
With over 20 years' experience, Saveway is an internationally established company
specializing in measuring technologies. We manufacture and distribute diagnostic systems
for refractory linings and other components of melting, holding and treatment equipment.
Global service is ensured by our international operating subsidiary companies and
distribution partners.
Based on our years of experience, we develop customized solutions even for very specific
applications. The close cooperation with our customers, universities and professional
associations is an important component in turning innovative ideas into practical solutions.
® SAVEWAY 4 0
® SAVELINE 80
® SAVEDRY 12
® SAVESEARCH 16
OPTISAVE 20
REFERENCES 26
slope
Saveway
2 3
Your qualified partner for furnace safety and lining diagnostics
With over 20 years' experience, Saveway is an internationally established company
specializing in measuring technologies. We manufacture and distribute diagnostic systems
for refractory linings and other components of melting, holding and treatment equipment.
Global service is ensured by our international operating subsidiary companies and
distribution partners.
Based on our years of experience, we develop customized solutions even for very specific
applications. The close cooperation with our customers, universities and professional
associations is an important component in turning innovative ideas into practical solutions.
® SAVEWAY 4 0
® SAVELINE 80
® SAVEDRY 12
® SAVESEARCH 16
OPTISAVE 20
REFERENCES 26
slope
Saveway
4 5
®SAVEWAY Measurement of remaining lining thickness
®SAVEWAY
• Continuous measurement of refractory wall
thickness during furnace operation
• Display accuracy: 1/16 of initial wall thickness
• Localization of wear
• Reliable indication of smallest metal fins
• Reliable indication of drying condition
and cooling water leakages
• Detection of overheating caused by bridging
Measuring unit
Control and visualization unit
Operating principle
The measurement is based on intense decrease
in specific electrical resistance of the refractory
material with increasing temperature. With
progressive wear, molten metal penetrates
towards the sensors and the temperature of the
adjacent refractory material rises. Thereby the
measured resistance by the sensors is decreasing
and will be displayed as appropriate remaining
wall thickness.
• Prevention of furnace damages and molten runouts• Reduced costs for maintenance and production losses
• Optimized service life of refractory linings and components • Increased safety for operating staff and equipment
Technical realization
To locate the wear, the monitored area is covered
with separate sensor segments. The initial wall
thickness of the lining is divided into 16 stages.
The minimum distance between approaching
molten metal and each sensor segment is
displayed continuously. The recorded wear data
allows the optimization of furnace operation and
the risk-free extension of refractory life. The
safety for operating staff and furnace operation
is increased significantly.
Temperature [°C]
Sp
ecif
ic e
lectr
ical re
sis
tan
ce [
Oh
m c
m]
200 400 600 800 1000 1200 1400 1600
10
10
10
10
10
10
10
10
10
10
Alumina ProductsSilica ProductsFireclay ProductsChromia Products(30% Cr O )2 3
AZS Material
1
2
3
4
5
6
7
8
9
10
Coil
Normalwear
Metal fin
Coil grout
Electrodepanel
Vertical crack
Sensor connections
Coil grout
Electrode panel / Sensor
Lining
Coil
Top ring
4 5
®SAVEWAY Measurement of remaining lining thickness
®SAVEWAY
• Continuous measurement of refractory wall
thickness during furnace operation
• Display accuracy: 1/16 of initial wall thickness
• Localization of wear
• Reliable indication of smallest metal fins
• Reliable indication of drying condition
and cooling water leakages
• Detection of overheating caused by bridging
Measuring unit
Control and visualization unit
Operating principle
The measurement is based on intense decrease
in specific electrical resistance of the refractory
material with increasing temperature. With
progressive wear, molten metal penetrates
towards the sensors and the temperature of the
adjacent refractory material rises. Thereby the
measured resistance by the sensors is decreasing
and will be displayed as appropriate remaining
wall thickness.
• Prevention of furnace damages and molten runouts• Reduced costs for maintenance and production losses
• Optimized service life of refractory linings and components • Increased safety for operating staff and equipment
Technical realization
To locate the wear, the monitored area is covered
with separate sensor segments. The initial wall
thickness of the lining is divided into 16 stages.
The minimum distance between approaching
molten metal and each sensor segment is
displayed continuously. The recorded wear data
allows the optimization of furnace operation and
the risk-free extension of refractory life. The
safety for operating staff and furnace operation
is increased significantly.
