Breaking the Cycle: Innovative Cladding Solution Extends Reactor Lifespan and Saves Millions

The Recurring Challenge: Frequent Shutdowns for Erosion Damage

A petrochemical plant in the Middle East faced a persistent problem since commissioning: the need to shut down their unit every two years to replace components damaged by erosion. This issue was considered an unavoidable part of operations, with no apparent solution in sight.

The Hidden Costs: Financial and Operational Impacts

The two-yearly shutdowns had significant repercussions:

Risk of unexpected tube leakage due to erosion
Production loss for 3-4 weeks during each shutdown, costing millions
Safety concerns related to working inside the reactor with specific entry protocols

The Search for Alternatives: A History of Limited Options

Initially, the company’s only recourse was to replace damaged items during each shutdown. No viable alternatives seemed to exist, leaving them stuck in this costly cycle.

A Glimmer of Hope: IGS Cladding Technology

The company had been using IGS for erosion protection since 2007, but never within the reactor. In a breakthrough, IGS developed a specialized material for this application in collaboration with the process licensor. In 2019, the company applied this cladding to some materials and found it intact even after four years.

Reactor U Bolt Component Protected with IGS HVTS

The Decision: Embracing a Proven Solution

The impressive durability of the cladding after four years in service convinced the company that they had found the perfect solution. Key benefits included:

Avoiding production losses
Extending the duration between turnarounds
Implementation: Adapting to Uncertainty

The implementation process presented unique challenges:

Scope of work was uncertain until 1-2 days before execution
Challenging reactor entry protocols

To overcome these obstacles, the team continuously improvised their plan daily based on the customer’s inspection team observations and adjusted resource allocation accordingly.

The Outcome: A New Era of Operational Certainty

Over four months, the cladding was applied to different parts of the reactor, providing comprehensive erosion protection. This solution:

Delayed the next shutdown
Eliminated the risk of unplanned shutdowns due to erosion issues
Provided certainty in operations

The biggest success of the project was the team’s ability to adapt to changing scope and requirements throughout the implementation.

Lessons Learned: Innovating Beyond Initial Limitations

This case study demonstrates that even when solutions aren’t available during a plant’s commissioning, unique solutions can be developed later to change legacy maintenance practices and improve reliability. Companies facing similar challenges should remain open to innovative approaches that can transform their operations and significantly reduce costs over time.