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Online Hot Spot Repair

What are Hot Spots?

Hot spots occur when there is damage to the existing internal insulation such as refractory or ceramic fiber lining on the wall or the ducting of a fired heater system.

Internal Insulation Repair

Some of the units vulnerable to hot spots includes:

1. Process Furnaces or Heaters:

  • Crude Distillation Furnaces
  • Hydro Treater Furnaces
  • Platformer Furnaces
  • Ethylene Cracking Furnaces
  • Thermal Oil Furnaces/Heaters
  • Crude Charge Heaters
  • Hydrocracker Furnaces
  • Reformer Furnaces
  • Hydrogen Reformers

2. Boilers:

  • Utility Boilers
  • Co-Generation Boilers
  • Coal Fired Boilers
  • Waste Heat Boilers
  • CO Boilers
  • Fluidised Bed Boilers

Fixing Hot Spots Online

Our Hot Spot Repair Service is a trouble-free specialty service which prevents the need for unscheduled and extremely costly shutdowns when hot spots occur.

The conventional way of repairing hot spots requires the system to be shutdown, affecting the plant availability and profitability dramatically. KLAY EnerSol’s Online Hot Spot Repair Service enables the repairs to be carried out whilst allowing the system to remain online (no shutdowns).

Many Successful Hot Spot Repair Jobs

KLAY EnerSol has over 10 years of experience in repairing damaged furnaces 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 perform these activities in a safe and sustainable manner.

KLAY EnerSol undertakes online hot spot repair services in the South East Asia region, including Malaysia, Singapore, Indonesia, Thailand and The Philippines and beyond. We have successfully completed many hot spot repair jobs for major refiners and petrochemical plants in the region and our technical experts are available to consult on the most effective online repair solution for your current situation.

Repairing Damaged Furnaces
Repairing Damaged Boiler Linings
Hot Spot Repair Solution

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 until the next scheduled maintenance shutdown. The damaged sections can then be repaired or replaced in a planned manner, sometimes even after a number of years.

How Online Hot Spot Repair is Done

Thermographic Hot Spot Repair

Step 1

Using thermographic equipment, the hotspot area is scoped and a repair plan is developed. Once agreed with the client, while the furnace remains fully operational, openings are drilled in the casing plate to access the damaged areas.

Repairing Boiler Lining Service

Step 2

Specially formulated compounds are then injected through the openings
As soon as the compounds are injected, the injected areas cools down immediately and eventually repaired. We have a range of compounds with varying temperature and viscosity ratings which are selected based on the site conditions and damage that needs to be rectified.

Online Hot Spot Reparing

Step 3

Our team of specialist applicators will assess the repair using both thermographic and visual inspections to ensure the area is completely repaired.
The injected compunds are re-inforced with additional anchors if required. Once the repairs are completed, the casing is covered again with new plates allowing the owner to run the furnace continuall without incurring costly unplanned downtime.