A prominent olefin manufacturer In eastern Europe faced unprecedented challenges following a major fire. Four pyrolysis furnaces were damaged. IGS Tube Tech, renowned for its innovative cleaning solutions, was invited to inspect, unblock and clean crucial components — the steam cracking radiant tubes and Transfer Line Exchangers (TLE).
In the aftermath of an explosion caused by a leaking valve, the plant engineers were looking for solutions to come back online cost-effectively.
“Four pyrolysis furnaces were damaged and were stopped without purging and decoking procedures. There was no possibility of cleaning them traditionally,” said the process engineer.
IGS Tube Tech was initially enlisted to inspect and clean the radiant tubes within the steam cracker.
IGS Tube Tech’s inspection utilized a steerable camera, entering through outlet flanges. This approach facilitated an internal assessment, revealing deposit types and severities.
Radiant Coil Type 1: Identified a hydro-wax deposit, complicated by water in the bottom sections. Applied a specialized cleaning process to address hydro-wax deposits, ensuring contaminant removal.
Radiant Coil Type 2: Uncovered hard coke deposits, presenting blockages and solid obstructions. Managed severe coke deposits meticulously, ensuring complete removal without causing additional damage.
The plant’s general contractor attempted to clean the TLEs as part of their scope but was unable to effectively remove the deposits, which appeared to be iron ferrite material. IGS Tube Tech has agreed to add TLE decoking to its scope and developed a custom cleaning solution, targeting fouling and deposits to reinstate optimal heat exchange efficiency.
“After the incident in September, IGS Tube Tech promptly addressed our urgent needs. Within three weeks of initial contact, their team conducted a video inspection, followed by a complete cleaning team on site.
Their execution was precise, tackling not only the radiant tube as part of their initial scope but also cleaning six Transfer Line Exchangers (TLEs). The entire operation concluded seamlessly in a matter of weeks.
The team was quick and well-prepared. This experience has impressed us thoroughly, leading to our interest in further collaborations with Tube Tech on upcoming cleaning projects. Their commitment to excellence and quick problem-solving makes them a valuable partner in our pursuit of operational efficiency.”
—Plant’s Process Engineer
Executed over a month, the TLE decoking operation not only averted replacements but also yielded substantial savings. IGS Tube Tech’s expertise and cost-effective cleaning solutions enabled the refinery to recover over six million dollars in replacement costs.
This case study underscores the collaborative efforts between IGS Tube Tech and the olefin producer. It exemplifies the critical role of innovative cleaning solutions in overcoming unforeseen challenges, demonstrating IGS Tube Tech’s commitment to operational efficiency and engineering excellence.