Efficiency and Reliability Audio Case Studies

In this podcast, we explore how Cementos Panam improved production efficiency by overcoming raw material humidity issues with IGS air cannons and multipliers.

Learn the latest materials and techniques that combat internal pipeline corrosion, including IGS's Metalspray Pipe ID cladding, which enhances durability, safety, and cost-effectiveness across oil and gas infrastructure.

In this episode, we explore the importance of high emissivity coating durability for fired heaters and how it enhances process efficiency while reducing fuel consumption. Join us as we discuss key factors such as surface preparation, application techniques, and quality control measures that ensure long-lasting performance in extreme operating environments.

Discover how IGS played a key role in the success of the Ras Tanura Refinery 2024 Mega Turnaround.

This episode discusses an ethylene furnace's declining fuel efficiency and increased emissions over six years due to fouling, with limited options for cleaning.

This audio case study highlights the importance of treating vacuum heater systems as a single unit to optimize refinery operations, addressing the impact of phase separation and tube coking on efficiency and safety.

The copper smelter’s waste heat boilers, used to recapture heat, faced significant issues with corrosion, erosion, and accretion due to SO2 and other contaminants. The previous coatings, while somewhat protective, exhibited cracking and spalling, necessitating an effective solution to mitigate these problems and reduce maintenance costs.

Discover how a petrochemical plant struggled with persistent erosion and frequent costly shutdowns, leading to significant production losses and safety issues, and how they turned to IGS for a custom solution to tackle these challenges.

Chief Technical Officer Iain Hall discusses how IGS's technology addresses energy companies' biggest challenges around reliability, efficiency, and reducing fuel consumption.

In this audio case study, Nugen Energy faced a significant challenge when their facilities began experiencing refractory failures, requiring extensive downtime for repairs. This downtime not only halted production but also led to substantial financial losses, nearly $6.59 million per incident.

Integrated Global Services (IGS) deployed Tube Tech’s engineered VCFE cleaning solution to remove fouling from 2688 tubes across two Texas Towers. 100% of tubes were cleaned to a production standard and 10% of tubes received enhanced cleaning for IRIS inspection.

This episode explores the issue of oxidation scale formation on steel tubes in fired heaters. This problem disrupts heat transfer, causing over-firing, high bridgewall temperatures, and reduced production rates.

Today, we'll delve into a case study surrounding the challenges faced by a plant due to erosion and corrosion in their waste heat recovery system, and how they tackled this issue without compromising plant availability or production.

This audio case study is about fouling challenges faced by a petrochemical company. There is a crucial need to restore heater efficiency and operational reliability, leveraging advanced robotic technology in alignment with the company's commitment to sustainability, this process generated minimal waste.

A refinery faced a challenge during a turnaround project in 2022, aiming to enhance hydrotreater efficiency with a unique convection section configuration dedicated solely to boiler feed water heating, lacking process coils. This setup presented an opportunity to maximize processing efficiency in the radiant section, which required an innovative approach to optimize radiant heat transfer efficienc...

A prominent player in the Japanese market, this energy company operates several refineries across the country, including Miyagi, Ibaraki, Chiba, Kanagawa, Okayama, Yamaguchi, and Oita, facing various corrosion and erosion challenges in critical refinery equipment, leading to premature deterioration and costly repairs or replacements during turnarounds.

In this audio case study, we discuss the corrosion challenges within a sulfolane unit, showing why it's important for proactive maintenance strategies to safeguard operations and reinforce commitments to process safety, efficiency, and environmental responsibility.

A critical issue arose during the construction of a groundbreaking direct air capture facility in the US Gulf Coast, risking the project timeline and costing over $500k per day in delays, as a particular coating specification for a vessel proved inadequate for the required environment and temperature ranges, requiring urgent intervention to prevent further setbacks. The urgency was heightened by t...

In this episode, Larry Emch, Furnace Efficiency Specialist from IGS, joins us again to discuss a project where his team audited furnaces and heaters at an oil and gas site, identifying inefficiencies and offering solutions for increased production, including a notable 13.5% improvement, and long-term efficiency.

In this audio case study, we discuss a situation at a Gulf Coast chemical plant where an ethylene furnace encountered a hot spot challenge, requiring prompt action.

In this episode, we're joined by Kevin Phillips, Director of Business Development for Integrated Global Services and a Thermal Spray expert. He discusses a Pulp and Paper CFB Boiler dealing with extreme erosion issues, worsened by the presence of plastics, resulting in corrosion problems. The boiler experienced forced outages due to tube leaks, leading to frequent mechanical repairs. Fast forw...

In this audio case study, we discuss how refineries can instantly reduce fuel consumption and save costs with the process tube Hot Tube Descaling process on their live heater.

In this audio case study, we'll talk about the changing maintenance strategy of the power plant operating two Circulating Fluidized Bed boilers. In 2015, they required 500 tube repairs across their units, leading to severe production disruptions. We'll explain why their boiler reliability was compromised and what they learned from it.

In this audio case study, we explore how a copper smelter addressed extensive downtime, high replacement costs, and logistical challenges associated with their waste heat boiler.

In this audio case study, discover how IGS's Hot Refractory Repair prevented a potential $156 million shutdown cost for a Central Asian oil and gas producer. It also highlighted the crucial role of proactive maintenance in sustaining uninterrupted energy production.