Evaluate the furnace liner using Infrared Thermography Inspection (IR)

Infrared Thermography scans are an essential step for evaluating the quality of the furnace lining. Lining quality is critical to protecting the steel from heat and also to limiting the heat loss and promoting overall furnace efficiency.

Use On-Line Maintenance Repair

Depending upon the temperature, the difficulty of getting to a particular area, or how big the hot spot is, conduct on-line repairs wherever possible. Most maintenance managers prefer the on-line repair option because it’s reliable, fast and economical.

Choose the right material for furnace rebuilds

When IR scans indicate that the area of concern is too large for on-line repairs, the unit must be shutdown for furnace reline or process heater reline. Material selection is key to a successful furnace rebuild that will improve efficiency and reliability and lower maintenance costs. Material properties, including hardness, density, mechanical resistance, or insulating factor may vary depending upon the furnace’s application.

Carefully consider engineering design

After selecting the proper materials, be sure that the engineering design is suitable. Engineering is extremely important to ensuring that the furnace relining is as long-lasting as possible. Make sure the materials have enough studs to hold them in place and have sufficient joints for expansion or shrinkage.

Proper installation is key to success

Be sure that the installation of furnace lining material is done properly and those doing the job have proper skills for the task. There is a wide variety of products available and each one has different installation requirements. The bottom line is, that is you don’t install it right, it is as bad as not having a good design and not making good material choice.