Temperature Sensors Temperature Sensors

W
hen it comes to the
industrial furnaces,
heaters and boilers
used in the chemical,
petrochemical and utility industries, the
actual operational designs are as varied
as the many applications. Some plants
have only two or three heaters while
larger plants may have more than 50.
Some heaters simply deliver the feed at
a predetermined temperature to the next
stage of the reaction process while oth-
ers perform reactions on the feed while
it travels through the tubes.
Whatever the application, accurate,
cost-effective inspection of these pro-
cess heaters, furnaces or fired heaters in
action presents unique challenges. Ever
more, industrial predictive maintenance
(PdM) programs and external inspec-
tion companies turn to thermal cameras
fitted with a spectral waveband filter
designed specif ically to see through
f lame, at temperatures from -40 to
1500F (-40 to 816C) and more.
Infrared Locates Coking,
Provides Temperature
Validation
Tube metal temperatures are particular-
ly critical to distillation furnace opera-
tions. When operating a furnace close
to the maximum allowable tube metal
temperature, changes of less than 200F
(111C) can dramatically reduce tube
life on tubes rated for 100,000 hours to
only a few hundred hours.
In distillation furnaces, a primary ser-
vice consideration is the determination of
carbon scale buildup, or coke formation.
Areas with coke buildup preclude the
product from uniformly absorbing the
tubes heat and can result in higher fur-
nace firing rates. In some cases, overfir-
ing can cause temperatures that exceed
the tube metal design criteria, and this,
coupled with pressure inside a plugged
tube, may cause a rupture and leak.
Unfortunately, viewing buildup on
the inside of a tube (coking) from a set
number of access ports can only supply
a limited amount of information that is
somewhat compromised by an oblique
viewing angle. A through-f lame ther-
mal camera, however, fitted with an
Through-Flame
Thermal Cameras
Can Take the Heat
Does your process heating operation need a fast, noncontact, nondestructive way to
gather both qualitative and quantitative information to prevent or minimize downtime? Of
course it does, and that is why you should consider a through-flame thermal camera.
By Paul Czerepuszko,
FLIR Systems, Inc.
Thermal imaging combined with visual images allows you to see conditions
invisible to the naked eye yet place them in context in a visible world. A visual
image of a ruptured tube (left); a visual image of tube through a viewing port
(middle); and a hydrogen fire from a leaking tube that cannot be seen visually,
causing impingement overheating on adjacent tubes (right) provides insights
into the process equipment. The thermal image was taken with a long-wave
thermal camera so the flame would be obvious.
As seen in Process Heating Magazine
Reprinted with permission from the October 2013 issue of Process Heating magazine
Temperature Sensors
extender, at that same port, can provide
an improved angle of vision that safely
allows for a far more comprehensive
scan. Thermal data and imagery can
clearly reveal areas of coking, usually
due to excessive temperatures, as well as
locations where there are tube restric-
tions or outright plugging.
An expert examination of furnaces
with a through-f lame thermal camera
can reveal whether refractory is dam-
aged, if f lames have the right shape
and even dust deposits on the tubes,
which cause poor heat transfer and
typically lower the product tempera-
ture. Unlit burners are revealed as are
burners causing f lame impingement on
the tubes. Oxidation development also
shows up on the thermal image valu-
able knowledge as this area will eventu-
ally become a weak spot.
Infrared cameras also can provide
insight into process equipment by
validating traditional temperature-
measurement devices. In furnaces,
thermocouples are installed at sev-
eral points to provide accurate tube
temperature readings. However, when
coking occurs around a thermocouple,
the sensor is liable to detach or pro-
vide inaccurate data. An infrared scan
can quickly validate the accuracy of
a furnace tube temperature reading
provided by a thermocouple. With
thermal imaging cameras to validate
the thermocouple readings, ref ineries
can safely increase production with-
out safety concerns.
The data provided by thermocouples
is limited, however. Typically, only one
to three thermocouples per pass are
installed that supply data for a specific
point on the tube.
Thermal imaging cameras allow tem-
peratures to be read from every pixel
in the radiometric thermal image or
video taken during internal and external
furnace and maintenance inspections.
Coking can be detected over the extent
of the tube with suitable high-tempera-
ture infrared equipment because areas
with coke buildup show up as warmer
than other areas of the tube surface.
Potentially catastrophic problems that
could be easily missed when relying
solely on thermocouple data or visual
inspection are caught in the early stag-
es, preventing unscheduled shutdowns
and creating safer working conditions.
With the implementation of an ongoing
infrared inspection program, compara-
tive and trending analysis is possible,
permitting changes in firing conditions
so that run times can be extended. As
an added benefit, the cameras can do
double duty in thermal inspections of
mechanical or electrical components.
How Through-Flame
Imaging Works
Designed specif ically to monitor all
types of furnaces, the f lame filter on
cooled mid-wave thermal cameras
allows only thermal radiation with cer-
tain wavelength 3.8 to 4.05 m to
pass through to the detector. Flames
emit much more thermal radiation at
some wavelengths than others, and at
certain points in the spectrum. A f lame
emits hardly any thermal radiation at
all. Because everything but that spe-
cific range of the spectrum is filtered
out, the thermal imaging camera can
see through the f lame and make tem-
Through-flame thermal imaging cameras can detect many equipment problems during operation.
Temperature Sensors
perature measurements even through
exceptionally hot f lames.
Thermodynamically and hydrauli-
cally complex, process heaters incor-
porate turbulent convective gas f low in
addition to radiant heat from the f lame,
refractory and other tubes, with tem-
peratures f luctuating widely over time.
