Integrated Temperature, Oxygen and Pressure Systems – Fykays' TOPS

Totally automates monitoring and control of Furnace temperature, excess oxygen in the flue gas and furnace pressure to achieve dramatic reduction of fuel consumption and losses due to scaling and also prevents surface decarburization

TOPS from Fykays, is a System developed to monitor and control Temperature, Oxygen and Pressure in re-heating furnaces for dramatic reduction in fuel consumption and losses caused by scaling. Fykays TOPS can reduce fuel consumption by as much as 10 litres per ton and scale loss by as much as 1%. (These are approximate figures. Actual achievement will vary depending upon size, conditions prevailing at the site, processes being adopted, etc.)

TOPS is a system that FULLY AUTOMATES monitoring and control of Furnace temperature, excess oxygen in the flue gas and furnace pressure to realize hitherto considered impossible achievements.

1. Temperature monitoring and control is the primary loop, sensing soaking zone temperature and regulating the air and fuel control valves by means of a PID controller, which can be either pneumatically or electrically actuated. The air : fuel ratio is built into the controller software. One of the noteworthy features of the temperature loop is the special facility provided for manual intervention – on occurrence of a mill breakdown, the furnace temperature can be turned down to pre-determined levels simply at the click of a button.
2. The second loop - Oxygen measurement and control: This is done by a highly sensitive probe positioned at the furnace exhaust. The signal from the probe is fed to a precise oxygen controller. This in turn injects a trim signal to vary the air : fuel ratio built into the temperature control loop.
3. The third loop – Pressure control is an independent loop and is achieved by precise furnace pressure sensing and the controller actuating the furnace damper so as to maintain the desired furnace pressure. Here again the actuation can be either electrical or pneumatic.

1. Savings - This is something that cannot be overstated. A one-time investment will ensure savings year after year to the tune of crores of rupees. Depending on the size of the furnace and the tonnage of steel rolled, it can be appreciated that the pay back period can be as low as a few weeks to a maximum of a couple months EVEN IF THE COMPOSITE PACKAGE IS installed at one go.
2. Dramatically reduced surface de-carburization, thereby enabling you to assure the quality of your products.
3. Virtually no maintenance: Our instruments are developed with a view to keeping maintenance costs down. No special maintenance of the system is required, beyond the routine, preventive maintenance recommended by us. Buy it, commission it, forget it! In the unlikely eventuality of a major problem, we have a team of qualified service engineers who can visit your site at short notice and provide effective solutions.