In petrochemical and refining operations, critical vessels such as reformers, reactors, and pressurized tanks play an essential role in day-to-day performance and long-term safety. These vessels often contain volatile substances under extreme conditions, and failure is not an option.
Effective vessel monitoring is key to maintaining the integrity of these assets. Traditional monitoring methods, however, present a range of limitations, from incomplete coverage to delayed detection of faults. Without constant temperature data and real-time visual insights, plant operators may not recognize signs of deterioration until significant damage has already occurred.
This article is part of our series on Continuous Critical Vessel Monitoring. To explore this topic in greater detail, download our white paper: Improving Safety and Reliability in Petrochemical Plants With Continuous Critical Vessel Monitoring.
Limitations of Thermocouples
Thermocouples remain a widely used tool for measuring temperature on or within critical process vessels. Installed in thermowells or embedded in vessel walls, they provide local readings that help operators monitor heat levels.
However, thermocouples offer only point-based data and lack the range needed for a complete temperature profile. They often miss issues occurring between sensors and are susceptible to degradation due to vibration, corrosion, and extreme heat. Because thermocouples require direct contact with the asset, they also demand frequent calibration and can be labor-intensive to maintain, sometimes requiring downtime for safe technician access.
The Reach and Limits of Fiber Optic Systems
Fiber optic temperature sensing technology provides distributed measurements along a continuous path, enabling detailed detection of thermal gradients or hotspots along the fiber’s route.
While they improve upon thermocouples in terms of coverage, fiber optic systems are not without limitations. They still only detect changes along the fiber line, which means certain surface anomalies may go unnoticed. In addition, installation and maintenance are complex, and interpreting the data requires specialized knowledge and software, raising both the cost and the training burden.
The Constraints of Physical Inspections
Despite technological advances, manual inspections remain a necessary part of most Asset Integrity Management programs. These inspections help validate structural health and provide visual confirmation post-maintenance.
However, physical inspections are not continuous. They are scheduled, costly, and involve personnel working in high-risk zones. Hazards such as high pressure, extreme heat, and chemical exposure increase safety risks. More critically, because inspections occur intermittently, conditions that arise between inspections may go undetected until it’s too late.
A Smarter Solution: Continuous Monitoring With Visual & Thermal Cameras
Modern Continuous Critical Vessel Monitoring systems deploy thermal and visual imaging to deliver uninterrupted, 24/7 surveillance of the vessel’s exterior surface. These systems allow operators to build a complete picture of the vessel’s thermal behavior and identify problems as they develop.
Unlike traditional methods, these non-contact technologies are reliable, easier to maintain, and offer greater insight. The visual data provides real-time awareness, while thermal imagery enables early detection of thermal anomalies that might signal structural or operational concerns.
By leveraging both historical and real-time data, operators can take immediate, informed action to maintain safe conditions, optimize process inputs, and prevent failure.
To learn more about how Continuous Critical Vessel Monitoring can improve plant safety and operational efficiency, download our latest white paper: Improving Safety and Reliability in Petrochemical Plants With Continuous Critical Vessel Monitoring.