Temperature [°C]
Sp
ecif
ic e
lectr
ical re
sis
tan
ce [
Oh
m c
m]
200 400 600 800 1000 1200 1400 1600
10
10
10
10
10
10
10
10
10
10
Alumina ProductsSilica ProductsFireclay ProductsChromia Products(30% Cr O )2 3
AZS Material
1
2
3
4
5
6
7
8
9
10
Coil
Normalwear
Metal fin
Coil grout
Electrodepanel
Vertical crack
Sensor connections
Coil grout
Electrode panel / Sensor
Lining
Coil
Top ring
6 7
®SAVEWAY Application examples
slope
Standard sensor panels installed on a coreless induction furnace
Sensor electrode in the floor construction of a glass melting tank
Sensor panels and vacuum sealed feed through on a RH degasser
Sensor panels in a submerged arc furnace
S-shaped-sensor panels for large coreless induction furnaces and special applications
Special sensor panel in the insulating layer of a ladle furnace lining
6 7
®SAVEWAY Application examples
slope
Standard sensor panels installed on a coreless induction furnace
Sensor electrode in the floor construction of a glass melting tank
Sensor panels and vacuum sealed feed through on a RH degasser
Sensor panels in a submerged arc furnace
S-shaped-sensor panels for large coreless induction furnaces and special applications
Special sensor panel in the insulating layer of a ladle furnace lining
8 9
Comprehensive measurement of hot spots and wear monitoring
• Comprehensive temperature monitoring of refractory
linings and components during furnace operation
• Calculation of remaining lining thickness
• Always measuring the highest temperature of a sensor segment
• Localization of wear by placement of multiple sensors
• Reliable measurement in electrically conductive linings
• Measuring range of sensors 100 °C - 1350 °C
(210 °F - 2460 °F)
Measuring unit
Control and visualization unit
Operating principle
Linear sensors are used for the measurement. If
the temperature rises at any spot, the electrical
resistance of the ceramic sensor filling will
decrease there. Each measured resistance is
associated with a temperature. The sensor
measures not only at one point like thermo-
couples, but always the highest temperature
along is entire length. Various sensor ceramics
are available for different temperature ranges.
The remaining wall thickness is calculated from
the temperature and the thermal conductivity of
the refractory lining.
• Increased equipment uptime• Optimized work and operating safety
• Tool for improving refractory construction and furnace handling• Improvement of process control and documentation
Technical realization
The SAVELINE sensor is placed in the refrac-
tory according to the measurement task. The
sensor is flexible. Comprehensive monitoring
can be realized by a serpentine arrangement of
the sensors. By using multiple sensor seg-
ments, wear can be located specifically.
Because of its coating, the sensor can also be
used in graphitic linings, or where electrically
conductive precipitation can be expected. The
measuring system displays the current status
and records the temporal wear and temperature
trend.
®SAVELINE
®SAVELINE
Temperature [°C]
Sp
ecif
ic e
lectr
ical re
sis
tan
ce [
Oh
m c
m]
200 400 600 800 1000 1200 1400 1600
10
10
10
10
10
10
104
5
6
7
8
9
10
0
Ceramic A
Ceramic B
Ceramic C
Ceramic D
SiO2
25
100
50
0
75
Rem
ain
ing
lin
ing
th
ickn
ess [
%]
Tem
pera
ture
[°C
]
200
500
800
Dec 2013Dec 2012 Mar 2013 Jun 2013 Sep 2013
Bushing 1
Bushing 2
Time
Internal Conductor
Shield(External Conductor)
Measuring system
Ceramic
SAVELINE SensorØ 3 … 6 mm
Length variable
Measuring system
Refractory material
SensorMelt
8 9
Comprehensive measurement of hot spots and wear monitoring
• Comprehensive temperature monitoring of refractory
linings and components during furnace operation
• Calculation of remaining lining thickness
• Always measuring the highest temperature of a sensor segment
• Localization of wear by placement of multiple sensors
• Reliable measurement in electrically conductive linings
• Measuring range of sensors 100 °C - 1350 °C
(210 °F - 2460 °F)
Measuring unit
Control and visualization unit
Operating principle
Linear sensors are used for the measurement. If
the temperature rises at any spot, the electrical
resistance of the ceramic sensor filling will
decrease there. Each measured resistance is
associated with a temperature. The sensor
measures not only at one point like thermo-
couples, but always the highest temperature
along is entire length. Various sensor ceramics
are available for different temperature ranges.
