What are Hot Spots?

A hot spot is experienced when there is damage to the existing insulation such as refractory or ceramic fibre lining on the wall or ducting of a fired heater system such as Process Furnaces or Process Heaters (e.g. Crude Distillation Furnaces or Crude Charge Heaters, Hydro treater Furnaces, Hydrocracker Furnaces, Platformer Furnaces, Reformer Furnaces, Ethylene Cracking Furnaces, Hydrogen Reformer Furnaces, Thermal Oil Furnaces or Heaters) as well as Boilers (e.g. Utility Boilers, Waste Heat Boilers, Co-Generation Boilers, CO Boilers).

Fallen fabric on furnace inner insulation wall

As seen in the picture, a portion of the furnace ceramic fibre lining has fallen off.

Fixing Hotspots Online

The hot spot repair service is a trouble-shooting specialty which prevents an unscheduled and extremely costly shutdown.

When hot spots on a Furnace or Boiler wall requires urgent repair, a forced shutdown would affect the plant availability and profitability dramatically. Our service ensures that you can continue operating your fired heater while we are fixing the hot spot!

Many successful hot spot repair jobs

Insulcon B.V. have developed over the last 20 years a suite of tools and techniques to repair damaged furnace and boiler linings from the external casing of the units. We have a more than 95% success rate on the jobs we undertake and adhere to strict personnel and workplace safety standards to undertake these activities in a safe and sustainable manner.
KLAY EnerSol works exclusively with Insulcon B.V. for the provision of Online Hot Spot repair services in the South East Asia region, including Malaysia, Singapore, Indonesia, Thailand and The Philippines. We have successfully completed a number of Hot spot repair jobs for major refiners and petrochemical plants in the region (See Case Studies) and our technical experts are available to consult on the most effective online repair solution for your current situation.

No Shutdown or Slowdown required

We provide a ‘first aid’ repair of the hot spots with our hot spot repair service, which enables the thermal unit to remain online. When the first scheduled maintenance stop is reached, the lining can be replaced if necessary. But most of the time the repaired hot spot is a permanent hot face repair.

How its done:

Drilled holes on the casing plate

Step 1 :

While the furnace remains operational, holes are drilled in the casing plate.

Injecting Insulmould to rebuild the internal refractory lining

Step 2 :

Specially developed Insulmoulds are then injected through the openings

As soon as Insulmould is injected, the injected area cools down immediately and eventually the area is repaired.

Drilled holes on the casing is closed

Step 3 :

Experienced applicators will assess the repair to ensure the gap is completely filled.

The drilled holes are finally closed. Additional anchors are inserted to ensure the repair has additional support in these areas.