On June 25, 2025, IGS successfully hosted its latest A-L-E-R-T (Asset Life, Efficiency & Reliability Technology) Workshop at the InterContinental Al Jubail Resort. The event brought together asset integrity managers, turnaround experts, corrosion engineers, and operational leaders from across the region to explore pressing industry challenges—and more importantly, to uncover practical, field-tested solutions.

Bridging Knowledge and Operational Value

Throughout the workshop, participants gained firsthand exposure to real-world case studies, technical insights, and solution-oriented technologies presented by a panel of seasoned experts. The agenda, rich in both content and relevance, focused on two core themes: Asset Integrity & Life Extension and Fired Heater & Furnace Efficiency.

Asset Integrity & Life Extension

Attendees explored methods to mitigate corrosion and erosion in high-temperature/high-pressure (HT/HP) process environments—including vessels, towers, heat exchangers, and pipelines. Presenters shared case studies from major operators, emphasizing project outcomes and technology performance. These sessions gave engineers and specialists tools to assess their own asset strategies and apply proven interventions that extend asset life without disrupting productivity.

Throughout the ALERT Workshop, attendees explored practical technologies being applied right now in some of the most demanding energy environments. These weren’t theoretical discussions—they were grounded in real-world applications, offering clear takeaways for improving reliability, efficiency, and turnaround planning.

Live Fired Heater Hot Spot Repair

One session focused on live fired heater intervention, where attendees were walked through how hot spots in operating heaters can be diagnosed and repaired without requiring shutdown. The methodology included thermal mapping to identify compromised areas and targeted application of high-temperature repair materials—restoring efficiency and preventing costly outages. This approach is particularly effective for operators looking to avoid the production and safety risks of unplanned downtime.

HVTS for Corrosion Mitigation

Corrosion control in high-temperature/high-pressure equipment was another focal point. Experts detailed the use of High Velocity Thermal Spray (HVTS) as a high-performance solution for protecting internal surfaces of columns, towers, and piping systems. Compared to traditional weld overlay or cladding, HVTS provides faster application, superior corrosion resistance, and long-term reliability. Case studies demonstrated successful deployments in corrosive environments—resulting in extended asset life and reduced inspection intervals.

Tube Tech’s Robotic Fouling Removal

A highlight of the heat exchanger efficiency discussion was the introduction of Tube Tech’s robotic cleaning rover—a remotely operated system designed to remove fouling from vertical and horizontal heat exchanger bundles with unmatched precision. The system uses laser-guided tools to restore thermal performance while improving operator safety and reducing cleaning time. Participants saw how this solution supports both pre-turnaround preparation and routine maintenance, making it easier to recover lost heat transfer capacity without intrusive methods.

Turnaround Efficiency and In-Situ Technologies

In addition to these technologies, the workshop addressed in-situ protective coating systems that can be applied without removing equipment from service—minimizing scope during turnarounds. These solutions included erosion-resistant linings, non-metallic coatings, and engineered composites designed for high-temperature service. Attendees gained insights into planning strategies that integrate such solutions into TAR windows to extend run length and minimize future disruptions.

Practical, Interactive, and Collaborative

The workshop stood out not only for its depth but also for its format. Interactive presentations, real-time demonstrations, and open discussions created an engaging environment where attendees could openly share their challenges and walk away with actionable ideas. The event encouraged cross-functional dialogue, sparking collaborative thinking that extended beyond the session itself.

The workshop’s insights were delivered by seasoned IGS experts: Johannes Poth, Rohit Kardile, Colin Bateman, Dennis Snijders, and Al Muhannad Al Johani. Their combined expertise in fired heaters, corrosion mitigation, protective coatings, and turnaround solutions ensured each session was grounded in proven, real-world applications.

A Platform for the Future

With increasing pressure on operational efficiency, emissions reduction, and asset performance, the ALERT Workshop proved timely and highly relevant. Participants left the session better equipped to tackle their current challenges—with a sharper understanding of the technologies and methodologies driving measurable improvements across the energy sector.

IGS hosts these workshops globally. Please reach out to us via the contact form to find out the dates of the next local workshop near you.