The remaining wall thickness is calculated from
the temperature and the thermal conductivity of
the refractory lining.
• Increased equipment uptime• Optimized work and operating safety
• Tool for improving refractory construction and furnace handling• Improvement of process control and documentation
Technical realization
The SAVELINE sensor is placed in the refrac-
tory according to the measurement task. The
sensor is flexible. Comprehensive monitoring
can be realized by a serpentine arrangement of
the sensors. By using multiple sensor seg-
ments, wear can be located specifically.
Because of its coating, the sensor can also be
used in graphitic linings, or where electrically
conductive precipitation can be expected. The
measuring system displays the current status
and records the temporal wear and temperature
trend.
®SAVELINE
®SAVELINE
Temperature [°C]
Sp
ecif
ic e
lectr
ical re
sis
tan
ce [
Oh
m c
m]
200 400 600 800 1000 1200 1400 1600
10
10
10
10
10
10
104
5
6
7
8
9
10
0
Ceramic A
Ceramic B
Ceramic C
Ceramic D
SiO2
25
100
50
0
75
Rem
ain
ing
lin
ing
th
ickn
ess [
%]
Tem
pera
ture
[°C
]
200
500
800
Dec 2013Dec 2012 Mar 2013 Jun 2013 Sep 2013
Bushing 1
Bushing 2
Time
Internal Conductor
Shield(External Conductor)
Measuring system
Ceramic
SAVELINE SensorØ 3 … 6 mm
Length variable
Measuring system
Refractory material
SensorMelt
10 11
Application examples
slope
SAVELINE sensor on the upper part of a channel inductor to
monitor the flange gap
SAVELINE sensors in a steel ladle
Monitoring the heater casing of a casting furnace
SAVELINE installation for remaining length measurement on a porous plug
SAVELINE sensors placed on the bushing before casting the safety lining
Floor monitoring in a coreless induction furnace
®SAVELINE
10 11
Application examples
slope
SAVELINE sensor on the upper part of a channel inductor to
monitor the flange gap
SAVELINE sensors in a steel ladle
Monitoring the heater casing of a casting furnace
SAVELINE installation for remaining length measurement on a porous plug
SAVELINE sensors placed on the bushing before casting the safety lining
Floor monitoring in a coreless induction furnace
®SAVELINE
12 13
Drying measurement and leakage monitoring
• Continuous measurement of remaining moisture
in refractory linings
• Reliable detection of cooling water leakages
• Localization of moisture problems
• Reliable display of drying condition
• Monitoring of furnaces during relining,
sinter heat and regular operation
Measuring unit
Control andvisualization unit
Operating principle
Certain substances such as salts or oxides dissociate
in water to mobile ions. Ions are charge carriers and
lead to electrical conductivity, which is measured.
The number of mobile ions, and therefore the
measured conductivity, depends on the water
content. Based on the sensor type, the dissociated
substances are absorbed into the sensor ceramic.
• Prevention of plant damage and furnace explosions• Optimized sinter and drying time
• Reduced production losses and maintenance costs• Significantly increased safety for operating staff and equipment
Technical realization
Depending on the measurement task, the
sensors are placed in specific locations in the
refractory material or the furnace wall. There are
different types of sensors available which are
placed in the furnace during relining, as well as
sensor types which can be replaced during
furnace operation. The localization of water
leakages or remaining moisture is possible by
the arrangement of multiple sensors. The
measuring system records the temporal trend of
the remaining moisture and displays the current
condition. For water leakages, customized
warnings are issued.
®SAVEDRY
®SAVEDRY
Moisture
Dissociation
Mobile ions
Electric conductivity
Drying
No water
Immobile ions
No electrical conductivity
25
100
50
0
75
Resid
ual m
ois
ture
at
sen
so
r lo
cati
on
[%
]
22.01.1301.01.13 08.01.13 15.01.13
Furnace floor
Time
Ceramic
Measuring system
Shield(external conductor)
Internal conductor
Perforation
SAVEDRY sensor type 1
Stainless steel shell
Inner surface of furnace wall
Protection tube
Perforation
ReplaceableSAVEDRY sensor type 4
12 13
Drying measurement and leakage monitoring
• Continuous measurement of remaining moisture
in refractory linings
• Reliable detection of cooling water leakages
• Localization of moisture problems
• Reliable display of drying condition
• Monitoring of furnaces during relining,
sinter heat and regular operation
Measuring unit
Control andvisualization unit
Operating principle
Certain substances such as salts or oxides dissociate
in water to mobile ions. Ions are charge carriers and
lead to electrical conductivity, which is measured.
