By: TIM HILL, Group Leader, Strategic Asset Management
INSIDE INDUSTRY Quest Integrity Group
IR inspection program for fired heater
mechanical integrity
I nfrared (IR) thermometry has been
used for 40 years to monitor tube
metal temperatures in refining and chem-
program allows the mechanical integrity
of fired heaters to be managed.
Today, IR thermometry is primarily
gas effect on the measured temperature.
The instrument factors affecting the tem-
perature measurement are the instrument
temperatures, corrections must be made
to the instrument readings based on the
geometry of the furnace, the emissivity
ical furnaces. The application of IR ther- accomplished with two instrument types: infrared wavelength, calibration, size of of the tube material, atmospheric effects
mometry has often been characterized as thermal imaging cameras and pyrometers. source effect and the emissivity setting. and knowledge of the operating charac-
highly operator dependent and therefore The thermal imaging camera forms a two- Each of these factors must be understood teristics of the instrument, all of which
developed a very poor reputation in the dimensional thermal image of the target and accounted for in an effective infrared are performed by the software.
industry from poorly applied and inter- surface, while the pyrometer provides inspection program, otherwise measure- An effective infrared inspection pro-
preted results. There is no question that only a single target point temperature. ment errors as much as 180 F can occur, gram is an absolute necessity to monitor
when absolute accuracy is unimportant, Each instrument has its advantages and which also affects the repeatability of the the integrity of the fired heater tubes, as
IR thermometry is an excellent diag- disadvantages, and effective programs measurements. well as provide a wealth of diagnostic
nostic tool for detecting tube hot spots should include using both. The imaging An effective infrared inspection pro- information that may be used to evaluate
from internal fouling and heat distribu- camera provides meaningful images and gram for fired heaters accounts for these the performance and reliability of major
tion non-uniformity in fired heaters. measurements for a historical record that measurement factors. Software is avail- fired heater parts (e.g., tubes, tube sup-
However, to capture the full capability can be used to assess tube creep damage able that automates the rigorous correc- ports, burners, refractory and structural
of IR thermometry, a proven methodol- rates and long-term performance chang- tion calculations based on simple field systems). By fully understanding the IR
ogy is required to measure accurate tem- es. The pyrometer should be used for data collections. This allows any opera- measurement factors and employing field
peratures in a repeatable process. accurate field measurements to compare tor using either IR instrument to col- collection practices and IR temperature
IR thermometry is the nondestruc- specific tubes and troubleshoot real-time lect repeatable tube metal temperature correction software, accurate and repeat-
tive, nonintrusive, noncontact mapping performance issues. measurements. The correction software ability infrared temperature measure-
of thermal patterns on the surface of All infrared measurements, whether employs algorithms based on well-estab- ments are achievable.
objects (e.g., tubes). For fired heaters, made by an imaging camera or pyrometer, lished physical principles of blackbody For more information, visit www.
understanding the tube metal tempera- are subject to measurement factors which infrared radiation and radiation exchange, QuestIntegrity.com or call (303)
ture defines the performance capability affect the accuracy and repeatability of including a specific geometrical model of 415-1475. •
and inherent reliability of the fired heater the measurement. The fired heater’s envi- the subject fired heater and characteristics
Reference: “Radiation Thermometry:
and ultimately the risk of a tube rupture ronmental factors are the target tube’s of the measurement instruments. In order Fundamentals and Applications in the
failure. An effective infrared inspection emissivity, target reflectance and the flue to determine the true (or actual) tube Petrochemical Industry” by Dr. Peter Saunders.
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70 April 2013 Read BIC Magazine online at www.bicalliance.com
