Careers Rapid ACC Cleaning Restores Efficiency and Safety at UK Oil Refinery
Air-Cooled Fin Fan Condensers Cleaned Using a ‘Contained’ Method
Serious fouling inside and outside several air-cooled condenser tubes had begun to affect production at an oil refinery in the UK. IGS TubeTech team was tasked with reducing the time required for this critical cleaning project by half.
The Challenge
The delicate external aluminium fans and internal tubes had become fouled and blocked, leaving virtually no remaining heat transfer capacity across three banks of updraft fin fan condensers. This buildup was significantly reducing the refinery’s production efficiency.
- The fouling on the fin fan air cooled condenser (ACC) was negatively affecting the oil refineries production capacity.
IGS Deployed In-House Developed Tools for Rapid, Safe Fouling Removal
IGS TubeTech carried out both internal and external cleaning of the air-cooled condensers using our in-house developed multi-lance cleaning system, combined with a 100% biodegradable, environmentally friendly wash that expands on contact for a deep and effective clean.
Key features of the approach included:
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Advanced multi-lance capability, enabling multiple jets to operate simultaneously and safely by one or two technicians.
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No scaffolding required, even within the narrow 3-foot walkway where cleaning was performed.
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Biodegradable wash applied from both sides, allowing the fin-fan units to remain online throughout the cleaning process.
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Fully contained cleaning method, capturing and directing waste to ground level to maintain a clean and controlled work area.
This twin-pronged approach enabled several cleaning actions to take place at once, unlike standard high-pressure jetting, which typically involves one manual lancing process at a time within confined spaces.
By optimizing safety, efficiency, and containment, TubeTech completed the project in under two days, reducing cleaning time by more than half compared to typical timelines.
“We were asked to reduce downtime, improve cleanliness, and enhance overall safety. The team delivered on all three.
This project demonstrates how approaching long-standing challenges with fresh thinking and innovative technology can generate exceptional results. We encourage clients to move beyond the ‘we’ve always done it this way’ mindset and explore more efficient, data-driven solutions.”
– Scott Donson, VP – International Business Development and Technical Operations
TubeTech™ Fouling Removal Services
Heat Exchanger Fouling Removal Services:
- Shell and Tube Heat Exchanger Fouling Removal
- Fired Heater Furnace Fouling Removal
- Texas Tower (VCFE) Fouling Removal
- Twisted Tube Heat Exchanger Fouling Removal
- U-Tube (Hairpin) Heat Exchanger Fouling Removal
Air Cooled Condenser Fouling Removal (ACC)
Fouling Removal for Inspection:
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