The number of mobile ions, and therefore the
measured conductivity, depends on the water
content. Based on the sensor type, the dissociated
substances are absorbed into the sensor ceramic.
• Prevention of plant damage and furnace explosions• Optimized sinter and drying time
• Reduced production losses and maintenance costs• Significantly increased safety for operating staff and equipment
Technical realization
Depending on the measurement task, the
sensors are placed in specific locations in the
refractory material or the furnace wall. There are
different types of sensors available which are
placed in the furnace during relining, as well as
sensor types which can be replaced during
furnace operation. The localization of water
leakages or remaining moisture is possible by
the arrangement of multiple sensors. The
measuring system records the temporal trend of
the remaining moisture and displays the current
condition. For water leakages, customized
warnings are issued.
®SAVEDRY
®SAVEDRY
Moisture
Dissociation
Mobile ions
Electric conductivity
Drying
No water
Immobile ions
No electrical conductivity
25
100
50
0
75
Resid
ual m
ois
ture
at
sen
so
r lo
cati
on
[%
]
22.01.1301.01.13 08.01.13 15.01.13
Furnace floor
Time
Ceramic
Measuring system
Shield(external conductor)
Internal conductor
Perforation
SAVEDRY sensor type 1
Stainless steel shell
Inner surface of furnace wall
Protection tube
Perforation
ReplaceableSAVEDRY sensor type 4
14 15
Application examples
slope
SAVEDRY sensor type 3 installed on a submerged arc furnace for monitoring the tap holes
Replaceable SAVEDRY sensor type 4 in the furnace wall of an arc furnace
SAVEDRY sensor type 2 in an arc furnace
SAVEDRY installation type 1 below the cooling water channel
of an arc furnace
SAVEDRY sensor type 1 on a cooling water channel before installing castable of the heat shield
SAVEDRY sensor type 1 installed on top of the cooling water pipe in the bottom of a graphitization furnace
®SAVEDRY
14 15
Application examples
slope
SAVEDRY sensor type 3 installed on a submerged arc furnace for monitoring the tap holes
Replaceable SAVEDRY sensor type 4 in the furnace wall of an arc furnace
SAVEDRY sensor type 2 in an arc furnace
SAVEDRY installation type 1 below the cooling water channel
of an arc furnace
SAVEDRY sensor type 1 on a cooling water channel before installing castable of the heat shield
SAVEDRY sensor type 1 installed on top of the cooling water pipe in the bottom of a graphitization furnace
®SAVEDRY
16 17
Monitoring of coil-shunt-insulation
• Preventive maintenance tool for coreless
induction furnaces
• Detection of impending insulation faults
• Clear localization of insulation faults
• Significantly higher ohmic measurement range compared to ground leakage indicator
• Moisture detection in the insulation structure
• Separate monitoring of each shunt
Measuring unit
Control andvisualization unit
Operating principle
Common ground leakage indicators measure the
electrical resistance between the water-cooled coil
and ground connections. Therefore ground leakages
between coil and shunt cannot be located and
detected early. The SAVESEARCH system mea-
sures the insulation resistance between the individ-
ual ground-isolated sensor electrodes and the coil.
As a result, a much higher impedance measurement
range is covered and developing insulation faults are
detected at an early stage. The condition of the
electrical insulation of each shunt is monitored
separately.
• Enormous time savings when searching for insulation faults• Minimized production losses and maintenance costs
• Increased equipment uptime• Optimized work and operating safety
Technical arrangement
Sensor electrodes are arranged in the coil-shunt-
insulation so that the regular electrical insulation is
not weakened. The sensors are transparent to the
electromagnetic field. A self-diagnosis function
ensures the system is operating properly. The high
impedance measurement range allows preventive
maintenance, and “flashovers” between coil and
shunt can be avoided. For visualization, the instanta-
neous values of the insulating resistance and
temporal trend are available.
