Careers Tube Bore Recovery Restores 100% Throughput in Twisted Tube® Exchanger
Plant and Challenge Description
At a major Louisiana refinery, a Twisted Tube® heat exchanger within a vertical combined feed exchanger (VCFE), commonly referred to as a Texas Tower, was experiencing severe internal fouling that compromised both thermal efficiency and process throughput.
This unit, essential to maintaining reliable production output, had accumulated significant deposits that rendered nearly 30% of its 3,328 tubes either fully or partially blocked.
The plant’s operational team needed a fast, effective cleaning solution that could restore performance without prolonged downtime.
Evaluating Available Cleaning Methods
The plant’s maintenance team evaluated multiple cleaning methods, including traditional water jetting and chemical cleaning, but these approaches had previously proven ineffective or even detrimental.
The plant had previously attempted chemical cleaning, aiming to dissolve internal fouling and restore flow. However, not only did the chemical treatment fail to improve the condition of the exchanger, but it also exacerbated the blockage, resulting in even poorer flow rates post-cleaning.
This outcome is not uncommon; chemical cleaning agents can react unpredictably with hydrocarbon-based fouling, resulting in hardened deposits or dislodged material that reaccumulates downstream.
Based on past outcomes and technical constraints, the plant required a solution purpose-built for twisted tube geometry – one that could deliver deep cleaning while maintaining the integrity of the equipment. IGS’s TubeTech™ service was selected for its proven track record, patented systems, and ability to adapt in real time to on-site challenges.
Key Decision Factors Included:
- Precision cleaning with no hydraulic recoil, enhancing safety, control, and effectiveness
- Non-invasive lance technology tailored for twisted tube applications, ensuring effective cleaning without damaging or compromising the unique geometry of the exchanger
- High safety and schedule adherence standards
IGS Solution Delivery – Phase 1
IGS deployed two proprietary cleaning systems purpose-built for complex heat exchanger geometries. This dual-approach strategy was optimized to address both lightly and heavily fouled tubes, ensuring thorough internal cleaning without compromising the asset’s integrity.
- 7-day execution window
- 1,248 total man-hours with zero safety incidents
IGS Solution Delivery – Phase 2
IGS further refined its cleaning method to match fouling severity and exchanger configuration. The system operated safely under confined space protocols while maintaining high-pressure capability, ensuring complete internal restoration.
- Tailored cleaning method adjusted to fouling severity and exchanger configuration
- Operated safely under confined space protocols with high-pressure capability
Quantifiable Impact and Proven Results
The cleaning successfully restored the exchanger’s tube-side performance — IGS TubeTech™ exceeded the plant’s expectations. Prior to TubeTech’s intervention, over 1,000 tubes (30%) were partially or fully blocked, including 402 completely obstructed tubes.
The outcome not only enhanced process flow but also extended the exchanger’s operational lifespan and improved heat transfer efficiency.
Results:
- Internal tube cleaning achieved
- Significant cost avoidance in replacement or rework expenses
- Schedule met without deviation, with zero safety incidents
- Fouling reduced without chemical exposure or risk to asset integrity
Future Recommendations
Following the success of this project, IGS TubeTech™ recommended several steps to sustain asset performance and minimize future fouling risk:
- Avoid chemical cleaning. IGS advises against chemical cleaning in such scenarios. While it may seem like a quick fix, chemical treatment can introduce new risks and offer limited effectiveness—especially in exchangers with complex geometries. In addition, chemical cleaning often involves volatile solvents that create environmental hazards and generate difficult-to-dispose waste streams. For high-value assets like Twisted Tube® exchangers, targeted mechanical cleaning remains the most effective, environmentally responsible, and asset-safe method.
- Implement regular preventative cleanings using mechanical methods tailored for Twisted Tube® configurations to maintain optimal flow and heat transfer.
- Monitor unit temperatures and efficiency trends to identify early indicators of fouling, allowing for more proactive maintenance planning.
These steps will help extend the life of the exchanger, improve operational consistency, and reduce the likelihood of unplanned downtime.
Client Testimonial
Christian Chanel, Director of Technical Sales, IGS TubeTech
“This wasn’t just about clearing tubes — it was about restoring a high-value asset to peak condition so the plant could run with confidence. We partnered closely with site leadership to deliver a solution that worked for their equipment, their schedule, and their long-term goals.”
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