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Texaco's Use of Infrared On Fired Process Heaters
Texaco's Use of Infrared On Fired Process Heaters
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389.5°C 404.8°C
Heater Tube
Refractory
Scaling
Figure 1. Sample survey thermograms with heater tubes, refractory and scaling identified
The IR camera was also used to predict if there was excessive tube fouling on the heater tube, external or internal, that would
effect the safe operation of the heater. Daily IR surveys were scheduled to allow the fired heater to continue to safely operate
until the outage could be planned. Since this heater used fuel oil and fuel gas as its heat source, there is always some scaling
on the tubes. Depending on the properties of the fuel being used and whether it is fuel gas or fuel oil, the properties and
appearance of the scale changes. What is not known is what the actual L of this scale is. There were observed differences
in the scaling. The scaling appearance varied in different areas on the heater tubes. After an analysis of some of the scaling,
it was discovered that we have some scale had burned onto the tube surface. These differences in properties gave high
confidence that the L and reflectivity properties would also be different. In fact, during the infrared inspection, you could
see variations in the tube temperature as the flame moved up and dawn. Much care was taken to visibly identify where the
scale was and what its physical appearance was. The white scaling generally showed up as a hotter area. It was known not
to be hotter than the bare metal areas. Care was taken not to mistake a hotter bare metal area for a scaled area. Another
consideration that had to be watched for was possible internal coking. An area of a tube that is coked-up has poor heat
transfer and will indicate a hotter area. These coke-up areas are also more susceptible to external fouling. So a hotter scaled
area could also be a coked area. The maximum acceptable tube temperature readings were kept very conservative during this
mode of operation.
An impingement problem was also detected during this period. It was confirmed by comparing the various refractory
temperatures around the heater. The IR readings detected that there was poor bad heat distribution on the tubes. This
situation was confirmed by reviewing the physical and operating conditions of the fuel burners.
4. CONCLUSION
The result of REFPAN’s successful infrared predictive and preventive maintenance program was evident during the
described thermocouple incident. Effective use of the Thermography allowed for continued operation of the process unit
while plans were finalized for the thermocouple repairs. The infrared tool detected the thermocouple inaccuracies, predicted
the flame impingement and prevented a heater tube failure. Infrared gave operations the ability to maintain heater
mechanical integrity during operation of the plant while repairs were planned and replacement materials acquired. It also
allowed other needed work in that unit to be planned and scheduled during this same outage.
It has been proven at several Texaco refineries that unscheduled maintenance work cost at least ten times more than
scheduled maintenance work and takes at least 25% longer than scheduled work. Infrared allowed REFPAN and Texaco to
get save the time and dollars difference between reactionary maintenance work and planned work. Added to this are the
prevention of a heater tube failure and the high cost of the downtime to replace it.
The weaknesses of Thermography in fired heater application became very apparent. This increased the awareness of
management and operation technicians that good communication was an absolute necessity in making good, concise, and
safe decisions. The important of training in the infrared technology also became very apparent to plant management.
The final lesson learned was how important it was to have good work-process procedures and a work culture that knew what
tools to use, when to use them and when to get assistance from others. In Texaco, our business unit’s pride themselves on
being very competent in what they do and how they do it. They are always moving to be more self-sufficient in their
abilities. But there is always a point where the expertise of others may be needed to make the best decisions. REFPAN has
shown this maturity in their infrared work process.
Thermography is an excellent tool to optimize the operation of a fired process heater. It will increase operability,
availability, and fuel usage economics. There are limitations in using the camera on a fired heater. The inability to know the
actual emissivity of the tube surfaces is the primary limitation. The IR analyst must be conservative and understand the
limitations of the infrared technology.
5. ACKNOWLEDGEMENTS:
Texaco Panama Refinery support staff
Texaco IR Users group
6. REFERENCES:
Infraspection Institute Level I Training Materials
ITC Level II Training Materials
Snell Inc Level III Training Materials
Fundamentals of Heat Transfer, 4th Edition, Incropera and DeWitt
Convent Refinery (Star Enterprise) Infrared Survey Procedure
Texaco Infrared Guideline Procedure