®SAVESEARCH
®SAVESEARCH
Measuringsystem
H O2
Coil profile SAVESEARCHelectrode
Mica
Shunt
Cooling waterresistance
Measuring system
Electrical insulationcoil - shunt
Insulation fabric
Coil
Shunt
Electrical insulationcoil - shunt
SAVESEARCH electrode
16 17
Monitoring of coil-shunt-insulation
• Preventive maintenance tool for coreless
induction furnaces
• Detection of impending insulation faults
• Clear localization of insulation faults
• Significantly higher ohmic measurement range compared to ground leakage indicator
• Moisture detection in the insulation structure
• Separate monitoring of each shunt
Measuring unit
Control andvisualization unit
Operating principle
Common ground leakage indicators measure the
electrical resistance between the water-cooled coil
and ground connections. Therefore ground leakages
between coil and shunt cannot be located and
detected early. The SAVESEARCH system mea-
sures the insulation resistance between the individ-
ual ground-isolated sensor electrodes and the coil.
As a result, a much higher impedance measurement
range is covered and developing insulation faults are
detected at an early stage. The condition of the
electrical insulation of each shunt is monitored
separately.
• Enormous time savings when searching for insulation faults• Minimized production losses and maintenance costs
• Increased equipment uptime• Optimized work and operating safety
Technical arrangement
Sensor electrodes are arranged in the coil-shunt-
insulation so that the regular electrical insulation is
not weakened. The sensors are transparent to the
electromagnetic field. A self-diagnosis function
ensures the system is operating properly. The high
impedance measurement range allows preventive
maintenance, and “flashovers” between coil and
shunt can be avoided. For visualization, the instanta-
neous values of the insulating resistance and
temporal trend are available.
®SAVESEARCH
®SAVESEARCH
Measuringsystem
H O2
Coil profile SAVESEARCHelectrode
Mica
Shunt
Cooling waterresistance
Measuring system
Electrical insulationcoil - shunt
Insulation fabric
Coil
Shunt
Electrical insulationcoil - shunt
SAVESEARCH electrode
18 19
Application examples
slope
SAVESEARCH electrode in a 4 t vacuum induction furnace
Electrical connections of the SAVESEARCH electrodes
on a 12 t furnace
SAVESEARCH electrodes in a high-performance furnace 8 t / 8 MW
High-Voltage resistant wiring of the SAVESEARCH electrode
Horizontally divided SAVESEARCH electrodes in a 12 t furnace
SAVESEARCH connections after coil installation on an 8 t furnace
®SAVESEARCH
18 19
Application examples
slope
SAVESEARCH electrode in a 4 t vacuum induction furnace
Electrical connections of the SAVESEARCH electrodes
on a 12 t furnace
SAVESEARCH electrodes in a high-performance furnace 8 t / 8 MW
High-Voltage resistant wiring of the SAVESEARCH electrode
Horizontally divided SAVESEARCH electrodes in a 12 t furnace
SAVESEARCH connections after coil installation on an 8 t furnace
®SAVESEARCH
20 21
Extensive temperature measurement
• Continuous temperature measurement
up to 600 °C (1110 °F)
• Local resolution: 0.25 m (10”)
• Maximum 8 sensors with sensor lengths up to 2000 m (1.25 miles)
• Up to 8000 temperature values per sensor
• Measurement not influenced by surrounding
environment
• Insensitive to electrical and magnetic fields
• Calculation of remaining wall thicknessesMeasuring andvisualization unit
Operating principle
The temperature measurement is based on
the Raman Effect. For this purpose, light is
transmitted through the optical fibre, and the
intensity of the temperature-dependent part of
the reflected spectrum is analyzed. By the
runtime of the light, the location of the specific
temperature points can be determined.
• Prevention of furnace damages and molten runouts• Increased equipment uptime
• Optimized work and operating safety • Improved process control and documentation
Technical arrangement
The mechanically-protected optical fibre sensor is
placed over long distances or large areas. For
monitoring water-cooled components, the sensor
fiber can be placed in grooves on the surface or in
embedded channels inside the component.
