Products and Services

Audits & Inspections

Furnace audits and inspections are an important tool to ensure longevity of the furnace campaign and efficiency of operation with regard to fuel consumption, gaseous emissions and glass quality.

Tecoglas recommend that a furnace audit be carried out twice annually to ensure regular evaluation and review.

A typical Tecoglas audit is split into three distinct areas:

(1) Visual Structural Survey

This involves a visual “walkthrough” studying the regenerators, glass bath and superstructure for any areas of wear or movement. Any areas that require attention and/or monitoring will be identified on drawings and subsequent recommendations made. We maintain that the engineers who carry out this study are fully conversant with the original furnace design. As the study progresses, it is essential that the auditor refers to and fully understands the original design drawings.

(2) Thermal Survey

The first thermal survey is cross-referenced to the original drawings and acts as the initial reference for subsequent surveys to be compared against. The thermal imaging will plot temperatures for the furnace bottom and the glass bath. The report will consist of an overview of the thermographic condition and thermographic data recorded, together with details of any anomalies or problem areas detected. These areas are thermal imaged and photographed for identification purposes and appear on fault sheets within the thermographic report.

Follow on visits will identify any thermal changes to the structure which the visual survey may not pick up. Again, to fully interpret the results, it is important to understand the design and operation of the furnace.

(3) Operational Survey

This survey completes the audit and is required to fully understand two important issues:

(a) Is the operation contributing to any problems highlighted by the structural and thermal imaging surveys?
(b) Is the furnace optimised to its full potential with regard to fuel efficiency, emissions and glass quality?

This survey will include the following:

  • Review of past operating data
  • Flame control, burner angles and flame length
  • Port flow distribution
  • Effective use of boost
  • Any maintenance issues
  • Port oxygen control
  • Combustion equipment audit
  • Operating philosophy
  • Hot spot control
  • Air and water cooling systems
  • Thermometry issues