High Density Critical Vessel Monitoring System for Earlier Detection of Refractory Wear

A new monitoring system for critical vessels uses thermal imaging cameras to provide higher measurement density than traditional systems based on thermocouples. The Critical Vessel Monitoring System from Land Instruments International (USA), a unit of AMETEK measures surface temperature once every 16 cm2, as compared with one measurement every 250 cm2 in typical thermocouple systems.

By measuring temperatures in more locations, the system allows for earlier detection of refractory wear or breakdown. Benefits include greater protection against catastrophic vessel failure and extension of refractory lifetime based on actual data.

The system is optimised for use in gasifiers and other critical vessels in petrochemical refining, power generation, chemical and coal processing, waste management, and fertiliser and plastics production.

Industrial cameras suitable for harsh environments are placed to view all parts of the vessel including the critical cone and dome sections. Each camera records over 110,000 individual measurements, ensuring that even the smallest degradation can be detected.

Measurements from all cameras are reported using graphical software that signals an alarm if a potential breakout is detected. The software also compiles temperature trends to support statistical analysis of refractory wear. An integrated web interface allows visualisation of current vessel conditions from all plant locations.

The system supports operating efficiency by allowing installation and maintenance to be performed without shutting down the process.