OPTISAVE F
OPTISAVE F
Main fields of application
• Water-cooled components and surfaces
Arc furnaces•
Melting equipment for primary • metallurgy and smelting
Reaction tanks•
Recycling smelting furnaces•
Combustion plants•
Retu
rn s
ign
al in
ten
sit
y
1 / Wavelength
Stokes amplitude
Input light
T3
T1
T2
Anti-Stokes amplitude
Steel shell
Detail
Optical fibre
Protection tube, stainless steel
Level ALevel BLevel CLevel DLevel ELevel FLevel GLevel H
20 21
Extensive temperature measurement
• Continuous temperature measurement
up to 600 °C (1110 °F)
• Local resolution: 0.25 m (10”)
• Maximum 8 sensors with sensor lengths up to 2000 m (1.25 miles)
• Up to 8000 temperature values per sensor
• Measurement not influenced by surrounding
environment
• Insensitive to electrical and magnetic fields
• Calculation of remaining wall thicknessesMeasuring andvisualization unit
Operating principle
The temperature measurement is based on
the Raman Effect. For this purpose, light is
transmitted through the optical fibre, and the
intensity of the temperature-dependent part of
the reflected spectrum is analyzed. By the
runtime of the light, the location of the specific
temperature points can be determined.
• Prevention of furnace damages and molten runouts• Increased equipment uptime
• Optimized work and operating safety • Improved process control and documentation
Technical arrangement
The mechanically-protected optical fibre sensor is
placed over long distances or large areas. For
monitoring water-cooled components, the sensor
fiber can be placed in grooves on the surface or in
embedded channels inside the component.
OPTISAVE F
OPTISAVE F
Main fields of application
• Water-cooled components and surfaces
Arc furnaces•
Melting equipment for primary • metallurgy and smelting
Reaction tanks•
Recycling smelting furnaces•
Combustion plants•
Retu
rn s
ign
al in
ten
sit
y
1 / Wavelength
Stokes amplitude
Input light
T3
T1
T2
Anti-Stokes amplitude
Steel shell
Detail
Optical fibre
Protection tube, stainless steel
Level ALevel BLevel CLevel DLevel ELevel FLevel GLevel H
22 23
Selective temperature measurement
• Continuous temperature measurement
up to 650 °C (1200 °F)
• Position measurement
• Sensors with user definable measuring points
• High measurement accuracy
Operating principle
The system uses optical fibres with integrated
Bragg gratings. The arrangement of the Bragg
gratings over the sensor length is customized
for each application. A change in fibre length,
caused by temperature influences, results in a
change of grating distance; and therefore in a
varied wavelength. The wavelength difference
is evaluated to identify the temperature at
the discrete sensor points.
• Prevention of furnace damages and molten runouts• Increased equipment uptime
• Optimized work and operating safety • Improved process control and documentation
Technical arrangement
The optical fibre sensor is mechanically protected by
being placed in a stainless steel or monel tube. There
are a wide variety of industrial heating and melting
functions where OPTISAVE can be applied. Project-
specific installation solutions are implemented based
on individual monitoring tasks.
OPTISAVE G
OPTISAVE G
Main fields of application
• Equipment and components
with small dimensions
Measurement tasks with high •
demands for local resolution
Measuring andvisualization unit
slope
Sensor 1 Sensor 2 Sensor 3
Inte
nsit
y
Wavelength λ of reflected light
Decrease of temperature=
Decrease of grating distance
Increase of temperature=
Increase of grating distance
T↓T↑
1 K = 7 pm
T↓ T↑T↑ T↓
Cooling water channel
Optical fibreDetail:
Monel tubeØ 5 mm
CopperMonel tubewith optical fibre
Cooling water channel
Hotsurface
22 23
Selective temperature measurement
• Continuous temperature measurement
up to 650 °C (1200 °F)
• Position measurement
• Sensors with user definable measuring points
• High measurement accuracy
Operating principle
The system uses optical fibres with integrated
Bragg gratings. The arrangement of the Bragg
gratings over the sensor length is customized
for each application. A change in fibre length,
caused by temperature influences, results in a
change of grating distance; and therefore in a
varied wavelength. The wavelength difference
is evaluated to identify the temperature at
the discrete sensor points.
• Prevention of furnace damages and molten runouts• Increased equipment uptime
• Optimized work and operating safety • Improved process control and documentation
Technical arrangement
The optical fibre sensor is mechanically protected by
being placed in a stainless steel or monel tube. There
are a wide variety of industrial heating and melting
functions where OPTISAVE can be applied. Project-
specific installation solutions are implemented based
on individual monitoring tasks.
