{"id":18736,"date":"2025-07-02T12:57:11","date_gmt":"2025-07-02T17:57:11","guid":{"rendered":"https:\/\/blog.wika.com\/us\/?p=18736"},"modified":"2025-11-07T13:58:18","modified_gmt":"2025-11-07T18:58:18","slug":"accurate-tubeskin-sensor-for-coker-heaters","status":"publish","type":"post","link":"https:\/\/blog.wika.com\/us\/products\/temperature-products\/accurate-tubeskin-sensor-for-coker-heaters\/","title":{"rendered":"A More Accurate Tubeskin Sensor for Coker Heaters"},"content":{"rendered":"

An energy company\u2019s process furnaces were experiencing excessive coking, leading to wasted energy and frequent downtimes for tube cleaning. After installing WIKA\u2019s Tefracto-Pad\u00ae<\/sup> thermocouples, the energy company enjoyed longer run lengths between decoking cycles. <\/strong><\/p>\n

In oil refineries, furnaces play a critical role in several key processes, from the initial distillation of crude to the conversion of different fractions to produce cleaner, higher-quality fuels. The effectiveness of these processes depends on not only the quality and design of the furnaces, but also the quality and design of the temperature sensors in distillation columns and catalyst beds, at coil outlets, on furnace tubeskins, and other key locations.<\/p>\n

Importance of Temperature Measurement and Control<\/h2>\n

There are important reasons for precise temperature control in furnaces, which typically operate at extremely high temperatures to convert and refine the feedstock.<\/p>\n

Plant safety: <\/strong>With<\/span> high temperatures come safety risks. Accurate readings help refineries <\/span>prevent thermal runaway reactions<\/span><\/a> and ensure that the coils\u2019 temperatures are within safe metallurgical limits.<\/span><\/p>\n

Energy efficiency: <\/strong>When the temperature is too low, chemical reactions are slower or incomplete. But when the temperature is too high, one result is excess coking. Since the coke layer acts as insulation, operators then must increase the firing rate to maintain adequate process temperatures. Both scenarios waste energy. Thus, precise temperature control optimizes fuel consumption.<\/p>\n

Product quality: <\/strong>Temperature has a direct effect on the process media\u2019s physical and chemical characteristics. Keeping the temperature within a specific range minimizes unreacted feedstock and undesirable by-products.<\/p>\n

Asset lifecycle: <\/strong>Too-high temperatures reduce the lifespan of furnace tubes<\/a>, measuring instruments, and even the refinery unit itself.<\/p>\n

Regulatory compliance: <\/strong>Regulatory bodies set standards that specify temperature limits for the safe and efficient operation of industrial equipment, including fired heaters. Accurate temperature monitoring helps refineries avoid penalties and downtime.<\/p>\n

Problem: Excessive Coking Leading to Excessive Downtime<\/h2>\n

A multinational energy company based in western Europe was having problems with delayed coker heaters in several of its refineries. Coke was forming too quickly, resulting in short run lengths before having to pause operations to spall and pig the furnace tubes.<\/p>\n

Several factors determine the rate in which coke is formed and deposited. Low feedstock quality and uneven feedstock flow<\/a> are two reasons, but excessive temperature is also a major contributing factor. Accurate temperature sensors would mitigate the issue by allowing the control room to keep temperatures within the optimal range.<\/p>\n

The energy company was already familiar with WIKA products, having used them in the past. When our engineers learned that this customer was dissatisfied with its current tubeskin thermocouples\u2019 performance and design, they met with the company\u2019s representatives to fully understand the issue.<\/p>\n

Solution: A Comprehensive Package of Custom Sensors and Installation<\/h2>\n\n

TC59-T Tefracto-Pad\u00ae tubeskin thermocouple assembly<\/p><\/div>\n \n

After several more calls and meetings, WIKA recommended a complete solution:<\/p>\n