Automated Tube Cleaning Saves Millions
Plant type: Petro-Chemical

Client Challenge

Each day that one of the client’s five vertical reactors is offline costs the plant an estimated $200,000. With one or two reactors taken down each year for catalyst repack, the financial impact of getting back online quickly is significant. The client needed to identify opportunities to modify specific processes that would reduce the overall outage time.

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Rapid Mobilization of the Right Talent Saves Time and Money
Plant type: nuclear

Client Challenge

Client’s gate valve double angle wedge was in need of repair or replacement due to excessive wear of Stellite 6. The 29 week lead time for delivery made replacement of the wedge impractical. The selected repair supplier was not capable of the precise machining and hardfacing techniques that were required and did not have the qualifications to provide first-time repair results.

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Aquilex Sets the Standard for MSIV Repair
Plant type: Petro-Chemical

Client Challenge

During the plant’s routine inspection, MSIV outboard and inboard valves did not pass Low Leak Rate Tests (LLRTs). Since LLRTs cannot be determined prior to an inspection, valve replacement or refurbishment became the critical path project in the resulting outage. Valve replacement was determined to be cost-prohibitive, so the plant required rapid valve repair. And, because high internal radiation doses expose workers to continuous dose, first-time LLRT approval was an absolute necessity.

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Custom Solutions Improve Quality and Slash Schedule and Cost
Plant type: refinery

Client Challenge

The client’s Methane Steam Reformer Furnace was cracking in the lower flange weld with cracking and corrosion present in the original weld. The location of the cracking provided limited access to manual welding.

The client’s options at the time were complete replacement of catalyst tubes or dismantling the lower furnace to create access for manual welding, both of which would have been expensive and labor-intensive.

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Reducing Schedule & Cost without Sacrificing Quality & Safety
Plant type: Petro-Chemical

Client Challenge

With an upcoming 50-day turnaround scheduled, the client required reductions in schedule and cost, while improving quality and safety. The primary objective of the turnaround was to connect new piping from a capital project to an existing coker unit. The scope included included installation of a Distillation Column, Fractionator Tower and knockouts for processing heavy crudes.

With a general contracting resource scoped for the project, the work was to be completed utilizing conventional weld methods. Instead of reducing the schedule, more time would actually be required and there was a possibility of having to change the turnaround date to accommodate GC’s workload. Neither of these possibilities was acceptable to the client.

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Doubling the Crew to Complete Major Overhaul in Half the Time
Plant Type: Fossil

Client Challenge

Of the two generators at a major utility, the tubing in the newer generator was wearing out twice as fast due to the frequent pressure washing required by new federal regulations on nitrogen oxide emissions. Every five years, the generators are taken down for two months for major overhaul. However, with both generators to be overhauled, the outage period was reduced to just one month.

The scope of work to be completed was enormous, particularly considering the aggressive outage schedule and limited access to the boiler. The primary superheater was to be replaced, including removing and replacing 438 PSH elements and 58 Chordal water wall panels of assorted sizes.

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Access to Resources Ensures Project Schedule
Plant Type: Fossil

Client Challenge

One of the largest coal-fired generating plants in the U.S. required reheater and heat recovery area tubing replacement and installation. In the 38 day total outage, only 26 days were scheduled to complete a significant scope of work:

• Remove side water wall for boiler access
• Remove and replace reheater assemblies
• Install 20 boiler access doors
• Replace the west side of the transition chute

All welds would be subject to LPA and x-ray verification.

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