OPTISAVE G
OPTISAVE G
Main fields of application
• Equipment and components
with small dimensions
Measurement tasks with high •
demands for local resolution
Measuring andvisualization unit
slope
Sensor 1 Sensor 2 Sensor 3
Inte
nsit
y
Wavelength λ of reflected light
Decrease of temperature=
Decrease of grating distance
Increase of temperature=
Increase of grating distance
T↓T↑
1 K = 7 pm
T↓ T↑T↑ T↓
Cooling water channel
Optical fibreDetail:
Monel tubeØ 5 mm
CopperMonel tubewith optical fibre
Cooling water channel
Hotsurface
24 25
Application examples
Cross section of a worn out wall panel with embedded
OPTISAVE sensors
DC (direct current) arc furnace with OPTISAVE F for remaining wall thickness
measurement of the MgO-lining
Detailed view of an embedded OPTISAVE sensor in front of the
cooling channel in the copper panel
Water-cooled copper module of a slag tap hole with integrated
OPTISAVE G sensors
OPTISAVE installation on the inside wall of a water-cooled submerged arc furnace
Slag tap hole of a submerged arc furnace with integrated OPTISAVE G sensor
OPTISAVE
24 25
Application examples
Cross section of a worn out wall panel with embedded
OPTISAVE sensors
DC (direct current) arc furnace with OPTISAVE F for remaining wall thickness
measurement of the MgO-lining
Detailed view of an embedded OPTISAVE sensor in front of the
cooling channel in the copper panel
Water-cooled copper module of a slag tap hole with integrated
OPTISAVE G sensors
OPTISAVE installation on the inside wall of a water-cooled submerged arc furnace
Slag tap hole of a submerged arc furnace with integrated OPTISAVE G sensor
OPTISAVE
26 27
slope
SAVEWAY was installed after a run-out that caused extensive damage
to our VIM furnace. [...] Thyssen Krupp VDM USA has not experienced any molten metal
runouts or contact with the induction coil since the inception of this
system. [...]
SAVEWAY provides the level of operational safety we demand, and
we will not operate the furnace without it.
S. Chapman, TK-VDM USA
REFERENCES
[...] In 2012 we installed the SAVEWAY system for measuring the
remaining lining thickness in both furnaces. The reason for the installa-
tion was to objectively evaluate the influences of the furnace operating
characteristics and other production parameters on the lining life.
Because of the safety the system provides, we extensively tested
different refractory materials and analyzed the influence of all produc-
tion parameters.
We reached double the previous lining life by optimization of the
furnace operating characteristics and production process. [...]
S. Zovak, VULKAN INOX GmbH
[...] As there had been frequent unpredictable faults between the coil
and the shunts on our 8-t-coreless induction furnaces, we decided to
install the SAVESEARCH shunt monitoring system at the beginning
of 2009. [...]
The availability of our coreless induction furnaces was clearly
increased by the SAVESEARCH system. The time necessary to search
for ground leakages was minimized and production losses
have been avoided. [...]
H. Bauch, M. Gaag, SIEMENS Gusstechnik GmbH
[...] We are operating two 6-t MF induction furnaces for melting and two 6-t induction
furnaces for pouring steel at tapping temperatures of 1.650°C. The initiation for
utilizing a SAVEWAY system was primarily to increase safety in our melting shop. [...]
Lining life in our crucibles using a silica-based refractory was extended up to 100 %,
where lining life of a crucible using neutral refractory material was extended to
approximately 250 %. [...]
The SAVEWAY system has been very useful equipment for our company. We definitely
are going to use the SAVEWAY system for new induction furnaces in the future.
S. Kulka, METALLTECHNIK SCHMIDT GmbH & Co. KG
In summer 1993 VAC Hanau installed a SAVEWAY system on a 4-t vacuum induction
furnace (VIM) for the first time. The main reason for that decision was the fact that
there was a potential risk of explosion and serious injuries to employees caused by
runouts.
Our experience proved that only the SAVEWAY system provides appropriate and
reliable safety concerning runouts. [...]
Due to these positive experiences and our safety philosophy, all our furnaces have
been equipped with a SAVEWAY system. [...]
T. Scheidig, VACUUMSCHMELZE GmbH & Co. KG
[...] The SAVEWAY system was installed after a heavy metal run through which was
accompanied by serious injury of an operator on both furnaces in 1996 and 1997. With
those installations we made sure that such accidents never happened again!
Furthermore we now fulfill working on demands of the OSHA (Occupational Safety
and Health Administration) and the industrial insurance companies regarding increas-
ing the operational safety. Based on our experience, proof can be given that only the
SAVEWAY system ensures that high safety standard. [...]
Based on the objective measurement of the remaining lining thickness we were
able to increase the number of heats from 170 to 250 now. [...]
