The refinery saved $15 million by avoiding a forced shutdown. The shutdown would have cost the plant more than $1 million per day in lost production to repair the hot spots. Conventional repair would have taken 2+ weeks to complete.
Multiple adjacent anchor failures in the roof of the catalytic reformer (CCR) heaters caused the ceramic fiber lining to fall to the floor, allowing hot flue gas to reach the exposed shell, oxidizing the steel & exposing the centre beam, which could jeopardize the structural integrity of the heaters.
Integrated Global Services (IGS) installed the Hot-tek hot refractory repair online without disrupting daily operations. The initial scope of work consisted of repairing three (3) hot spots on the south end of the roof of the heaters. Once the maintenance team witnessed IGS’ expertise and safety standards, they immediately asked for the extension of the repair scope to include additional hot spots within furnace 1 as well as adjoining furnaces.
Image: Hot Spot and Hot Spot IR.
“I wanted to take a moment to express my sincere gratitude for the great job your team did on our furnace roof while the furnace was still online. We were impressed by your team’s level of skill, precision, and professionalism. The repair was completed successfully without any disruptions to our production schedule, which is a testament to your team’s hard work and dedication. I also appreciate your patience and willingness to answer our questions and concerns throughout the process. Your guidance was invaluable.”
– Head of Maintenance, Refinery