Critical Vessel Refractory Monitoring

Critical Vessel MonitoringIn the typical Critical Vessel application their is Limited Capability of thermocouples:
It has long been acknowledged that the most effective method for monitoring refractory integrity is through vessel skin temperature measurements. However this is typically performed using contact thermocouples bonded to the vessel surface and connected via a fibre optic mesh.
The measurement coverage on the vessel is often one measurement per 250cm2/0.25 ft2. Such systems are both expensive to install, require regular maintenance and often need to be replaced after less than 3 years of vessel operation.

Proven Monitoring System
The proven Critical Vessel Monitoring System from LAND is able to provide a significantly improved measurement density with one measurement per 16cm2/0.02 ft2 allowing earlier detection of refractory breakdown often before the problem becomes dangerous.
The system uses low maintenance, industrial thermal imaging cameras installed around the vessel to maximise the coverage of the entire vessel and provide complete coverage of the critical dome and cone sections.

Key Benefits

  • Maximum protection – Over 110,000 individual measurements per thermal imager, ensuring that even the smallest degradation in the refractory can be detected improving safety for both plant and personnel
  • Low cost of ownership – Installation and maintenance can be performed under a hot permit reducing the plant downtime
  • Reliable and robust – Industrial thermal imaging system which is designed for harsh environments, ensuring ultimate measurement reliability and availability backed up with a 36 month warranty and expected lifetime in excess of 10 years
  • Payback – Potential cost savings by extending refractory lifetime based on actual data rather than historic experience
  • Simple Integration – Integrated web interface allow visualization of current vessel condition from all plant locations with a network connection (user account on the server is required for additional security)


Intelligent imaging solutions aim to solve problems by providing more than just a measurement. Land Instruments is able to provide a custom solution according to your requirements; this includes custom temperature ranges, application specific mountings, and bespoke communications protocols.

Gasifier – Typical camera locations to cover the entire surface of the vessel (below)

Vessel Montoring


Critical Vessel Monitoring

Technical Details

Measurement range 0 to 500°C
Accuracy ±2°C or 2%
Hazardous Area Ratings Zone 2, Gas Group IIC, T4 Zone 1, Gas Group IIC, T4
Ambient Temperature -20 to 50°C (Extended ambient option available)
Field Connection Box
Power Supply 24VDC
Connections Redundant Fibre Optic to Control Room
Hazardous Area Rating Zone 2, Gas Group IIC, T4
Zone 1, Gas Group IIC, T4
Ambient Temperature -20 to 60°C (Extended ambient option available)
Control Room
PC 1x Live Data Server, 1x Archive Data Server
Network Panel Fibre Optic Termination and Distribution
Managed Ethernet turbo ring for redundancy
Optional Items
Hazardous Area
Power Supply
90-240VAC Input / 24VDC Output
(Note: This only suitable for ClassI, div 2 and zone 2 option. For Zone 1 client must provide their own 24 VDC supply)
Hardware Outputs Hardware outputs can be connected to the software or connected directly to the camera for independent alarms.
Areas of Interest 4 polygonal AOI’s per camera (Up to 32 cameras per system)
Areas of Interest Alarm Functions Maximum Temperature
Average Temperature
Minimum Temperature
Rate of Change
Hotspot Detection & Tracking Within an Area of Interest Per Camera Overall System
Measured Values & Alarm Output OPC Server
Trending and Archiving All measured values are logged into a database and can be trended over time to allow the development of a hotspot to be monitored
System Status Monitoring Alarm if camera is over temperature, loses communication or power failure
Configurable Parameters • Focus of camera Alarm setup
• Warning Levels (Low / High)
• Shut down alarms Low-Low / High-High Adjust electronic zoom
Browser-Based Viewer Visualisation of current vessel condition from remote locations using Web Browser


  • High temperature gasifier vessels (typically coal and oil fuelled)
  • Gas to liquid process vessels

More Information

Critical Vessel Monitoring – Application Datasheet



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