How We Solved Expensive Furnace Temperature Probe Failures — A Smarter, More Reliable Approach

In many high-temperature plant environments, especially furnaces handling corrosive gases, temperature probe failure is an ongoing frustration.

We see this frequently in energy from waste plants and similar process industries — where even expensive Inconel-coated probes can degrade rapidly under harsh conditions.

For one client, this problem was a constant operational headache:

• High-cost temperature probes failing well before their expected service life

• Frequent replacements disrupting plant operation

• Maintenance budgets strained by excessive instrumentation costs

Our Approach

At BIA Engineering Ltd, we don’t accept “that’s just how it is.”

We approached the problem systematically:

• Analysed historical data and failure patterns across multiple probe installations

• Studied process conditions and gas dynamics contributing to corrosion

• Examined not just the probes, but the wider system — how temperature data was being used and what was actually required for reliable control

The Solution

Our solution was both counter-intuitive and highly effective.

Rather than chasing ever more expensive probes, we devised a system architecture change:

• Redesigned the measurement approach to reduce direct probe exposure

• Implemented complementary monitoring and control strategies based on system understanding

• Delivered a solution that maintained reliable temperature data for control purposes, at a fraction of the original probe replacement costs

The Outcome

The new approach has:

• Reduced probe-related costs by more than 90%

• Delivered consistent, reliable temperature data to the control system

• Improved maintenance efficiency and reduced unplanned downtime

Why It Matters

Too often, plants accept ongoing instrumentation costs as unavoidable.

At BIA Engineering Ltd, we challenge these assumptions — applying deep process understanding and creative engineering to deliver solutions that are simpler, more reliable, and far more cost-effective.

Engineering solutions beyond expectations means solving problems that others simply tolerate.