Careers Full-Capacity Furnace Recovery with Zero Downtime
When critical radiant tubes were found displaced during live operation, the plant faced an urgent reliability and safety challenge. Through rapid mobilization and precise online tube stabilization, the team delivered a zero-downtime solution that kept the unit running safely until the next planned turnaround. It’s a real example of fast action, smart engineering, and strong collaboration in a high-stakes environment.
Plant And Challenge Description
At a major European refining complex, displaced radiant tubes inside the firebox of one of the facility’s vacuum furnaces were identified during live operation. Several tubes had fully slipped from their supports, while others were partially unsupported due to broken, bent, or missing hanger brackets. The plant immediately reduced the furnace to 50% capacity to mitigate the risk of further tube movement or mechanical damage. The plant’s objective was to secure all compromised tubes, restore the furnace to full capacity, and keep the unit online safely for the next six months until the scheduled turnaround. The work needed to be completed without causing downtime or changing production plans.
Evaluating Alternative Options
The plant evaluated multiple paths, including temporary rate reductions or a partial shutdown to replace supports. Each alternative introduced operational risk, potential delay, or significant production loss.
IGS was selected based on:
- Ability to perform Hot-Tek™ Tube Stabilization while the furnace remained in operation
- Proven history executing complex online repairs in high-temperature environments
- Rapid mobilization and global resource availability
- A safety-first approach trusted across refinery-fired heater applications
After IGS performed an internal live-firebox inspection, the situation proved more extensive than anticipated.
- The original scope included stabilization of 6 tubes.
- The inspection revealed 20 additional tubesthat were either completely unsupported orbeginning to slip
This expanded the requirement to stabilizing morethan 20 tubes, more than doubling the originalproject scope. The team still had to complete thework without adding time or delaying production
Solution Delivery
Hot-Tek Tube Stabilization was deployed using custom stainless steel J Hooks, installed through inspection ports while the heater remained at operating temperature. Work was conducted across 8 days, following all site-specific safety, heat-stress, and access requirements.
Scope Executed
- 20 tubes stabilized across the vacuum furnace
- Ports opened, completed, and resealed with refractory
- IR scans performed to confirm no hot spots post-installation
- Zero safety incidents
Extreme Ownership in Action
The late expansion in scope required immediate material availability. Two rapid-response solutions were executed simultaneously:
- IGS flew additional equipment to get the hardware onsite as fast as possible and avoid any delay.
- The on-site team supported the project with locally produced tools. This combined approach ensured that no portion of the project was held up, and the schedule never shifted.
This combined approach ensured that no portion of the project was held up, and the schedule never shifted.
Operational Execution Highlights
- Work completed under tight heat-mitigation protocols
- Continuous coordination with the plant’s safety and operations teams
- Daily toolbox talks, observation cards, and walkdowns
- Full compliance with lockout, heat-compliance, and permit requirements
- Documentation and communication maintained throughout execution
“Our priority wasn’t just to secure a set of slipped tubes: it was to give the plant complete operating confidence. When the scope doubled overnight, our team mobilized globally, delivered the needed hardware immediately, and executed safely without affecting production. That level of ownership is what our customers rely on, and it’s what we bring to every fired-heater challenge.”
– Rocco Palumbo, Business Development Manager, IGS
Quantifiable Impact and Proven Results
The furnace returned from 50% to 100%capacity immediately after tube stabilization.
This restored the plant’s ability to run at full production rates safely and reliably, delivering:
- No unplanned outage
- No change in production schedule
- No capex intervention or intrusive repair
- Stabilization of 20 previously compromised tubes
- Confirmed tube support performance via plant-provided images and follow-up checks
The completed work ensures the furnace can operate safely and consistently until the next planned turnaround. It also reduces the risk of slippage, vibration, or progressive tube damage.
Watch: Hot Tube Stabilization: Repairing Fired Heater Tubes Without a Shutdown
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