Large boilers and furnaces use thermocouples to monitor temperatures at strategic locations to locate "hot spots," identify tube dry-out and tube blockage conditions, monitor efficiency and uniformity, and optimise operations. In almost all cases, the thermocouples are welded into place, which creates a horrendous problem when maintenance is needed. Thermocouples fail, and must be replaced periodically. Unfortunately, replacing thermocouples inside a boiler or furnace requires shutting down the unit so it can cool enough for technicians to enter, remove the old thermocouple, and weld a new one in place. For a major power utility boiler, outage time can be incredibly expensive-lost revenue, startup costs, equipment stress, etc.
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