How data paves the way for greener thermal systems

Process heating is vital in hydrocarbon processing. While conventional methods involve burning fossil fuels, an increasing number of plants are transitioning to electric process heaters. One of the key advantages of this shift is the capability to achieve highly precise control over both the heating element surface temperature and the power consumption of the system. This level of control now extends to predictive control, made achievable through actionable insights derived from data. In this article, Chelsea Hogard, engineering team leader at thermal systems provider Watlow (pictured), explores the role that data plays in predictive maintenance.

ElectrificationProcess heating is a significant source of energy use and greenhouse gas emissions in the industrial sector, and so replacing fossil-fuel based heaters with electric ones running on green energy should yield significant progress towards decarbonisation goals. Adopting solutions for the first time will naturally bring about questions for process end user engineers regarding process variation, network loads, as well as component failure. Modern data collection technology, along with sophisticated data analysis, can monitor processes and allow these kinds of questions to be answered in real time.

Common challengesPetrochemical refining operations often use heat exchangers in processes that are conducive to coking and fouling. Fouled heaters can contaminate or disrupt processing, and must be cleaned and/or replaced when issues arise.

The right data, in real timeHaving accurate data concerning the operation and health of systems and components is crucial in reducing the risks associated with new technology. For example, identifying temperature fluctuations in a process can serve as an early indication of potential coking or fouling, which could lead to maintenance issues in the future. By enabling process end users to recognise patterns of drift that signal impending problems, unplanned downtime can be averted through timely planned maintenance cycles.

To learn more about WATCONNECT integrated with Data Insights, please visit: www.watlow.com