Careers Enabling Precise Inspection to Safeguard Plant Uptime
Specialized Heat Exchanger and Fin Fan Cleaning for IRIS-Ready Asset Condition
Boosting inspection readiness across multiple assets, IGS enabled successful Internal Rotational Inspection System (IRIS) evaluations through specialized heat exchanger cleaning, preserving equipment integrity and protecting operational efficiency.
A leading refinery in Canada partnered with IGS to prepare critical fin fan and shell-and-tube heat exchangers for advanced non-destructive inspections. The objective was to achieve near-design internal conditions required for IRIS and Remote Field Testing (RFT) to validate asset integrity during a tightly scheduled turnaround.
IRIS inspections demand virtually bare-metal tube surfaces; however, conventional jetting methods often leave helical scale patterns and tramlines that compromise inspection accuracy. Recognizing the need for a specialist capable of achieving the elevated cleanliness standards necessary for high-confidence integrity data, the refinery selected IGS for the project.
Tailored Cleaning Approach to Complex Equipment Demands
IGS applied multi-technology precision to clean more than 17,000 tubes across six plant areas. Drawing on its TubeTech™ division, IGS executed a comprehensive cleaning program using:
- Rigid Lance Technologies for fin fan tube internal diameters
- Precision lancing for standard exchanger internals
- PlateJett™ patented technology for shell-side fouling removal Rotaflex Tube Polishing
- Technology for enhanced clean and IRIS preparation
- Shotgun high-pressure hydro blasting for final pass cleaning.
The heat exchangers and fin fans featured a range of tubing materials, including SA-179 carbon steel, SA-214, SA209-T1, and brass. Configurations included both straight and U-tubes, with tube diameters ranging from 0.75″ to 1″ and wall thicknesses between 12 and 16 BWG. Each variation demanded a specific cleaning protocol to protect base materials while achieving IRIS inspection readiness.
Ensuring Inspection Success with Close Technical Collaboration
Persistent fouling was removed through double-pass cleaning, guided by real-time inspection feedback. Several exchangers showed fouling severe enough to require multiple cleaning passes. IGS teams worked in conjunction with on-site inspection personnel, validating the tube condition after each cleaning section before proceeding. This iterative approach avoided rework, ensured optimal inspection visibility, and preserved the tight turnaround schedule. Attention to detail was critical—IGS eliminated residual tramlines and scale often missed by traditional cleaning methods, helping inspection crews gather accurate 3D integrity data from IRIS testing.
Restoring Full-Scale Reliability Standards Without Extending TAR Timelines
Reinstating 20% IRIS inspection confidence previously limited by cleaning performance, the refinery had, for several years prior to working with IGS, been forced to reduce its IRIS inspection coverage from a standard 20% down to just 5%. This reduction resulted from persistent fouling and the inability of previous cleaning methods to prepare tubes to the condition required for successful inspection while meeting strict turnaround timelines. After deploying the IGS TubeTech™ solution, the refinery successfully reinstated its full 20% IRIS inspection standard without exceeding its TAR schedule. This achievement represented a significant win for both the turnaround and reliability teams, enabling them to uphold internal standards without compromising on execution time.
“When inspection readiness is non-negotiable, we know we have to deliver more than just cleaning — we need to deliver confidence. This project demonstrated our team’s precision, adaptability, and commitment to excellence.”
— Christian Chanel, Director of Technical Sales, IGS
Protected Budget, Supported Timeline, and Trusted Results
IGS delivered the project within the original scope, supported by strong client endorsement and collaboration. The entire scope was executed within budget while meeting quality expectations for all exchangers. The client played an active role in coordinating logistics and ensuring inspection readiness throughout the project. The success of this engagement has paved the way for future collaboration on additional equipment within the same facility.
Reliable Inspections Begin with Smarter Cleaning
This project demonstrates how specialized exchanger cleaning unlocks assured inspection, minimizes rework, and protects critical path efficiency.
That’s Asset Vitality.
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