Restore Fired Heater Performance Without Shutdown

Fired heater performance often degrades between turnarounds. Convection fouling, rising stack temperatures, and mechanical deterioration can increase fuel demand, reduce heat recovery, and introduce safety and reliability risks.

When shutdown is not an option, these issues must be managed in service.

Hot-tek™ provides engineered online intervention services to restore performance, stabilize critical components, and maintain safe operation under live conditions.

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Why Leading Refineries Use Hot-tek 

  • 100% Safety Record
  • $2M+ in potential production savings per repair
  • Deployed for 100+ sites
  • Mobilization in days, not weeks
  • Repeatable maintenance enabled through installed access

Typical Triggers for Intervention

  • Increasing stack temperature and reduced heat recovery
  • Evidence of refractory failure or external hot spots
  • Declining steam generation or process pre-heat
  • Tube displacement, bowing, or support failure
  • Increasing bridgewall temperature
  • SCR pressure drop or reduced catalyst performance
156 M$
shutdown prevented by TG incinerator repair
15 M$
shutdown prevented in CCR Platforming unit
30 M$
shutdown prevented in Methanol facility
5 M$
shutdown prevented in Ammonia facility

Hot-tek Online Services

Hot-tek services address both performance loss and mechanical risk during operation. All methods are engineered for execution at temperature, under controlled conditions, without interruption to production.

Hot Refractory Repair
Repair of refractory failure and shell hot spots while the heater remains online. Restores lining integrity, prevents escalation, and avoids forced shutdown.

Hot Convection Cleaning
Removal of fouling and scale from convection section tubes to restore heat transfer, reduce stack temperature, and lower firing demand.

Hot Inspection (Lancescope™)
High-temperature internal inspection to identify fouling, damage, and failure mechanisms in real time. Supports early intervention and accurate scope definition.

Hot Tube Descaling
Removal of fireside scale from radiant tubes to improve heat absorption and reduce bridgewall temperature.

Hot Tube Stabilisation
In-situ stabilisation of displaced or unsupported tubes to maintain mechanical integrity and prevent failure during operation.

Hot Vacuum Service (SCR Cleaning)
Online removal of fouling from SCR catalyst surfaces to restore gas flow, reduce pressure drop, and maintain emissions performance.

What Our Clients Say 

 

“We were impressed by your team’s skill and precision. The repair was done online, no disruption, no delay. It’s the first time we’ve done this, and it worked perfectly.”

– Head of Maintenance, Oman Oil Industry Company

 

 

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I’m here to help

Larry Emch

IGS Subject Matter Expert

Related Case Studies:

Let’s keep your fired heaters running. 

Our team will be in touch shortly to discuss your needs and help you take the next step toward a fast, proven solution – no shutdown required.

Contact us