Technical informationIR++

Comprehensive furnace monitoring
WIKA data sheet IN 00.55

Infrared scanning + in-depth analysis +custom advisory = enhanced performance
Furnaces and heaters are the heart of a refinery,and sub-optimal operation leads to loss of time andmoney. WIKA USA is a trusted partner for the oil andgas industry, offering not only high-quality measuring
instruments, but also an array of services that optimize
furnace performance.
WIKA USA has long been an industry leader for temperature
measurement solutions in the oil and gas industry, becoming
a trusted business partner for refining operations aroundthe world. Our experts, who often conduct onsite visits anddiscuss equipment monitoring requirements, have noticed
that certain issues prevented critical furnaces from reaching
peak performance.
This led to the development of IR++, a thorough assessment,
diagnostic, and advisory service that finds opportunities for:
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Optimal placement of tubeskin thermocouples (TSTC)
Enhanced throughput
Extended run lengths
Preventing unscheduled shutdowns
Improving turnaround planning
Averting tube failures

With our expertise in designing temperature instruments
and in IR scanning, WIKA offers the industry’s mostcomprehensive solutions for monitoring and improving
furnace performance.
IR++ begins with infrared diagnostics of yourfired heaters
The mission of IR++ is to help equipment operate as close
as possible to target conditions. The first step is to collectdata on a furnace’s current state and its operating history.
This is accomplished through field data, infrared scans of
furnace walls and tubes, historical operating data, and other
input from the site (information on operations, production,and inspections). This initial assessment detects hotspots,
heat flux imbalances, tramp air ingress, issues with hardware(burner, tubes, etc.), and then identifies issues of concern
and areas for improvement.

WIKA data sheet IN 00.55 · 06/2022

IR scanning is a powerful tool for understanding the spatial
temperature distribution and relative temperature difference
between various zones in fired equipment. Equally important,however, is data analysis. We use proprietary softwareand robust methodology to accurately predict tubeskintemperatures and to recommended placement. Thismethodology comes from the know-how we have gained
through extensive testing in the heater at the WIKA R&D
Center in Houston, and validated using industry standard
references for accurate tubeskin temperature measurement.

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IR++ helps tell the whole story
Coking and fouling layers build up inside a furnace tube
over time, resulting in hotspots, localized overheating, andaccelerated coke formation. Existing tubeskin temperatures(TST) while in operation provide guidance to the operator
on specific locations for maintaining temperatures within its
integrity limits. However, these temperature sensors do notalways capture the critical zones.

1100 °F

How WIKA USA supports customers withcomprehensive furnace monitoring
IR++ comes in three different tiers to fit your refinery’s needs.
Choose from the following options:1.

Basic Package: IR scanning + one-time equipment
health check2.

Annual Service Plan: sequenced IR scanning +analysis and monitoring of critical furnaces

3.

Advanced Analysis & Troubleshooting: IR
scanning + diagnostics and problem-solving of
fired heaters

IR++ comes with the following key deliverables:

1020 °F
In the above image, the upper two-thirds of the middle
furnace tube (circled) shows extensive coking. We know
this because the IR scan reveals the coke signatures, andthe temperature is around 1100°F. Meanwhile, the TSTC,
installed lower on the tube, registers 80°F lower.
To resolve this issue of extensive coking, WIKA’s temperatureexperts might suggest remedial actions, such as cleaning afouled burner, tuning the burners, and/or adjusting the flow
through the tube. Depending on the furnace’s operating
history, another recommendation might be a more optimal
placement of the existing thermocouples.

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Field assessment of key furnaces using advanced
diagnostic tools•

Reviewing preliminary findings with operations,inspections, and technical personnel•A full furnace performance report withrecommendations (optional: guidance on the optimal
number and locations of thermocouple sensors)•

Supporting the customer’s site personnel as they
implement the suggested improvements

In addition to these IR scan packages, WIKA USA offers
thermocouple validation and repairs. Our state-of-theart R&D facility has a full-size test furnace to accurately
characterize the behavior of tube metal temperature (TMT)
sensors, bridge-wall thermocouples, velocity thermocouples,and other temperature measurement devices.

The bottom line: If it weren’t for comprehensive furnacemonitoring, this furnace tube’s coking issue would never
have been detected.

WIKA USA leads the market in furnace temperature measurement, and the IR++ service provides a complete andaccurate profile of equipment conditions. The analyzed data, along with observations and recommendations fromour experts, can help customers make informed decisions that improve furnace performance, meet production
targets, and ensure safe operations. Make WIKA USA part of your refinery business.
WIKA data sheet IN 00.55 · 06/2022

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WIKA USA
1000 Wiegand Boulevard
Lawrenceville, GA 30043-5868
Tel: 888-WIKA-USA • 770-513-8200
Fax: 678-739-2569
E-Mail: info@wika.com
www.wika.us