Efficient maintenance of fired heaters in the energy industry is crucial to ensuring safety, efficiency, and continuous operation. In this context, smart pigging has emerged as a key technology in coil inspection and cleaning, enabling refineries and industrial plants to optimize their monitoring and maintenance processes. Richard Roberts, Advisor and fired heater subject-matter expert at Becht, highlights the benefits of this process.
Monitoring and inspection methods
Proper monitoring of coils in fired heaters is essential to prevent failures and optimize operation. One of the most effective methods is the use of infrared cameras, which allow the identification of areas with coke buildup before they become a critical issue. The company has developed an infrared monitoring program that validates the accuracy of the data obtained, using systems such as Gold Cup to ensure reliable results. Thanks to these techniques, maintenance teams can detect the formation of hot spots in time and take preventive measures.
Decoking and cleaning techniques
Coil cleaning is a delicate process that requires the right tools and procedures to avoid structural damage. Becht emphasizes the importance of selecting the correct equipment and having trained operators to ensure efficient and safe cleaning. A crucial aspect of this process is the prior inspection of the equipment, as issues such as worn-out valves or defective seals can compromise the effectiveness of the cleaning and affect the subsequent operation of the heaters. Therefore, the implementation of written and standardized procedures is key to maintaining quality and consistency in each decoking process.
Smart pigging in the inspection and cleaning of fired heater coils
The adaptation of smart pigging for fired heater coils represents a key innovation in inspection and maintenance. By using high-precision ultrasound sensors, this technology provides a complete image of the interior of the tubes, identifying coke buildup, corrosion, and other anomalies. Unlike conventional methods like infrared scanning, which detect temperature variations associated with coke deposits, smart pigging directly measures the internal condition of the coil walls using high-resolution ultrasonic data. This allows for a more precise assessment of wall thickness loss, corrosion, and deposit formation. Additionally, these devices are designed to operate with a pressure of just 3-5 PSI, minimizing impact on the heater’s structure and minimizing structural risks through controlled pressure and proper pig selection.
Applications and benefits of inspection data
The analysis of data obtained through smart pigging provides critical information for decision-making in heater maintenance and operation. This data helps calculate corrosion rates, determine the remaining service life of the coils, and conduct fitness-for-service (FFS) assessments. Moreover, maintaining detailed records of inspection and cleaning facilitates the planning of future interventions, preventing unexpected failures and optimizing operational efficiency.
Becht positions itself as a leader in implementing these advanced technologies, providing its clients with innovative solutions for the safe and efficient maintenance of their equipment. With these solutions, refineries and industrial plants can significantly improve the reliability of their fired heaters, minimizing risks and maximizing productivity.
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Source and Photo: Inspenet.