Sharing a technical solution for an endoscopic flame monitoring system

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I. Overview: The GS-Vision-P system is an endoscopic furnace flame monitoring system for petrochemical heating furnaces that utilizes machine vision technology; it is designed for use in environments containing explosive substances within the IIC gas group (typically hydrogen, acetylene, ethylene, coke oven gas, dimethyl ether, etc.). The GS-Vision-P system enables operators to intuitively understand conditions such as flame combustion and atomization inside the furnace, as well as coking in the furnace tubes, insulation layers, and nozzles, through smooth images. II. Referenced standards: SH/T 3028-2007 “Code for Telecommunication Design of Petrochemical Plants”; GB 50115-2009 “Code for Engineering Design of Industrial Television Systems”; GB 50160-2008 “Code for Fire Protection Design of Petrochemical Enterprises”; GB 3836.1-2010 “Explosion-protected environments – Part 1: General requirements for equipment”; GB 3836.2-2010 “Explosion-protected environments – Part 1: Equipment protected by flameproof enclosures ‘d’”; GB 4208-2008 “Degrees of protection provided by enclosures (IP code)”; GB/T 15414-94 “General technical requirements for high-temperature television systems for furnaces”; GB/T 15415-94 “Measurement methods for high-temperature television systems for furnaces”; GB 2423-2008 “Basic environmental testing procedures for electrical and electronic products”; GB 2887-2012 “Technical requirements for computer station sites”; GB 4943-2012 “Safety of information technology equipment (including electrical and electronic equipment)”; GB/T 13850-1998 “Electrical measuring transmitters for converting alternating current quantities into analog or digital signals”; GB/T 17626.1-2006 “General principles for immunity testing”; IEEE 802.3U 100BASE-TX “Fast Ethernet interface standard”.

III. System overview: The GS-Vision-P system utilizes an industrial-standard service-oriented network architecture to create a comprehensive management platform that integrates video surveillance, image analysis, display, and management functions. It features a well-structured hierarchical design as well as a C/S architecture, which helps to reduce the complexity of system construction and enhance the flexibility of distributed deployment. The system provides unified internal and external interface services, facilitating system expansion and centralized management. The system supports the ONVIF interface protocol and provides access ports for the office network as well as the CCTV systems throughout the facility. The flameproof high-temperature integrated camera is a monitoring device that combines digital high-definition industrial cameras with machine vision technology; its high-temperature resistant cover, equipped with forced vortex cooling, allows the camera to be inserted into furnaces at 2000°C for observation ； Digital HD industrial cameras automatically adjust the output level based on changes in flame brightness to maintain clear images. The image analysis server is a powerful analysis tool that utilizes machine vision technology to simulate the visual behavior of the human eye. It can accurately detect burner shutdowns and tube leaks within its field of view, and generate alarm signals; together with explosion-proof integrated high-temperature cameras, it forms a complete monitoring system. file:///C:/Users/thinkpad/AppData/Local/Temp/msohtmlclip1/01/clip_image002.jpg System Configuration Diagram 1. Functions and Technical Specifications of the GS-Vision-P System: GS-Vision-P1 model, GS-Vision-P2 model. Camera temperature tolerance: ≤2000°C; cooling method: forced vortex air cooling. Image resolution: 1280×960. Minimum illumination: 0.01 Lux for color images, 0.001 Lux for black-and-white images. The system has self-protection features against over-temperature, under-voltage, and power loss conditions; in such cases, the camera retracts automatically. The cooling air is discharged outside the furnace (optional per user’s request). Network interface protocols: ONVIF, GB28181. 