Case Study: MG5 Laser Thickness Gauge - Pickling Line Installation

A leading steel producer sought an inline thickness measurement solution for their pickling line to ensure precise quality control and optimal production efficiency. Steels coils that have undergone acid-treatment during the pickling process require continuous monitoring and accurate measurement of thickness. This case study details how the MG5 Laser Thickness Gauge was customized to meet the challenges of a highly corrosive pickling environment, providing real-time thickness data, improved process control, and seamless data integration.

The pickling line environment presents several challenges for conventional measurement systems:

• Corrosive Conditions: The use of hydrochloric acid (HCl) in the pickling process can cause rapid degradation of standard equipment.
• High Measurement Accuracy Requirements: The customer stated a need to measure center-line thickness with an accuracy of +/- 0.7% or better of the nominal thickness.
• Accommodating Large Coil Sizes: The gauge had to measure coils up to 86 inches wide with a 55-inch measuring stroke requirement in order to reach the centerline.
• Seamless Integration: The system needed to fit into the existing infrastructure without disrupting production flow.

To meet these requirements, we used the MG5 Laser Thickness Gauge with specific enhancements for the pickling line:

Robust Construction and Enhanced Corrosion Resistance

• Powder-Coated Stainless Steel Frame:
• • Combines the natural corrosion resistance of stainless steel with an additional powder coating for enhanced durability.
  • Provides an extra layer of protection against aggressive acid attacks.
• Sealed Sensor Housing:
• • The laser sensors are housed in sealed, powder-coated stainless steel enclosures.
  • Prevents exposure to corrosive HCl vapors, ensuring long-lasting sensor performance.

Air Purge System for Control Hardware Protection

• The system includes an air purge mechanism that:
• • Supplies clean, cool air to the control enclosure.
  • Prevents the buildup of corrosive gasses and vapors around the control hardware.
  • Maintains the reliability and longevity of electronic components.

Real-Time Monitoring and Reporting Features

• Continuous Data Display:
• • Displays key process indicators including center-line thickness, thickness run charts, and coil reports.
• Automated Data Integration:
• • Publishes results automatically to the customer’s network for easy storage and access to historical data.
• Enhanced Operator Control:
• • Provides real-time visualizations to enable better decision-making and process optimization.

1. Improved Durability and Reduced Maintenance:
2. • The powder-coated stainless steel construction and sealed sensor housings ensure long-term reliability and reduce the need for frequent maintenance.
3. High Measurement Accuracy in a Harsh Environment:
4. • The dual-laser sensor system delivers accurate and reliable measurements, even in the presence of corrosive HCl vapors.
5. Streamlined Process Control:
6. • Real-time data display and automated reporting allow for better monitoring and control of the pickling process.
7. Seamless Integration:
8. • MG5 design fits into the existing infrastructure, minimizing installation time and disruption to operations. This aligns perfectly with our Turnkey Solution for pickling lines, ensuring a smooth, hassle-free implementation process for optimal performance and efficiency.

At Mate Gauge, we don't just sell products - we offer solutions that grow with your business. No complicated terms or empty promises - just robust, reliable technology designed to withstand the toughest environments and deliver the precise measurements you need. 

Mate Gauge will be with you to measure your progress.