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Online Hot Spot Repair for Furnace Roof

Furnace Repair (Online) at a Major Petrochemical Plant in Malaysia

“Client was pleased with the services provided by Insulcon and KLAY EnerSol that helped to reduce the duration of emergency shutdown for repair of hotspot.”

 

Executive Summary

The client was experiencing a rapidly growing hot spot on their Reformer Furnace due to collapse of a large section of modules. The client shut down the unit for 3 days for emergency repair (without man-entry) and contracted KLAY EnerSol to repair the gaps between new and old insulation after start-up of the furnace.

  • Furnace shut-down for 3 days for emergency repair without man-entry to reduce shutdown window.
  • KLAY EnerSol contracted to repair furnace after the start-up
  • The furnace repair was completed within 3 days while the furnace was operating

Challenges

Since the hot spot was rapidly growing it was a critical situation for the client to make a decision from the options available. In such a situation KLAY EnerSol had to ensure the material and specialist crew can be mobilized on short notice.

In the end client decided on a short emergency shutdown plus online furnace repair as the most efficient option and KLAY EnerSol did the needful.

How Online Hot Spot Furnace Repair Help?

The Online Hotspot Furnace Repair helped to avoid a shutdown which could last at least 2 weeks to shutdown, scaffold, repair and start-up.

In this case the furnace was shut down for only 3 days to replace the burnt plates. This was replaced without man-entry from outside the furnace which left gaps between new and old insulation as expected.

Once the plant started KLAY EnerSol and Insulcon did the Online Hotspot Repair. Furnace was successfully repaired with proprietary Insulcon technology by a specialist crew.

Results, Return on Investment and Future Plans

The Online Hot Spot Furnace Repair was successfully carried out by specialist crew using proprietary Insulcon technology. As a result the furnace repair was done with only 3 days of shut down without man-entry.

Online Hot Spot Furnace Repair avoided a shutdown that could last at least 2 weeks to shutdown, scaffold, repair and start-up. With an estimated loss of RM 700,000 for each day of shut down.

Further details are available in the Online Hotspot Repair Report