C. Sohm, W. Geser, MAHLE KÖNIG KOMMANDITGESELLSCHAFT Ges.m.b.H. & Co KGp
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SAVEWAY was installed after a run-out that caused extensive damage
to our VIM furnace. [...] Thyssen Krupp VDM USA has not experienced any molten metal
runouts or contact with the induction coil since the inception of this
system. [...]
SAVEWAY provides the level of operational safety we demand, and
we will not operate the furnace without it.
S. Chapman, TK-VDM USA
REFERENCES
[...] In 2012 we installed the SAVEWAY system for measuring the
remaining lining thickness in both furnaces. The reason for the installa-
tion was to objectively evaluate the influences of the furnace operating
characteristics and other production parameters on the lining life.
Because of the safety the system provides, we extensively tested
different refractory materials and analyzed the influence of all produc-
tion parameters.
We reached double the previous lining life by optimization of the
furnace operating characteristics and production process. [...]
S. Zovak, VULKAN INOX GmbH
[...] As there had been frequent unpredictable faults between the coil
and the shunts on our 8-t-coreless induction furnaces, we decided to
install the SAVESEARCH shunt monitoring system at the beginning
of 2009. [...]
The availability of our coreless induction furnaces was clearly
increased by the SAVESEARCH system. The time necessary to search
for ground leakages was minimized and production losses
have been avoided. [...]
H. Bauch, M. Gaag, SIEMENS Gusstechnik GmbH
[...] We are operating two 6-t MF induction furnaces for melting and two 6-t induction
furnaces for pouring steel at tapping temperatures of 1.650°C. The initiation for
utilizing a SAVEWAY system was primarily to increase safety in our melting shop. [...]
Lining life in our crucibles using a silica-based refractory was extended up to 100 %,
where lining life of a crucible using neutral refractory material was extended to
approximately 250 %. [...]
The SAVEWAY system has been very useful equipment for our company. We definitely
are going to use the SAVEWAY system for new induction furnaces in the future.
S. Kulka, METALLTECHNIK SCHMIDT GmbH & Co. KG
In summer 1993 VAC Hanau installed a SAVEWAY system on a 4-t vacuum induction
furnace (VIM) for the first time. The main reason for that decision was the fact that
there was a potential risk of explosion and serious injuries to employees caused by
runouts.
Our experience proved that only the SAVEWAY system provides appropriate and
reliable safety concerning runouts. [...]
Due to these positive experiences and our safety philosophy, all our furnaces have
been equipped with a SAVEWAY system. [...]
T. Scheidig, VACUUMSCHMELZE GmbH & Co. KG
[...] The SAVEWAY system was installed after a heavy metal run through which was
accompanied by serious injury of an operator on both furnaces in 1996 and 1997. With
those installations we made sure that such accidents never happened again!
Furthermore we now fulfill working on demands of the OSHA (Occupational Safety
and Health Administration) and the industrial insurance companies regarding increas-
ing the operational safety. Based on our experience, proof can be given that only the
SAVEWAY system ensures that high safety standard. [...]
Based on the objective measurement of the remaining lining thickness we were
able to increase the number of heats from 170 to 250 now. [...]
C. Sohm, W. Geser, MAHLE KÖNIG KOMMANDITGESELLSCHAFT Ges.m.b.H. & Co KG
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Saveway Group
Headquarters Germany
Saveway GmbH & Co. KGWümbacher Straße 8, 98704 Langewiesen, GermanyPhone: +49 3677 80 60-0E-mail: [email protected]
Sales & Service USA / North America
Saveway U.S.A. Corp.601 E Main Ave, Myerstown, PA 17067, USAPhone: +1 717 62 81 016 E-mail: [email protected]
Sales & Service Japan / Asia
Saveway Japan Ltd.3-16 Kawabuchi-Machi, Yahatahigashi-Ku, Kitakyushu-City, 805-0012, JapanPhone: +81 93 65 34 730 E-mail: [email protected]
Sales & Service Southern Africa
Saveway Furnace Monitoring Africa (Pty.) Ltd.74 Queen Street, Irene Proper, Centurion, Pretoria 0157, South AfricaPhone: +27 12 667-2178E-mail: [email protected]
Saveway U.S.A. Corp.4305 Mt. Pleasant Street NW, Suite 101North Canton, OH 44720, USAPhone: +1 330 96 69 300
More information:
www.saveway-germany.de