At IGS, our Hot-tek® services are designed to keep fired heaters and process units operating safely and efficiently, all without the need for costly shutdowns. Below, our experts answer the most frequently asked questions, drawing on decades of real-world experience across refineries, petrochemical plants, and power facilities worldwide.

Hot-tek® HRR FAQ: Safe and Proven Online Refractory Maintenance

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1- How safe is hot refractory repair?

Safety is our top priority. IGS has developed intrinsically safe procedures and performed dozens of successful repairs around the world – all without safety incidents.

 

2- Do you need to reduce the heater duty for Hot Refractory Repair?

No production impact is required. Hot Refractory Repair can be performed safely without impacting production on heaters with negative pressure.

 

3- How reliable is this solution?  

Extremely reliable. Many of our hot refractory repairs have remained in service for more than 15 years. Typically, the repaired refractory is inspected at the next turnaround and plant internal procedures are followed concerning the inspection and replacement. 

 

4- Can you repair any refractory material or configuration?

Yes. IGS has solutions for every type of refractory lining – including concrete, brick, and ceramic fiber.

 

5- What if the original refractory is made up of multiple materials/layers? 

This is of no concern; we have repaired refractory hot spots on several heaters with multiple materials/layers. 

 

6- Does the thickness of the refractory matter for the repair procedure?  

The thickness of the refractory is not a concern for hot repair; if necessary, we can extend the length of the handle to reach further into the repair area. 

 

7- Is the basket exposed to real heat? Will it oxidize away? 

Yes, the repair basket is directly exposed to the real heat. The basket is constructed of a high-alloy stainless steel and can withstand up to 1,250°C of continuous exposure, ensuring durability even in extreme furnace conditions.

 

8- Will the hot refractory repair survive in areas of high flue gas velocity zones? 

Absolutely. We have performed numerous successful repairs in high-velocity environments, with long-lasting performance results.

 

9- How are large refractory hot spots repaired?

For extensive areas, our technicians overlap multiple repair baskets or plates over the intact surrounding refractory. This creates a new internal wall which is backfilled with pumpable refractory as the repair progresses.

 

10- Is repair possible with wall-mounted (single-fired) process tubes? 

Yes, our approach works effectively even on single-fired wall-mounted tube configurations.

 

11- Does IGS perform calculations on the rigidity/stability of the panel you’re cutting into? 

Yes. Prior to beginning a repair, we work closely with the plant engineers and develop a site-specific plan that includes additional exterior support if required.

 

12- What PPE is used when working with open furnaces in relation to the temperature?  

All IGS personnel use high-temperature personal protective equipment (PPE) that complies fully with local safety regulations and site requirements.

 

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Trusted Online Maintenance Without Shutdowns

IGS Hot Refractory Repair has been trusted by refineries and process plants worldwide to restore integrity without interrupting operations. With intrinsically safe procedures, high-alloy repair materials, and decades of field experience, our teams deliver lasting results where downtime isn’t an option.

Learn more about Hot Refractory Repair or contact IGS for a plant-specific consultation.