Expanding Capability: Cokebusters’ Header Bypass System Enhances Access and Inspection Efficiency

Our suite of tube and pipeline maintenance solutions is expanding with the introduction of the Cokebusters Header Bypass System – a custom-engineered tool designed to provide safe, efficient access to process tubes within common header units, without requiring modification to existing infrastructure.

Practical Innovation for Complex Assets

Common header systems often present access challenges when attempting to mechanically clean and inspect the critical process tubing within the unit.

The Cokebusters Header Bypass System offers a practical, adaptable approach, enabling engineers to carry out essential maintenance operations quickly and safely while minimising plant disruption.

At Cokebusters each unit is individually designed and built to suit the geometry of the asset it serves, accommodating variations in inlet and outlet header size, process tube diameter or orientation. The design of each header bypass system will also vary depending on asset configuration and region. The custom seal, rated to withstand pressures up to 600 psi, ensures a reliable interface for the deployment of a wide range of pigging tools, including cleaning pigs, wire brush pigs and smart pigs used for in-line inspection.

Integrated Service and Proven Performance

Since Cokebusters was established 20 years ago, we have offered the energy market a “combined service” of decoking/descaling and inspection of tubes and pipelines. The Header Bypass System takes this turn-key service a step further.

When used alongside our established mechanical cleaning and tube inspection services, the Header Bypass System supports a comprehensive maintenance workflow – from safe access and cleaning through to our UT inspection service and 3D visualisation software.

This integration allows operators to benefit from a single, cohesive service, reducing downtime and improving confidence in asset integrity. Whether supporting refinery turnarounds, petrochemical maintenance campaigns or energy sector reliability programmes, the system delivers practical value through proven engineering.

After 18 months in development, our Header Bypass System has already been deployed across several markets.

Commitment to Ongoing Development

As part of our ethos of continuous improvement, we’re always striving to refine and adapt our technology portfolio to meet the evolving needs of global energy operators. This Header Bypass System represents another step forward in delivering safe, efficient and adaptable solutions for complex process environments.