Case study: comprehensive fired heater optimisation at a leading indian refinery
Background A private-sector energy operator in India manages a vast refining and petrochemical complex with a total capacity exceeding 1.2 million barrels per day. The facility includes more than 20 fired heaters that support CCR Platforming, hydrotreating, and thermal cracking units. In alignment with its sustainability and efficiency goals, the operator launched a strategic partnership with IGS to enhance fired heater performance. Phase 1 (2008-2009): online refractory repair The collaboration began with the deployment of Hot-tek services for online refractory repair. Active hot spots were identified and addressed without interrupting operations. By making minimal openings, specially designed components and repair materials were inserted to deliver a semi-permanent fix that lasted until the next scheduled turnaround. These services addressed premature refractory failure caused by operational upsets or anchor failures, allowing continued full-capacity operation. (HVTS) alloy cladding offers durable corrosion protection. Applied in situ without welding, HVTS enables long-term integrity of pressure vessels and piping, reducing the need for extensive replacements and prolonging turnaround cycles. Sustaining performance To preserve these gains, the facility implemented a proactive maintenance programme, which included biannual IR inspections and performance audits. Initial inspections revealed 100% coating retention, with no signs of scaling or thermal degradation, indicating the long-term durability of the solutions. Future integration of HVTS Recognising the value of long-term corrosion protection, the facility plans to incorporate This intervention not only prevented long-term structural damage but also
reduced emergency maintenance costs by approximately 30%, showcasing the potential of online repair technologies. Phase 2 (2018-2019): process tube coating In 2019, during a scheduled turnaround, IGS applied Cetek ceramic coating to both legacy and newly fabricated process tubes within the CCR 1 Platforming unit. The goals were to: • Prevent oxidation and carburisation. • Enhance radiant heat transfer. • Stabilise bridgewall temperatures. Post-commissioning IR inspections confirmed coating integrity, and process data revealed an 8-12°C increase in delta T across coated heater cells. Absorbed duty rose by up to 10.5%, allowing for higher throughput and improved thermal stability. Moreover, typical productivity benefits of 4% to 10% have been recorded in similar applications, with fuel savings and bridgewall temperature reductions delivering a payback period of less than six months. Phase 3 (2024): CCR 2 full radiant section optimisation In Q1 2024, the operator requested that IGS apply a comprehensive coating to all five heater cells in a second platforming unit (CCR HVTS alloy cladding in upcoming turnarounds. This approach is expected to bolster the site’s corrosion management strategy, particularly in pressure-retaining assets subject to aggressive service conditions. Globally, HVTS applications have extended component life by 15-20 years while avoiding extended downtime associated with weld overlays. Comparative insights from global projects The technologies described have also shown success in various international settings. • Egyptian refinery hydrogen generation unit (2023) : Robotic convection cleaning restored unit performance, resulting in a 14% increase in duty recovery and annual savings of $220,000. • Turkish SMR unit (Tüpraş Izmir Refinery) : Robotic convection section cleaning services
Refining India
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