SoW: Computer Vision based Blast Furnace Tuyere

Monitoring

Introduction:
This Statement of Work (SoW) defines the project framework for implementing a computer vision
system for blast furnace tuyere monitoring. This innovative system aims to enhance operational
efficiency and safety by enabling real-time anomaly detection within the tuyere.

The project will leverage strategically positioned cameras within peepholes to capture live video
feeds of the tuyere. By employing advanced computer vision algorithms, the system will analyze
these video streams to identify potential issues at an early stage, allowing for prompt intervention
and minimizing production downtime.

Objectives:
• Real-time monitoring: Continuously monitor the tuyere and raceway for any
abnormalities or deviations from normal operation.
• Early detection of anomalies: Identify potential issues such as:
o Tuyere sticking
o Lance Off centring
o Lance Chocking

Exiting Process As-Is:

o Monitoring Method: Manual observation by human operators
o Anomaly Detection: Relies on experience and may be prone to errors.
o Response Time: Delays in identifying issues based on inspection frequency.

System Functionality:
1. Image Acquisition:

• Install high-temperature resistant cameras at each tuyere, capable of withstanding

the harsh environment within the furnace.
• Implement a system for capturing and transmitting real-time images from the
cameras to a central processing unit (CPU). CPU should be on-premise. GPU
requirement, if any, will have to be handled from the vendor end.

2. Image Pre-processing:

o Develop algorithms to pre-process the captured images, including noise reduction,

contrast enhancement, and image segmentation to isolate relevant regions of interest
ROI within the image. (Image Annotation)

Sensitivity: Confidential (C2)

 o Model Training:
o Design and train deep learning models, likely based on CNNs, to analyze the
pre-processed images and identify various features and patterns.
o Train the models on a large dataset of labelled images representing different
operational conditions and anomalies within the blast furnace.

o Anomaly Detection and Classification:

o Implement algorithms to detect deviations from normal operation based on
the features and patterns identified by the trained models.
o Classify the detected anomalies into specific categories (e.g., Lance Off
centring, Lance Chocking ) for further analysis and decision-making.

3. Data Visualization and Reporting:

o Develop a UI to display real-time images from the tuyeres, along with any detected
anomalies and their corresponding classifications.
o Generate reports summarizing system findings, including timestamps, detected
anomalies, and relevant data for further analysis by furnace operators and
maintenance personnel.

4. Alert on Deviation:

o SMS & Mail alert on deviation.

o Alert in the dashboard/monitor.

5. Integration with LIMS & OSI Pi (if required during the project implementation)

Deliverables:
Fully functional computer vision-based tuyere monitoring system, including

o Hardware: Cameras-(QNTY -20) cabling, and Processing unit

o Software: Image acquisition, pre-processing, analysis, and visualization modules.
o User interface for system operation and data visualization.
o Source Code, Trained deep learning models for anomaly detection and classification.

Comprehensive documentation:

o System design specifications.

o User manuals for system operation and maintenance.
o Testing and validation reports.

ESL Scope:
o All the relevant VPN and Server access credentials will be provided from ESL end.
o ESL will bear the responsibility of ensuring cabling, network and power connectivity at vendor
proposed locations for successful hardware commissioning.

Sensitivity: Confidential (C2)

Exclusions:
o Integration with existing blast furnace control systems is not included.

Acceptance Criteria:
o The system should be able to detect and classify anomalies with a high degree of
accuracy (> 95%).
o The system should operate reliably in real-time with minimal latency.
o The user interface should be intuitive and easy to use for furnace operators.
o AD-ID integration in the software.

Payment terms and conditions:

• Payments will be done on successful completion of milestones, in alignment with the
Director – I&P, HOD BF and CDO.
• Milestones to be decided by ESL team in agreement with the vendor.
• AMC (if required) terms and conditions will be jointly prepared by vendor, BF SPOC
and Digital SPOC, after successful commissioning of the project and evaluating its
performance. Approval to be taken from Director – I&P, HOD BF and CDO.

Sensitivity: Confidential (C2)