Careers Hot Spot Repair on a Live Fired Heater
During earlier turnarounds, this particular client contracted IGS for their Tube Tech, Cetek, and HVTS (High Velocity Thermal Spray) applications. This was the first time an IGS Hot-tek online service was used on a ‘live’ heater, without interrupting production.
This case study covers repairs to hot spots on the roof of a live fired heater at a N. American facility in October 2024.
The Challenge – Refractory Failure
Failure of refractory material can threaten structural integrity and lead to energy wastage, poor performance and even the complete shutdown of a fired heater and loss of production. Steam quenching is a temporary solution.
Solution
IGS Hot-tek hot refractory repair.
Benefit
- Restore structural integrity
- Maintain production throughout the repair process
- Restore capacity
- Stop steam quenching
- Prevent shutdown
Implementation / Approach
Minimal openings in the fired heater shell are created and used to insert specially designed components to support the repair material. This technique offers a semi-permanent repair method lasting at least until the next planned turnaround. The IGS Hot-tek team swiftly mobilizes anywhere in the world to address hot spots on live fired heaters.
Specifications/Considerations
IGS use proprietary and patented Hot-tek HRR technology to eliminate hot spots safely during the fired heater’s normal operation.
Risks/Sustainability
IGS Hot-tek mitigate risks by utilizing proven technologies honed in over 30 years of experience, trained technicians with over 10,000 hours experience, and robust PPE.
Fast Solutions to Hot Problems
Hot spots resulting from damaged refractory, scaled or misaligned process tubes, plugged SCR catalyst banks, and fouled convection sections can all affect the performance, reliability and safe operation and ultimately the operating capacity of the fired heater.
If a planned shutdown is still years away, maintenance managers are faced with a dilemma. To accept the risks and inferior performance or attempt temporary repairs, potentially still risking an unplanned shutdown if the solution is not fit-for-purpose.
Refineries, Petrochemical and Agrochemical Plants rely on the Hot-tek service, delivered by Integrated Global Services (IGS) to effectively address fired heater maintenance challenges in between turnarounds, without the need to shut down or power down their fired heaters.
Each service has been designed and perfected in collaboration with major oil and gas refineries to ensure that the safety, performance, and the output of the fired heater is not compromised.
