Wonder Engineering

Furnace Tube Skin Temperature

Proper tube skin thermocouple installation is paramount in ensuring the success of an application. There is no universal tube skin thermocouple design that may fit all furnaces.
Wonder® tube skin thermocouple installation is a result of paying careful attention to design details: 
• Measurement locations
• Sheath routings
• Expansion loops
• Process connections
• Metallurgy & Corrosion
• Heat Expansion
With our extensive site experience in South East Asia and China, we provide a one-stop full design, supply and installation of the tube skin thermocouple solutions. Contact Wonder® Engineering Technologies  today and we will show you how it's done!

Reactor Multipoint Thermocouple Assembly

With today’s high activity catalyst and high-performance distribution tray technologies, upgrading reactor thermometry is critical to a refinery ability to maximize profitability and safety of the operating unit.  To stay competitive in today's market conditions, getting the most out of existing reactors and maximizing asset utilization is a top priority.

Optimal operating conditions vary from process to process and even within processes depending upon variables such as the types of catalysts and internals selected.  More than ever, ideal reactor performance is achieved within specific temperature ranges. Accurate and Reliable Temperature measurement (Reactor Multipoint) is the most critical factor to ensure profitable operation.

Based on Wonder®'s extensive experience in the reactor multipoint thermocouple technologies, we recommend the use of repair-free multipoint thermocouple assembly from the very beginning.

Reformer Heaters Thermal Imaging System

Reformer and Cracker furnaces are critical equipments in petrochemical & refining processes. Maximizing production efficiencies, while minimizing system downtime and eliminating safety issues, are primary concerns for any plant operator.

Furnaces are operated to the highest efficiency by optimizing the burners firing and maintaining furnace tubes at ideal temperatures to prolong the life of the heater tubes. The objective is to minimize variations in Tube Wall Temperatures (TWT) and operate at a higher Outlet Temperature (ROT) without violating maximum allowable TWT.

Conventional methods of monitoring the tubeskin temperatures include portable pyrometers, portable thermal imagers, and shielded thermocouples. However, these methods have been proven to be unreliable, expensive to implement, prone to operator variations, and do not provide comprehensive ability to detect hot spots.

Wonder® Engineering has introduced FurnaceSpection to tremendously improve the ability to monitor the tubeskin temperatures. It helps operators monitor process temperatures uniformity through streaming images and employing powerful software to enable data analysis and historical trending, bringing outputs to DCS, and even able to broadcast live images on the plant’s local network with a real-time web server.

Our Solution:

1. Direct measurements
2. Continuous monitoring tubeskin temperatures in the furnaces
3. Precise measurements of the temperature distribution on every components
4. High camera resolution of 640 by 480 pixels
5. Real-time analysis and display of temperature data (e.g. HotSpots, Isotherms).
6. Graphic thermal data used to calculate real-time TWT on DCS
7. Automated alarm modes for user-defined limits. 

Flare Monitoring

Continuous monitoring of pilot flames and flared gases is critical to ensure that the gases will be ignited and to confirm compliance with government-set pilot status recording requirements.  

Thermocouple failure, flame movement, varying luminosity and adverse climatic conditions are just a few of the obstacles which have to be overcome to gain long-term monitoring reliability without false alarms.

FlareSpection thermal imaging system designed to provide the clearest image monitoring of flare tips, which provides clear images of the flare tip for pilot monitoring of multiple pilots and flare tips with a single camera system.  Regional points of interest can be manually input by the operator and alarms assigned and linked to relays. 

The system can be deployed into either a full thermal imaging system or a single unit of flare detector with a 4mA & 20mA input. It is a remote installation can be easily maintained online.
 

Gasification Units [Gasifier]

Critical vessels in refineries operate at high temperature and pressure and are at risk of failure as joints and refractory degrade. The consequences of undetected failures can be very serious. Conventional methods like vessel skin thermocouple or Fibre Optic sensors are typically utilize wired or fibre optic networks and employ point sensors which only monitor the temperature of discrete points on the outside of a vessel. This can result in inaccurate
measurements due to skin temperature gradients.

Sulphur Recovery Units [SRU]

Optimal operation of Sulphur Recovery Unit (SRU) furnaces require accurate process Gas (Flame) measurement and Refractory measurement for operational safety (high temperature alarms). Of particular importance is control of the furnace process temperatures to prevent damage to the furnace refractory and assurance that reaction or destruction temperatures are reached and maintained.

There are essentially two types of devices suitable for monitoring the temperature of Claus Thermal Reactor refractory:
• Ceramic Thermocouple
• Infrared Radiation Pyrometer

A combination of Infrared Pyrometer E2T and 6” HTX thermocouple is a proven solution forSRU temperature monitoring. Wonder® Engineering exclusively supply all 6” thermocouples and Pyrometers for all SRU vessels in our region, our installed-base including ExxonMobil, Shell, Chevron, Petronas, ThaiOil, Bangchak Refinery Thailand, Singapore Refining Company [SRC] etc. 

Wonder Engineering Technologies Pte Ltd

10 Bukit Batok Crescent #04-05, Singapore 658079

T: +65 6686 0181 +65 6635 6759

E: support@wonder.com.sg

www.wonder.com.sg

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