2. Requirements for the system’s utility systems: Power supply: For field probes, 220VAC 50/60HZ, with a power consumption of 20W per unit; for the control room, 220VAC 50/60HZ, with a power consumption of 800W. Air supply: Purging air: 25 Nm3/h at 0.6 Mpa (instrument air); cooling air: 34 Nm3/h at 0.1 Mpa (instrument air or industrial air). 3. System composition: The GS-Vision-P system consists of explosion-proof high-temperature integrated cameras, automatic retraction protection devices, wall mounting kits, air filtration systems, field equipment boxes, image data servers, etc. 3.1 The GS-CVCZL-Ex explosion-proof high-temperature integrated camera system consists of: n explosion-proof high-temperature integrated cameras; n high-temperature resistant optical lenses (including sapphire windows); n air vortex cooling high-temperature protective covers; n 2 stainless steel air pipes to form the cooling air assembly; n 1 cable with a length of 10 meters; n pre-assembling and pre-debugging have been completed prior to shipment. 3.1.1 Explosion-proof high-temperature cameras: Types – GS-Vision-P1, GS-Vision-P2. Sensor: CCD Image Sensor. Resolution: 1280×960. Minimum illumination: Color: 0.01 Lux / Black and white: 0.001 Lux. Frame rate: 25 Hz. Dynamic range: 120 dB. Signal-to-noise ratio: >50 dB. Video/data interface: 100M Ethernet, RJ45 connector. Operating temperature: -30°C to 60°C. Operating humidity: less than 95% (without condensation). Power supply: 12V DC/6W max; 12V DC/16W. Protection rating: IP66. Explosion protection rating: Ex d IIC T6 Gb. 3.1.2 Infrared high-temperature resistant optical lenses: Total lens length: 650 mm. Diameter of the viewing hole: φ2 mm. Lens diameter: φ60 mm. Field of view: 72° (horizontal) x 54° (vertical) x 90° (diagonal); 90° (horizontal) x 74° (vertical) x 102° (diagonal). Lens types: Standard straight-view lenses, with options for right-angle and obtuse-angle lenses available. 3.1.3 Vortex cooling high-temperature protective covers: These covers are equipped with an innovative forced vortex cooling system, with cooling air being blown into the furnace through the viewing hole in front of the optical lens ； The cooling air is forced to circulate through the vortex duct in the protective cover for cooling before being discharged outside the furnace, which not only improves the cooling efficiency of the lens compartment but also reduces the impact of the cooling air on the combustion process of the heating furnace. n Lens compartment: Made of high-temperature resistant stainless steel, with forced vortex cooling (the temperature of the monitored area can reach 2000°C).
n Camera compartment: Made of high-temperature resistant materials (the ambient temperature can reach 80°C).
n Protection rating: IP66.
n Purging air: 25 Nm3/h at 0.6 Mpa (instrument air).
n Cooling air: 34 Nm3/h at 0.1 Mpa (instrument air or industrial air).
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Explosion-proof high-temperature integrated camera. 3.2, GS-CD-WQ65 automatic retraction protection device: The automatic extension/retraction mechanism is used to protect the cameras in the GS-Vision-P system. The explosion-proof high-temperature integrated camera relies on continuous compressed air to keep its internal lens components clean and cooled in harsh environments. Once the cooling air is lost, the automatic retraction protection system automatically pulls the camera out of the furnace, thereby avoiding the need for manual operation to retract or push the camera and preventing improper handling that could damage the system. It retracts automatically in case of a drop in compressed air pressure or a power outage; the cylinder drives it, and it operates in both manual and automatic modes. An automatic damper is available to prevent the escape of atmosphere from the furnace. The retraction distance is 650 mm, and its load capacity is 50 Kg. file:///C:/Users/thinkpad/AppData/Local/Temp/msohtmlclip1/01/clip_image006.jpg Automatic retraction protection device. 