Robotic Convection Section Cleaning Echances PDH Heater Efficiency

Plant and Challenge Description

Located in Yanbu, Saudi Arabia, a world-class polypropylene producer operates a propane dehydrogenation (PDH) facility equipped with four Oleflex™ heaters. As with many fired heaters, the convection sections faced performance decline due to fouling buildup on external tube surfaces. This issue was particularly severe around the economizer and steam generation coils, where refractory dust and fine particulates settled densely over time.

During a planned turnaround, the operator needed a fast, safe, and effective method to remove fouling across all convection sections—without introducing confined space risks or delaying the critical path. The client’s objective was to restore heat transfer efficiency and thermal performance while adhering to a stringent shutdown schedule.

Alternative Cleaning Methods Could Not Meet Access, Safety, and Timeline Requirements

Traditional manual cleaning methods were ruled out due to access constraints and safety limitations, particularly around the lower tube banks. Confined space entry was not acceptable, and the operator required a technology that could navigate complex tube geometries remotely.

The client partnered with IGS based on its ability to provide:

No-man-entry robotic access to tightly spaced finned tube areas
Demonstrated experience in high-performance convection cleaning
Fast mobilization and execution within a multi-unit shutdown window

Other cleaning alternatives, such as dismantling the full convection section or manual hydroblasting, were considered too time-consuming, risky, or inefficient.

IGS Deployed Robotic Fouling Removal for Multiple PDH Oleflex Heaters

IGS deployed its proprietary TubeTech™ ROV (Remotely Operated Vehicle) technology across all four convection sections and an additional surge pot.

The cleaning scope included:

Economizer coils
Steam Generation coils
Steam Superheater and Steam Generation coils
A surge pot, using remote fouling removal tools during the same mobilization

The ROV system removed over 90% of external fouling across tube surfaces, effectively navigating complex triangular-pitch tube configurations.

Where robotic access was limited—particularly in the lower outer tube banks—IGS applied plate jetting technology through inspection windows. This ensured uniform cleaning quality without the need for cutting access or extending project timelines.

Performance Restored Across All Units

>90% cleanliness achieved across all four convection sections
Zero confined space entry, improving safety and eliminating permit complexity
Project completed two days ahead of schedule
Fouling removed from over 232 tubes across complex coil banks using customized robotic lances
Post-clean visuals confirmed bare metal cleanliness throughout the economizer and steam coil sections
The surge pot, known for its constrained internal access, was also cleaned to inspection-ready condition using non-invasive techniques—avoiding cutting or repositioning

The successful execution supported the client’s goal of restoring process heating efficiency, reducing stack temperatures, and improving energy recovery—all without introducing execution risk or logistical complexity.

Repeatable Success Builds Trust and Future Partnership

This robotic cleaning campaign was executed concurrently with the surge pot cleaning scope, enabling the facility to consolidate services, reduce logistical overhead, and minimize costs.

The project’s success has opened the door to continued collaboration for future shutdowns, including the potential integration of complementary IGS solutions such as emissivity coatings and internal surface protection.

Client Testimonial

Dennis Snijders, Sr. Director – Middle East, IGS

“This project was about giving our client operational confidence. By eliminating manual entry and restoring performance across all four convection sections, we helped ensure the turnaround stayed on track and the plant returned to full production on schedule.”