In this blog post, we'll look at some real - world examples of how different industries have benefited from using thermocouple calibration furnaces.
Aerospace Industry: An aerospace manufacturer was facing issues with the accuracy of temperature measurements in their engine testing facilities. Incorrect temperature readings could lead to potential engine failures and safety risks. By implementing a high - precision thermocouple calibration furnace, they were able to regularly calibrate their thermocouples. The furnace's excellent temperature uniformity and stability ensured that the thermocouples provided accurate temperature data during engine tests. As a result, the manufacturer was able to improve the quality of their engines, reduce the number of engine - related issues, and enhance overall safety.
Chemical Industry: A chemical manufacturing plant in Houston, Texas was grappling with a significant problem. The tube skin thermocouples installed on their 9 large ethylene furnaces had an alarmingly high failure rate of 40 - 50% within just 6 months of installation. Moreover, these thermocouples exhibited large drift patterns before eventually failing. This was not only affecting the accuracy of temperature - controlled chemical reactions but also leading to costly production interruptions.
To address this issue, a specialized solution was proposed. A company fabricated proprietary “K” thermocouples to meet strict insulation resistance testing quality standards, specifically adhering to ASTM E 608 (500 VDC @ 1 giga - ohm). An established tube skin thermocouple installation procedure was then carefully followed. The result was remarkable. Duplicate sets of 16 “K23” thermocouples each were installed in 8 of the heaters, a total of 128 thermocouples. To this day, these thermocouples are still providing extremely accurate readings and have not experienced a single failure. This successful implementation not only improved the plant's operational efficiency but also significantly reduced maintenance costs associated with thermocouple replacements.
Pharmaceutical Industry: In a pharmaceutical manufacturing facility, precise temperature control is of utmost importance. Capsule production, in particular, requires the preparation and application of certain solutions within a very tight temperature range. The company was using alcohol - based formulations for the spray - coating solutions to ensure proper mixing and preservation of the chemical properties of the active ingredients in the capsules.
Previously, on hot days, the factory had to endure long waits for the alcohol to cool down from the outside tank farm before it could be used in solution mixing, sometimes taking hours. This was a major bottleneck in the production process. To expand and upgrade their capsule production capacity, they added a third fluid - bed dryer and associated equipment. Along with this expansion, they aimed to improve temperature regulation across all their production lines.
A heat exchanger system was installed that incorporated a heater / cooler unit. This unit was designed with two K series multi - pass corrugated tube heat exchangers. It had the ability to actively cool the alcohol if needed on hot days or heat it up on cold days. The hot water loop consisted of a heat exchanger, a centrifugal pump, safety features, and necessary ancillaries like a pressure gauge, temperature transmitter, and manual valves. Service water was recirculated in a closed loop with the solution tanks to heat or cool the solvent to the target temperature. Temperature transmitters and an autonomous control system were used to precisely control the process. Additionally, a secondary control loop with transmitters on each solution tank monitored the product temperature. This comprehensive solution reduced the cooling time from hours to less than 60 minutes, ensuring smooth and efficient production.
These case studies highlight the diverse applications and benefits of thermocouple calibration furnaces and related temperature - control technologies across different industries. In our next blog post, we'll discuss the maintenance and care of thermocouple calibration furnaces to ensure their long - term reliable performance.
