Mechanical Cleaning Myths: Debunking Misconceptions About Fired Heater Maintenance

Fired heaters are critical components in the oil and gas industry, ensuring efficient heat transfer for various refining and processing operations. Over time, these systems accumulate deposits such as coke and scale, which can severely impact their performance and efficiency. Mechanical cleaning is a proven method for restoring their functionality, but several misconceptions persist about its effectiveness and safety.

Here, we debunk some of the most common myths surrounding mechanical cleaning for fired heaters:

Myth 1: Chemical Cleaning is Always Better Than Mechanical Cleaning

While chemical cleaning can be effective in certain scenarios, it is not always the best solution. Mechanical cleaning provides a targeted approach for removing stubborn deposits without introducing potentially hazardous chemicals into the system. Additionally, mechanical methods can be more cost-effective, eliminating expenses associated with chemical handling, disposal and environmental concerns. Cokebusters specialises in mechanical decoking, using advanced pigging technology to deliver a thorough and environmentally responsible cleaning process.

Myth 2: Mechanical Cleaning Damages Fired Heater Tubes

Some asset owners worry that mechanical cleaning can cause damage to heater tubes. However, modern mechanical cleaning techniques use precision-engineered tools designed to remove deposits while preserving tube integrity. Cokebusters’ bespoke pigging technology ensures a controlled and effective cleaning process that eliminates coke and scale without compromising the structure of the tubes. Their industry-leading equipment has been extensively tested to ensure safe and reliable operation.

Myth 3: Routine Maintenance is Unnecessary for Fired Heaters

There is a misconception that fired heaters do not require frequent maintenance. In reality, neglecting regular inspections and cleaning can lead to reduced thermal efficiency, increased fuel consumption and unexpected failures, potentially resulting in costly shutdowns. Routine mechanical cleaning is essential to maintaining optimal heat transfer, preventing overheating, and prolonging the life of fired heater tubes.

Myth 4: Mechanical Cleaning Wastes Large Amounts of Water

Concerns about excessive water usage in mechanical cleaning are often overstated. Our specialist Double Pumping Units are designed and manufactured in-house to include advanced water filtration systems which ensure minimal environmental impact. Our decoking process is designed for efficiency, using water filtration and recycling systems to reduce waste while still achieving superior cleaning results.  We have also developed a fleet of specialist water filtration machines.  These are currently in operation in the United States, but we plan to expand this service to other geographical locations in future.

Check out this article on water conservation in mechanical cleaning for more information.

Myth 5: Cleaning and Inspection Should be Handled by Separate Contractors

Hiring separate companies for mechanical cleaning and tube inspection can lead to inefficiencies, miscommunication and unnecessary delays. A combined service approach ensures seamless coordination between the decoking and intelligent pigging operations. By integrating both services, asset owners benefit from reduced downtime, a single point of contact and enhanced accuracy in post-cleaning inspection data.

Conclusion

Dispelling these myths is essential for maintaining the efficiency and reliability of fired heaters. Mechanical cleaning, when performed by experienced professionals using modern pigging techniques, is a safe, effective and environmentally responsible solution for removing coke and other deposits. Choosing a trusted provider like Cokebusters ensures that maintenance practices are carried out with precision and expertise, leading to improved operational performance and extended equipment lifespan.

Contact us directly to learn more about our mechanical cleaning services, one of our expert team will be happy to help!