3.3 BXK field equipment box: This box contains an industrial Ethernet switch, servo controllers, and power adapters; it serves as the system’s component for data collection, transmission, and servo control. The servo controllers drive the automatic retraction protection device to carry out its functions. Input interface: 100M Ethernet, RJ45 connector. Output interface: 100M optical port. Transmission rate: Up to 100M. Standards: IEEE802.3, IEEE802.3u, IEEE802.3x. Power supply: AC 220V±10%, 20W. Operating temperature: -20°C to 65°C. Relative humidity: ≤90%. Physical dimensions: 360 (W) × 360 (H) × 175 (D) mm. Explosion protection rating: Ex d IIB T6 Gb or Ex d IIC T6 Gb 3.4, GS-SQK1A. The air control box is a device for on-site monitoring/adjustment of compressed air pressure and flow in the system; when there is a lack of air supply or the parameters do not meet the system’s set thresholds, the control box sends a signal to the servo controller of the on-site equipment box, causing the protective mechanism to automatically retract the camera out of the furnace. n Air interface: G1/4\" n Pressure rating: 1.0 MPa n Switching voltage: 250VAC/1.0A, 24DC/1.0A n File:///C:/Users/thinkpad/AppData/Local/Temp/msohtmlclip1/01/clip_image009.gif Operating temperature: -20°C to 70°C n Relative humidity: ≤90% n Net weight: 6 kg n Protection rating: IP65 n Dimensions: 285 (W) × 340 (H) × 165 (D) mm 3.5, GS-JL01 Air filtration system – Compressed air is used for purging and cooling lenses and electronic devices, and a continuous supply of air is necessary. The air filtration system has particle separation and coalescing filtration functions, effectively cleaning and drying the compressed air supplied by the factory. This makes the compressed air suitable for use in blowing and cooling the optical elements, ensuring the acquisition of long-term, stable, and clear images. Users should replace the filter element regularly based on air quality. N interface: G1/2\" (bore diameter 15mm); N operating pressure: 0.3–0.6 MPa; pressure resistance: 1.0 MPa; rated flow rate: 1000 l/min; filtration precision: 0.01 μm. 3.6, GS-SERVERFD-V1.5 Image analysis server – The image data server is designed based on a PC and serves as an image analysis system for high-temperature imaging systems. It is connected to the system via the factory’s local area network, and offers functions such as multi-screen viewing, image storage, remote control, alarm information display, retrieval, and management. It also supports multiple levels of user permissions. The software not only features flexible window layout options but also supports secondary screen display, which helps to reduce space usage and improve the efficiency of device utilization. 3.6.1 Server technical specifications: Processor – Intel® Core™ processor; Memory – 8GB (2x4GB) 1600MHz DDR3, non-ECC; Hard drive – 1TB 3.5-inch SATA (7,200 Rpm); Graphics card – AMD Radeon R5 240, 1GB, full-height (DP and DVI-I).
3.6.2 Overview of main software functions: The GS-Vision-P software is used for viewing images, performing image analysis, and transmitting images to automated devices and DCS systems. Images are transmitted within the power plant network via real-time network servers. The basic functions are as follows:
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General functions: Software license management, user permission management, device configuration management, group management, log management, alarm status monitoring, device control operations, remote recording and playback.
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System settings:
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Burner flame detection and furnace tube leakage alarm monitoring; Alarm event settings.
IV. Typical configuration of the GS-Vision-P system:
| Serial No. | Device Name and Model | Unit | Quantity | Remarks |
|-------------|-----------------------|------|----------|---------|
| 1 | Explosion-proof high-temperature integrated camera | Unit | 1 | |
| 2 | Automatic retraction protection device | Unit | 1 | |
| 3 | Furnace wall mounting kit | Set | 1 | |
| 4 | On-site equipment box | Unit | 1 | |
| 5 | Gas circuit control box | Unit | 1 | |
| 6 | Air filtration system | Set | 1 | |
| 7 | Image analysis server | Unit | 1 | GS-SERVERFD-V1.5 |
| 8 | LCD monitor | Unit | 1 | 22-inch DELL model; additional display screens can be added |
| 9 | Input/output module | Unit | 1 | GS-IO/DO0808 |
| 10 | Single-mode four-core armored optical cable | Meter | 1 | GYXTW-4B |
| 11 | Cable | Meter | 1 | RVV2*1.5 meters |