Efficiency and Reliability Audio Case Studies

A refinery faced a challenge during a turnaround project in 2022, aiming to enhance hydrotreater efficiency with a unique convection section configuration dedicated solely to boiler feed water heating, lacking process coils. This setup presented an opportunity to maximize processing efficiency in the radiant section, which required an innovative approach to optimize radiant heat transfer efficiency.

A prominent player in the Japanese market, this energy company operates several refineries across the country, including Miyagi, Ibaraki, Chiba, Kanagawa, Okayama, Yamaguchi, and Oita, facing various corrosion and erosion challenges in critical refinery equipment, leading to premature deterioration and costly repairs or replacements during turnarounds.

In this audio case study, we discuss the corrosion challenges within a sulfolane unit, showing why it's important for proactive maintenance strategies to safeguard operations and reinforce commitments to process safety, efficiency, and environmental responsibility.

A critical issue arose during the construction of a groundbreaking direct air capture facility in the US Gulf Coast, risking the project timeline and costing over $500k per day in delays, as a particular coating specification for a vessel proved inadequate for the required environment and temperature ranges, requiring urgent intervention to prevent further setbacks. The urgency was heightened by the need to address the problem during the New Year holidays.

In this episode, Larry Emch, Furnace Efficiency Specialist from IGS, joins us again to discuss a project where his team audited furnaces and heaters at an oil and gas site, identifying inefficiencies and offering solutions for increased production, including a notable 13.5% improvement, and long-term efficiency.

In this audio case study, we discuss a situation at a Gulf Coast chemical plant where an ethylene furnace encountered a hot spot challenge, requiring prompt action.

In this episode, we're joined by Kevin Phillips, Director of Business Development for Integrated Global Services and a Thermal Spray expert. He discusses a Pulp and Paper CFB Boiler dealing with extreme erosion issues, worsened by the presence of plastics, resulting in corrosion problems. The boiler experienced forced outages due to tube leaks, leading to frequent mechanical repairs. Fast forward six years later, and there are no tube leaks or forced outages.

Items discussed in the episode:

In this audio case study, we discuss how refineries can instantly reduce fuel consumption and save costs with the process tube Hot Tube Descaling process on their live heater.

In this audio case study, we'll talk about the changing maintenance strategy of the power plant operating two Circulating Fluidized Bed boilers. In 2015, they required 500 tube repairs across their units, leading to severe production disruptions. We'll explain why their boiler reliability was compromised and what they learned from it.

In this audio case study, we explore how a copper smelter addressed extensive downtime, high replacement costs, and logistical challenges associated with their waste heat boiler.