Integrated Global Services has won Asset Integrity & Reliability Initiative of the Year at the Oil & Gas Saudi Awards 2026 for a fired-heater project that combined measurable efficiency improvements with long-term asset protection.

The award recognizes the application of high emissivity ceramic coatings to the radiant tubes and refractory surfaces of four CCR Platforming fired-heater cells. The project addressed oxidation scale that was restricting heat transfer, increasing firing demand and contributing to progressive tube wall loss.

Turning Inspection Findings into a Reliability Plan

An infrared thermography assessment identified significant scale on the radiant tube surfaces, with a temperature differential of up to 220 °C across the scale layer. The deposits acted as insulation, making it harder to transfer heat into the process and increasing the energy required to maintain operating capacity.

During a planned shutdown, the project team prepared the surfaces and applied high emissivity ceramic coatings to both the tubes and surrounding refractory. The tube coating created a stable, high-emissivity surface while protecting the external metal from further oxidation. The refractory coating improved the transfer of radiant energy back towards the process tubes.

Measured Performance and Reliability Results

Post-application analysis showed that apparent radiant efficiency increased from 65.85% to 70.38%, a relative gain of 6.9%. At comparable operating conditions, the improvement delivered normalized fuel savings of 28.0 MMBtu/h and an estimated annual CO₂ reduction of approximately 13,180 tonnes. The same efficiency gain also created the potential to increase throughput by up to 3,054 barrels per day without increasing fuel consumption.

The reliability benefits were equally important. Thermography showed a more uniform tube surface temperature distribution, with apparent average surface temperatures reduced by up to 120 °C. Field data also showed tube metal temperature reductions of approximately 17 to 20 °C across the four cells. Engineering analysis indicated a potential five- to seven-fold increase in tube life under the modeled conditions through reduced oxidation and lower creep damage.

Recognition for a Joint Achievement

This award reflects close collaboration between the refinery and IGS teams, from the initial inspection and engineering assessment through application and post-project performance evaluation. The project demonstrates how an inspection-led intervention can improve energy performance while addressing the underlying damage mechanism affecting long-term asset reliability.

IGS thanks everyone involved in planning, delivering, and evaluating the project, and the judges for recognizing its contribution to asset integrity and operational performance.