Careers Reliable Cleaning for Hard-to-Reach Fouling in Critical Heat Exchangers
At a major Gulf Coast refinery known for its high standards and production volume, two large shell-and-tube U-tube bundles presented a severe cleaning challenge. These exchangers are integral to heat recovery and operational flow, but years of buildup had led to extreme shell-side fouling, the most severe seen at the plant in over 15 years. Restoring performance was essential to meeting turnaround deadlines and maintaining overall plant throughput.
The Objective
The refinery initially attempted multiple cleaning methods, including traditional hydro blasting, ultrasonic bath treatments, and even exposure to a pyrolysis furnace. None were successful. In fact, the pyrolysis treatment hardened the fouling further. Faced with a critical path bottleneck, the plant selected IGS TubeTech based on a proven ability to remove complex fouling that other methods could not touch.
Precision Cleaning Delivered With Consistent, Repeatable Execution
IGS TubeTech deployed its proprietary PlateJett system, a precision shell-side cleaning technology designed to penetrate dense fouling between tightly packed tubes. Supported by a newly engineered frame system for controlled delivery and increased safety, the team executed 21 shifts of confined space cleaning work over a 23-day period.
Key outcomes included:
- Zero safety incidents across high-risk, confined-space operations
- Complete fouling removal from both exchangers, restoring full heat transfer functionality
- On-schedule delivery despite high ambient temperatures and a compressed window
This project was not a one-time success, but it marked the second successful cleaning of these bundles by IGS. Based on this continued performance, the plant now plans to re-engage IGS for biannual cleanings, solidifying IGS as the refinery’s go-to partner for exchanger cleaning reliability.
“This project was about trust, demonstrating leadership in safety, and proving that IGS is the right partner for high-risk, high-value assets. We showed that we’re not afraid to evolve and deliver at the level our clients demand.”
– Christian Chanel, Director of Technical Sales, IGS
Proven Value That Strengthens Long-Term Partnerships
The successful execution of this project highlights IGS’s commitment to performance and safety under pressure. Through open communication and rigorous planning, IGS delivered results that exceeded expectations.
Watch: Restoring Heat Exchanger Performance in Refining Operations
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