Integrated Global Services Inc.
Integrated Global Services Inc.
Integrated Global Services Inc.
A petrochemical plant in the Middle East faced a critical problem with more than 10 hotspots on the roof of a roof fired reformer. This issue had persisted for almost a year, but the situation had escalated when some material fell, exposing the flames of the burner. The conventional repair method would require a unit shutdown for approximately three weeks, posing significant operational and financial risks.
The hotspots presented a serious HSE (Health, Safety, and Environment) hazard, with some areas now open and exposed. The risk of further hotspot propagation loomed large, threatening an unplanned shutdown. Financially, a three-week production loss could cost the plant an estimated USD 12 million.
Hot spots on the fired heater caused by refractory failure
The plant initially tried steam purging and plate welding to address the issue. However, these methods provided little relief, and the problem persisted. It seemed that a complete shutdown was inevitable.
Infrared view of the hot spot
Having successfully repaired a hotspot online in a transition area previously, the plant began to consider this as a potential solution. However, repairing hotspots near burners and process tubes presented a unique challenge.
There was limited access to perform the repair
After careful consideration and a detailed explanation from IGS experts, the plant gained confidence in IGS’s capabilities to perform the online repair. The potential to avoid production loss, prevent an unplanned turnaround, and ensure safe execution made this option particularly attractive.
Read more benefits of Hot-tek online repair, here.
Infrared view of the hot spot after repair
The implementation process faced several obstacles:
To overcome these challenges, the team:
The online repair successfully averted an immediate shutdown. Although the plant faced a shutdown two weeks later due to an unrelated issue, the plant was able to restart in just three days, due to the already completed refractory repair.
The biggest success of this project was the ability to repair the most difficult-to-access area of the fired heater without a prolonged shutdown.
Locations of hot spots and infrared imagery before and after IGS Hot-tek repair
This case study highlights the importance of considering online repair services to avoid unplanned shutdowns and the associated production losses. Companies facing similar challenges should explore innovative solutions that can maintain plant operations while addressing critical issues.
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