Careers SMR Convection Section Cleaning Restores Thermal Efficiency and Design Performance
The Challenge: SMR Efficiency Decline Due to Fouling
A leading chemical producer in Germany was experiencing significant efficiency losses in their Steam Methane Reformer (SMR) Recycle Gas Heater due to fouling buildup on the convection section tubes. The fouling was affecting the thermal performance of the heater, leading to:
- Reduced heat transfer efficiency
- Increased energy consumption
- Potential impact on production capacity
The client needed a solution that could effectively remove deposits from both finned and bare convection section tubes in a limited time frame while maintaining the highest safety standards.
SMR Fouling Solution
IGS TubeTech™ deployed its specialized Remote Operated Vehicle (ROV) technology to address these challenges. The solution focused on removing fouling from external surfaces of both finned and bare convection section tubes while improving the thermal performance efficiency of the reformer’s convection section. By utilizing this patented cleaning technique, the team was able to minimize downtime with a with a rapid, no-man entry cleaning process, ensuring safety remained the top priority throughout the operation. This comprehensive approach enabled quality and efficiency without compromising operational timelines or safety protocols.
Project Execution
Scope of Work:
- Day 1: Safety training and site establishment
- Days 2-3: Cleaning operations and inspections across all banks
- Day 4: Final inspection, site breakdown, and equipment packing
Implementation Challenges
1. Access Limitations
- The access windows could only be opened to a 60° angle, significantly restricting access to the cleaning areas.
2. Equipment Condition
- Large distortion was discovered on one of the bank’s pipes.
- Elevated pipe temperatures posed additional challenges for the project team.
3. Infrastructure Issues
- The project faced initial delays due to an inadequately sealed water containment system.
- The containment system required immediate repairs to prevent water leakage.
Technical Approach
- Cleaning was performed through four access windows. The ROV system enabled safe, no-man entry cleaning.
- Each bank was systematically cleaned and inspected.
- Photographic documentation was maintained throughout the process.
- Special attention was given to the lower section where significant limescale buildup was
discovered.
Results and Benefits
- Cleaning Efficiency: Over 90% surface area cleaning achieved across all banks
- Fouling Removal: Significant limescale buildup in the lower section of the heat exchanger was successfully removed
- Process Improvements: Positive effects were immediately noticeable during plant start-up, as confirmed by measured parameters
- Energy Efficiency: Post-project energy audit confirmed sustained improvements in efficiency
- Management Satisfaction: The client’s management expressed high satisfaction with both the service and on-site team
Technical Recommendations
Based on the findings from this project, IGS TubeTech™ made the following recommendations:
- Implement regular cleaning of the SMR to maintain maximum efficiency
- Consider performance evaluation services to establish baseline performance metrics
- Monitor the system to ensure heat transfer surfaces maintain near-design condition
Conclusion
This case study demonstrates how IGS TubeTech’s specialized ROV technology successfully addressed complex fouling challenges in an SMR at a German chemical production facility. Despite difficult access conditions and unexpected infrastructure issues, the project was completed successfully within a tight timeframe.
The significant improvements in thermal efficiency and positive feedback from the client’s process engineering team highlight the effectiveness of the solution. The sustained efficiency improvements confirmed by post-project energy audits demonstrate the long-term value delivered to the facility.
Watch: TubeTech Robotic Convection Section Cleaning System
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