A refinery in the U.S. has discovered serious refractory integrity concerns on its CCR unit. The refractory ceramic fiber was missing in a furnace. As a result, the outer steel shell was damaged due to the exposure to the high temperatures in multiple areas of the roof and sidewall.
IGS Hot-Tek team was invited to repair the damaged refractory roof areas, using Hot-Tek Hot Refractory Repair Services, while the unit was running at full capacity. All quoted areas of the furnace roof were repaired, along with two additional damaged areas, discovered during the project.
This U.S. Refinery is a downstream energy company with assets in petroleum refining, logistics, convenience stores, asphalt, and renewables with a capacity of fewer than 150,000 barrels per day. The Refinery produces types of gasoline, distillates, and propane products.
The Hot-Tek team took infrared images of the hot spots on the CCR fired heater roof during the pre-job meeting.
Temperatures of over 1500°F/815°C were being reached at the bridge wall, relatively high for a CCR fired heater. Material selection utilized in the previous repairs was not sufficient for these elevated bridge wall temperatures.
Hot-Tek #1 & #2 Repair Area.
Repaired using Hot-Tek Module Style on the ceiling of the installed dog boxes.
Hot-Tek #3 Repair Area.
Repair performed utilizing the Hot-Tek Basket Style Repair on the existing ceiling.
Hot-Tek #4 Repair Area.
Repair performed utilizing Hot Tek Basket Style Repair on the side of the Dog Box and existing ceiling.
The busy refinery maintenance manager was looking at a permanent solution to this problem while avoiding a shutdown, which would have severe consequences to their revenue and operations.
IGS Hot-Tek team repaired the damaged refractory roof areas, using Hot-Tek Hot Refractory Repair Services, while the unit was running at full capacity. We repaired all quoted areas of the roof, along with two additional damaged areas that we discovered during the repair.
We repaired the damaged areas using two techniques; IGS Hot-Tek’s unique basket style repair and the larger module repair. The larger damaged furnace roof areas we cut into sections and removed. Then, we installed prefabricated modules in place. Higher alloy plates and hardware along with higher temperature ceramic fiber created a long-term repair solution for the refinery.
Hot-Tek Furnace Repair #1 & #2 using Hot Tek Module Style on the ceiling of the installed dog boxes
We cut the first tile using a plasma cutter and removed it from the furnace ceiling. Approximately 1”-2” area of the original furnace shell we left for support for the new Hot-Tek Module. After installing the module temporarily, our Hot-Tek team then moves to the next tile.
Our team installed a prefabricated Hot-Tek module and tack welded it into the place.
The installation of the large module was completed in the next roof section. The module and technician were tethered for safety.
We fitted and fully welded the module in place with an alloy rod for dissimilar metal welding.
We repaired a large damaged roof area with 16” square alloy Hot-Tek baskets. We welded these baskets together to form the new “ceiling” of the roof.
We laid pourable/pumpable refractory into the large opening. After curing, the surface becomes cool to the touch. Once cool, we welded an alloy plate over the refractory.
We made an initial cut in the roof to verify any obstructions.
After verification, we made a larger slit into the roof for the installation of the baskets.
We placed Baskets or Plates in the opening, securing any loose roof refractory, and welded it in place before backfilling with pumpable refractory.
We extended the plasma cut opening while the unit was running. IGS can also repair vertical surfaces utilizing a similar technique.
After the cut was made, we installed fiber lined baskets, cooling the surface area immediately.
IGS team performed the Hot-Tek project within the agreed schedule of 8 days. Refinery continued operations in full capacity, completely unaffected by the repairs taking place. A shutdown would have cost the refinery millions in lost production.
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