Introducing the IGS Tube Tech rover system, the next generation in autonomous cleaning technology, capable of removing more than 90% of fouling and restoring your fired heater convection sections to their original design thermal efficiency.
Developed through extensive research and development, the convection section cleaning rover system is equipped with unique features designed to improve cleaning efficiency. It can autonomously traverse over support plates, along finned or studded tubes, reaching hard-to-reach areas with fewer access points required.
Ability to move across tubes and back to the open area without technician intervention.
Self-aligned movement along tubes, requiring no guides.
Universal usability – no setup required.
Automated recording and image capturing for efficient reporting.
Automated cleaning and move functionality, enabled by a one-button start command.
Power off and re-start functionality with memory feature.
Lidar-controlled distance sensing for greater accuracy in positioning.
Support plate climbing function, enabling fewer access points and further travel along the furnace.
Remotely Operated; Fewer Access Points Required
Lidar Technology Detects Blockages
Our bespoke cleaning robot is a compact remotely operated vehicle (ROV) placed on the top row of every convection coil to be cleaned (subject to height clearance between banks). The ROV travels along the length of the bank. The cleaning arm is computer-controlled and can be of various lengths depending on the pitch and depth of the coil. The ROV arm slides down between the (finned or studded) tubes. The ROV arm cleans deep between the tube rows. Due to the 5 to 10mm proximity of the cleaning head to the fouling, the pressure easily removes the hardest type of fouling, e.g., cement, sulphur, and concrete-like deposits. No other cleaning system can promise this.
The robotic system uses hydrojetting technology (water only). It uses a low flow of water and only 100mm of high-pressure cleaning area, so the system is very precise.
Some plants request the passivation of stainless-steel tubes before cleaning and supply us with a 5% soda ash solution, which we are happy to accommodate.
The working pressure can reach 15,000 psi (1,000 bar). However, we usually operate at 10,000 psi (700 bar).
The flow rate of the jetting arm is 24-l/ min, and the flush bar is 67-l/min.
The fins in the convection section are steel, not aluminium so they are very strong and robust – the pressure and flow rate are generally not an issue from a material protection perspective.
No. The debris falls with the water and is collected in a catchment area that is set up below the convection box. The water does not harm the refractory as it is not blasted or soaked with water; the cleaning head is kept away from the refractory. It may become damp but dries out very quickly.
There is also no need to protect the refractory in the convection section as it is castable or castable brick. The refractory that needs to be protected is in the radiant section. Therefore, a containment area is built below the convection section, so all effluent is collected and does not reach the burner floor. All water and debris are collected and can be disposed of responsibly.
The cleaning rover moves on the top of the bank and the patented lance system penetrates between the tube rows, oscillating as it moves and adjusting its angle to each bundle. It’s fully adjustable depending on the severity of fouling.
The ROV is designed to cross over tube supports up to 50-mm (2”) high above the top tube in the bank.
It depends on the size of the heater and the level of fouling.
For a project time estimation, submit your ‘as-built’ furnace drawings to our team at info@integratedglobal.com
The rover system is far advanced in terms of the level of cleaning provided. The only downside is that we can’t clean online.
Chemical cleaning or dry ice typically only reaches 20-30% of the surface area. The rover system can clean more than 90%. Chemicals can also compound the fouling if the type is unknown and environmental, health and safety concerns are associated with chemical use.
No – Unless fins are severely corroded. If they are generally in good order, and made from ca 1 to 2mm steel plate, they can theoretically take a distributed load of 500 kg over 24-cm2. Our rover system weighs no more than 25kg.
We provide audit and inspection via Robot/ROV-mounted cameras or video probes or digital camera, which is positioned to take images between the triangular pitch of tubes. When you start the unit, you’ll also see the stack temperature drop.
Pricing depends on heater dimension, accessibility, fouling levels, site supplies etc. For this reason, all projects are quoted independently.
For a quote, send us ‘as-built’ drawings to info@integratedglobal.com
a) We need a 90-days’ notice to book equipment and team
b) If the team have not been booked for other project, the mobilisation will take five to ten days
c) Visa requirements should be taken into consideration for countries other than USA, UK and Schengen area
You can request an in-person or Microsoft Teams meeting with a local representative where we will present to you and your team and show you videos and references of many projects.
To arrange a meeting, contact info@integratedglobal.com with your requirements.
We have completed projects globally. Read our range of case studies to find out more or contact your local representative by submitting an enquiry via our contact form.
We build/increase access ports as a part of our Hot Access Creation Service.
We can debottleneck the convection section online with our Hot Convection Cleaning Service.
Our Cetek coating often helps with the problem, increasing the efficiency of the radiant section.
We’re here to help. Contact our team for advice or information today.