Careers Fast Offline Refractory Repair for CO Boiler at UAE Refinery
Project Overview
IGS successfully executed an offline refractory repair for a Carbon Monoxide (CO) Boiler at a major UAE refiner’s facility in Abu Dhabi. The project addressed critical refractory failures where medium-weight castable refractory had delaminated and projected into the boiler.
IGS installed retaining plates that served as refractory anchors to secure the deteriorating refractory until a complete repair to original specifications could be performed. The project was completed within the refiner’s tight shutdown window, showcasing IGS’s expertise and agility in delivering specialized refractory maintenance solutions.
H24-35476
The Challenge of Failed Refractory Anchors
The facility faced significant operational risks due to:
- Medium-weight castable refractory delamination
- Failed refractory anchors in critical areas
- Complex repair environment with only 6-inch gaps between tubes and refractory
- Limited 15-day mechanical window during the planned October 2024 shutdown
The facility required specialized expertise to address these issues without extending the planned shutdown timeline, as any delay would result in substantial production losses.
Although IGS is known for its online hot refractory repair capabilities, which eliminate the need for shutdowns, in this case, the client had already scheduled an outage, making an offline repair approach most practical.
Offline Refractory Repair Solution
IGS implemented a comprehensive offline refractory repair solution.
- Targeted Repair Approach
Installation of retaining plates as refractory anchors in three areas, each measuring 950 x 550 mm, located at the East wall soot blower levels 2, 3, and 5. - Transition Duct Repair
Installation of 15”x15” baskets, plates, and pumpable refractory across approximately 2.5 m² of affected area. - Inside-Out Repair Methodology
All work was conducted from inside the offline unit, allowing IGS crews to work from both sides to install materials effectively. - Materials Selection
Use of high-quality, heat-resistant materials specifically engineered for the harsh operating conditions of the boiler.
Project Execution
The project was executed through a carefully planned and sequenced approach:
| Phase | Dates | Activities |
| Mobilization | October 10, 2024 | Team deployment and site setup |
| Preparation | October 11, 2024 | Site survey, safety briefings and equipment staging |
| Initial Work | October 12, 2024 | Cutting slots for plate installation |
| Primary Repairs | October 12-15, 2024 | Installation of retaining plates and baskets |
| Welding | October 15-16, 2024 | Securing installations through precision welding |
| Completion | October 17, 2024 | Final inspections and project handover |
Technical Approach
- Site Assessment: The IGS team conducted a thorough inspection to assess the full extent of refractory damage and confirm repair requirements.
- Engineering Solution: Custom-designed retaining plates were fabricated to secure the delaminated refractory.
- Installation Process: Precise slots were cut to accommodate the retaining plates, followed by careful installation to avoid further damage to the existing refractory.
- Transition Duct Repair: For the more severe damage in the transition duct area, a combination solution using baskets, plates, and pumpable refractory was implemented.
- Quality Assurance: Each installation underwent rigorous quality checks to ensure proper positioning and secure attachment in accordance with industry standards.
Results and Benefits
The project delivered several significant outcomes for the facility:
- Timely Completion: All repairs were completed within the planned shutdown window, avoiding costly extensions.
- Structural Integrity: The installed retaining plates successfully secured the delaminated refractory, preventing further deterioration.
- Extended Operational Life: The repairs provided a reliable interim solution until a comprehensive refractory replacement could be scheduled.
- Safety Enhancement: By addressing the refractory failures, potential hazards from falling refractory material were eliminated.
- Operational Reliability: The repaired areas allowed for the safe and efficient operation of the boiler.
Lessons Learned and Best Practices
- Early Engagement: Pre-project meetings held in March 2025 allowed for thorough planning and material preparation well before the October shutdown.
- Collaborative Planning: Close coordination with the refiner’s maintenance team facilitated efficient work sequencing, including the advanced removal of soot blowers and SS plates.
- Adaptable Solutions: The original scope involved seven areas, but after detailed inspection, a more focused approach on four critical areas proved most effective.
“IGS demonstrated exceptional technical expertise and project management throughout the project. Their ability to develop and implement an effective solution within our tight shutdown window was impressive. The quality of work has enhanced the reliability of our boiler operations.”
– Site Maintenance Manager
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