Monitoring High-Temperature Processes and Linings
Infrared Thermography (IRT) provides a non-intrusive means to monitor industrial refractory systems and high-temperature processes in real time. Refractory linings protect process vessels and furnaces from heat damage, but degradation leads to energy loss, shell overheating, or catastrophic failure.
Using specialized thermal cameras calibrated for high-temperature environments, BQCIS thermographers capture external shell temperatures and detect local hot spots that indicate refractory thinning or cracking. The same technology helps visualize uneven heating, gas flow imbalance, or heat loss zones that reduce process efficiency.
Routine IRT surveys form a vital part of predictive maintenance, enabling early detection of refractory damage, minimizing production disruptions, and extending equipment life while enhancing plant safety and energy efficiency.
Key IRT Process Monitoring Activities
Key Benefits of IRT for Process & Refractory
Prevent Catastrophic Failure
Detect refractory wear or shell hotspots early to avoid burn-through incidents and unscheduled shutdowns.
Optimize Maintenance Planning
Pinpoint exact areas requiring repair or relining, reducing downtime and maximizing maintenance efficiency.
Reduce Energy Loss
Identifies insulation defects causing excess heat emission, helping conserve fuel and improve process efficiency.
Improve Process Control
Provides real-time thermal insights for adjusting furnace balance, combustion uniformity, and product quality consistency.
Success Story
IRT Survey Identifies Failing Furnace Refractory
A petrochemical plant required integrity confirmation for furnace refractory during continuous production without halting operations.
BQCIS conducted a full IRT survey during operation. Thermal imagery showed a sharply elevated zone exceeding threshold limits along the mid-shell region.
The hot spot indicated refractory collapse behind the wall brick. Controlled shutdown confirmed the defect. Early detection prevented shell damage and hazardous failure, saving the plant millions in repair costs.