The Benefits of the Cokebusters ‘Combined Service’

Since Cokebusters was established in 2005, the company has been driven by a determination to position itself as the leading specialist contractor in its field to offer its clients a combined service of mechanical decoking and tube inspection.  This objective was realised when the first generation Cokebusters “smart pig” was launched. The technology has come a very long way since those early days, but by 2006 Cokebusters had become the first company to offer:
“One Company, One Combined Service, One Quotation and One Charge.”

Happily our marketing material has come on a little since then, but these archive brochure covers tell a story of the early days when Cokebusters was pushing to be the first to market with this “combined service” offer.  From the very beginning, we have been driven by a determination to find the most cost and time efficient solutions for our valued customer in the energy industry.

In the high-pressure environment of industrial maintenance, particularly in the energy sector, efficiency and precision are critical. Oil refineries, petrochemical plants and other heavy industrial operations rely on equipment that runs continuously, often under harsh conditions. One of the key areas that requires constant attention is the maintenance of furnace tubes and heat exchangers, which can suffer from the buildup of coke and scale over time.  This leads to operational inefficiencies and increased risks of failure.

This is where the benefits of hiring a contractor who offers combined mechanical cleaning (pigging) and piping inspection services can make a significant difference. By merging these two essential maintenance processes, plant operators can ensure the integrity of their systems while optimising operational uptime. In this article, we’ll explore the advantages of employing a contractor that offers this dual service, focusing particularly on its relevance to oil refineries and the energy sector.

1. Minimised Downtime

For oil refineries, downtime is costly. Every minute that a furnace is offline translates to lost production and revenue. Traditionally, mechanical cleaning and tube inspection are performed as separate tasks, often requiring multiple contractors and equipment setups. By hiring a contractor who can perform both services simultaneously, plant operators can significantly reduce the time their systems are offline. Instead of coordinating between different teams and timelines, a combined service means fewer disruptions to normal operations, leading to faster turnaround times and minimised production losses.

2. Cost Efficiency

Employing a contractor capable of both mechanical cleaning and tube inspection can lead to substantial cost savings. Combining these services into one operation reduces the need for multiple vendors, transportation of equipment, and separate labor costs.

By working with a single contractor, companies can negotiate better rates and streamline their maintenance budgets. Additionally, integrated services reduce the likelihood of unforeseen costs, such as delays caused by the need to coordinate between separate contractors. With all processes under one roof, logistics become simpler, contributing to more predictable and manageable maintenance expenses.

3. Improved Safety and Risk Mitigation

Safety is paramount in the energy sector, particularly in high-risk environments like oil refineries. Mechanical cleaning and inspection are complex tasks that require skilled professionals familiar with the potential hazards involved. Using a single contractor for both tasks can enhance safety by ensuring that all technicians follow a unified safety protocol, reducing the chances of miscommunication or incompatible safety practices between teams.

Additionally, combining these services minimises the number of mobilisations and equipment handling operations, reducing the risk of accidents or equipment damage. By limiting the number of personnel and equipment on-site, the overall risk profile of the maintenance operation is lowered, making the work environment safer for everyone involved.

4. Comprehensive Data and Reporting

When mechanical cleaning and piping inspection are carried out separately, data from each operation can sometimes become siloed, leading to incomplete or inconsistent reporting. A contractor offering combined services can provide a more integrated approach to data collection, analysis and reporting.

By inspecting tubes immediately after decoking or descaling, the contractor can provide accurate and real-time data on the condition of the tubes, without any interference from residual coke or scale buildup. This enables more effective monitoring of tube wear and corrosion, allowing operators to make informed decisions about repairs or replacements before a critical failure occurs.

Moreover, combining these processes results in more consistent and detailed records, which can be stored in a single reporting system. Over time, this provides a clearer picture of the furnace’s health, improving the accuracy of maintenance forecasting and helping refineries plan more effectively for future service needs.

5. Optimised Equipment Longevity

Fouling in furnace tubes can significantly impact the efficiency and lifespan of refinery equipment. Over time, this buildup not only impedes the flow of heat and product, leading to energy inefficiency, but it can also cause tube metal temperatures to increase, accelerating wear and increasing the likelihood of tube rupture or failure.

By integrating mechanical cleaning and inspection into a single maintenance process, contractors can ensure that any damage or thinning is identified immediately after decoking or descaling, allowing for prompt repairs or replacements if necessary. This early detection helps prevent more significant and costly damage from occurring later, ultimately extending the lifespan of the equipment and reducing the frequency of major overhauls.

6. Enhanced Environmental Compliance

With ever-tightening environmental regulations, oil refineries are under increasing pressure to maintain cleaner operations. Coke or scale buildup in furnace tubes can negatively impact emissions by causing furnaces to operate inefficiently and burn more fuel. By regularly cleaning furnace tubes and inspecting their condition, refineries can ensure their equipment operates at peak efficiency, minimising fuel consumption and reducing harmful emissions.

A contractor offering both mechanical cleaning and tube inspection services can help refineries stay in compliance with environmental standards, providing the necessary documentation and proof of maintenance that regulatory agencies often require. This proactive approach not only helps avoid costly fines but also enhances the refinery’s reputation as an environmentally responsible operator.

Conclusion: The Value of Combining Cleaning and Inspection Services

The energy sector demands precise, efficient and cost-effective maintenance strategies. The combination of mechanical cleaning and piping inspection services by a single contractor is an innovative solution that delivers a range of benefits: reduced downtime, lower costs, improved safety, enhanced data accuracy, prolonged equipment life and better environmental compliance.

In an industry where every second counts and the integrity of equipment is vital, partnering with a contractor who can provide this combined service offers a competitive edge. For refinery operators looking to optimise their maintenance programs and ensure the long-term health of their systems, this dual service approach is not just a convenience – it’s a smart investment in the future of their operations.