The highly sensitive cooled detectors
(NETD of less than 15 mK) utilized in
through-f lame cameras permit these
heat transfer patterns to be visualized
even minute temperature differences.
The real-time thermal video and still
image captures produced by these com-
pact, handheld infrared cameras can
reveal dangerous buildup on both the
interior (coking) and exterior (slag) of
furnace and boiler components that oth-
erwise would be obscured by f lame, com-
bustion gases and dust. Images, generally
320 x 240 pixels in resolution, are viewed
through a high-resolution viewfinder and
on a color LCD display. Both radiometric
and nonradiometric infrared video can be
recorded directly to an internal memory
card along with visual digital camera
video and images. The traditional visual
images then can be associated with the
matching infrared footage. The stored
data can be transferred to a computer
via several output options and undergo
further processing in proprietary infrared
software programs to yield the most com-
plete picture of heat-related conditions
in the plant. Detachable heat-shields can
be added to ref lect heat away from the
camera and camera operator, providing
increased protection.
3 Action Items for Reliable
Through-Flame Imaging
Now that you understand how through-
f lame imaging can help optimize plant
and process equipment operation, a
review of the profiling process will help
you begin to plan your predictive main-
tenance plan.
1. Gather All the Necessary
Information
Before beginning any furnace inspection,
it is important to acquire as much pro-
cess information as possible, including:
Infrared energy is longer than visual light. For the purposes of furnace
inspection, there are two useable bands: mid-wave infrared and long-wave
infrared.
A quality, high-resolution camera with the proper flame filter will yield images
with the clarity to distinguish scale from coking. The visual image (left) shows
patchy external scale, not coking. The thermal image reveals that burner is
lit, but no flame is evident (middle). The thermal image reveals that several
burners are out (right).
A special notch filter narrows the spectral response of the detector so that it
nearly matches the peak transmission of the gas flame spectra, allowing the
user to see through flame.
Infrared Transmission Spectra Gas Flame
Temperature Sensors
Type of service (coking or fouling).
Type of fuel (natural gas or
refinery fuel).
Location of the heater unit in
the run.
Inlet and outlet temperatures and
pressures.
Whether the unit is prone to fouling.
Obtaining information on the target
to be imaged also is imperative. What is
its material composition? Tubing mate-
rial may vary from section to section,
and the acceptable temperature of coked
areas may vary accordingly. Ignorance of
that fact could result in a call for emer-
gency service when, in fact, the decoking
could have been performed in the regular
reduced production window.
2. Perform Baseline Scans
and Implement Continuous
Inspection Program
Thermal anomalies on furnace tubes
can be a function of actual hot tubes,
surface conditions such as scale and
oxidation, or a combination of several
factors. The thermographer must be
able to accurately evaluate the thermal
profile data and make a determination
on what is valid tube-metal tempera-
ture data and what should be avoided.
A series of infrared scans over time can
help determine whether an anomalous
surface temperature is the result of
scaling or is actual coking on the tube
interior. Remember that consistency in
procedures always will facilitate com-
parative analysis and result in a better
understanding of the furnace.
Coked areas change in appearance
over time, usually increasing in tempera-
ture and size. If coke formation is sus-
pected in a furnace, it is much easier to
make a positive determination if previous
baseline data exists. A regular infrared
inspection program allows the extent of
the problem to be determined and pre-
emptive changes firing configuration
changes or charge-rate reductions, for
example to be made to mitigate the
issue. If decoking is necessary, post-infra-
red inspection can document effective-
ness. And if the decoking is a steam/air
process, infrared can be used to monitor
and control the actual procedure.
3. Understand Input Parameters,
Particularly Emissivity
Determining the actual tube-metal
temperature in some furnaces can be
extremely difficult. Be certain that the
area being measured is a valid target
that is, tube metal and not scale or
other surface anomaly and know the
emissivity of that target. Be certain of
background temperature based on field
measurement or furnace data. Correct
for interference from furnace atmo-
sphere. In very adverse atmospheres,
this is valid for a relatively limited area
and is based on a snapshot in time. If
possible, include a known valid ther-
mocouple or external reference ther-
mocouple in the image. Take multiple
images of the subject area and attempt
to minimize the interference. Minimize
the temperature span to determine the
extent of the f lame interference. This
will be a factor of fuel type (natural gas
vs. refinery gas), burner type, firing rate,
draft, and infrared camera and filter.
To calculate temperatures correctly,
you need to know the emissivity of
both the material under regard and
the background. The emissivity of the
tube surface can be difficult to deter-
mine and typically is derived from two
sources correlated to thermocouple
measurements. To achieve the highest
degree of accuracy, some companies
have designed probes fitted with ther-
mocouples known to be accurate that
can be positioned in the furnace next to
the tube under regard.
In conclusion, furnace and boiler
equipment is prone to failure cok-
ing that plugs the inside of tubes and
impedes product f low, slag buildup
on the outside of tubes, clinker dam-
age, under- and overheating, f lame
impingement on tubes due to burner
misalignment, and product leaks that
ignite and cause serious damage to the
equipment. These failures cause more
than quality problems: They also can
shut down an entire process line.
Through-f lame thermal imag-
ing cameras can detect most of these
equipment problems during operation
and at an early stage so failures can
be prevented. This allows an orderly
shutdown and component replacement,
thereby reducing maintenance costs
and production losses.
*
Paul Czerepuszko is a director of busi-
ness development at FLIR Systems,
Inc., a supplier of infrared technology
for industrial applications. For more
information, call 603-324- 7778 or
visit www.flir.com.
The thermal image reveals that thermocouples may not be telling the
whole story (left). In another application, thermal overview reveals areas of
overheating (middle); the infrared image shows that one pass is much hotter
than the other (right).