Case Studies

Baseline Inspections

In addition to market-leading mechanical decoking (pigging), Cokebusters are able to offer Merlin in-line inspection (smart pigging) which offers more accurate and efficient decoking as well as the most comprehensive ultrasonic testing of process piping available.

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Decoking with Bespoke Pigs

Cokebusters patented scraper pigs have been shown to cut through coke with a unique combination of speed and efficiency, saving our clients time and money. As a result of our ability to design and manufacture bespoke pigs in-house to suit client specific requirements, we are able to effectively clean a wider variety of furnaces without modification, reducing costly downtime and additional mechanical works.

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Diametric Growth Detection

The Cokebusters Merlin in-line inspection tool takes up to 11,700 wall thickness and internal radius measurements per foot and is able to detect defects, such as diametric swelling, which may not be identified by conventional NDT methodologies within fired heaters including visbreakers, delayed cokers, vacuum furnaces, crude furnaces, reboilers and heli coils.

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Caustic Gouging

Cokebusters Ltd was contracted by a client to carry out a Merlin™ in-line inspection of a ten-line Heat Recovery Steam Generator as part of their scheduled maintenance turnaround in 2015. The inspection was carried out using the patented Merlin™ Intelligent Pigging system for accurate geometric assessment of both the evaporator and economizer coils in ten separate lines, containing two different nominal tube sizes: 3 and 4-inch.

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External High Temperature Oxidation

Overheating caused by long-term flame impingement can be caused by refractory debris lodged in or around the burner, redirecting or deflecting the burner flame, coke build up, burner misalignment, or deterioration of all or part of burner tile block. Cokebusters are able to offer Merlin in-line inspection which offers more accurate and efficient decoking as well as the most comprehensive ultrasonic testing of process piping available.

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Internal Pitting Corrosion

Cokeusters Ltd were requested by a reputable global group of refining companies to carry out a Merlin™ in-line inspection of three separate sections of 6-inch furnace tube. The three sections of tubing had been removed from the furnace due to the presence of severe internal pitting corrosion. The aim of the investigation was to observe the geometric data acquired from the Merlin intelligent pig within these corroded areas.

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