Cokebusters’ Latest Double Pumping Unit Heads to Houston

We’re pleased to share more detail on the newest addition to our fleet: a state of the art Double Pumping Unit (DPU) that has now completed its full test programme at our UK Technology Centre and is on its way to our Americas Operations Centre in Houston.

This machine represents an important moment for Cokebusters USA – a clear investment in growth, capability and client service at a time when demand for mechanical cleaning and inspection is increasing.

Built Through Collaboration: A UK–USA Engineering Effort

This DPU is the result of a truly collaborative manufacturing process between our teams in Chester, UK and Houston, TX.

The Tier 4 Cummins QSL9 engines – together with their transmission units – were sourced in Texas and shipped to the UK for assembly. These modern engines significantly reduce exhaust emissions and meet the strictest environmental requirements, including those imposed by refineries on the US West Coast. While Tier 4 systems are larger, far more complex and considerably more expensive, they ensure we remain compliant, efficient and environmentally responsible wherever we operate.

The main tank unit was fabricated in Houston, while the machine was assembled at our workshops in Chester, incorporating our latest control room design built from insulated aluminium and fitted with updated electronic management systems.

Project Manager Lukasz Kremski led the build, ensuring every component met our high standards. During a visit to the UK, Cokebusters USA Workshop Manager Scotty Wilkins saw the machine at several stages of construction and testing.

“I visited the UK workshops last month and was excited to see this machine being tested,” Scotty said.
“The guys here in Houston are really looking forward to receiving this latest new DPU… we certainly need it. Then we want another one please Lukasz!”

Tested and Proven on Our Mixed-Size Tubing Loop

Before shipment, the new machine completed a rigorous test programme on our 300m mixed-size tubing test loop – a system designed specifically to challenge and validate the performance of our patented decoking, descaling, cleaning and intelligent pig technologies.

The loop includes tubing sections from 3⅜” through 4”, 6”, 8”, up to 12” ID, joined in multiple configurations. Short-radius bends, vertical and horizontal sections, simulated and donated box headers and long sections of convection tubes taken from a real refinery furnace all provide a demanding environment that replicates the complex geometries found in refinery heaters and process systems.

Our new DPU performed exceptionally throughout testing, demonstrating the reliability, power and precision required for deployment in North and Central America.

Meeting Growing Demand Across the Americas

This latest machine arrives at a pivotal moment. Cokebusters USA has undergone significant renewal following a change in senior management in 2024. Under the leadership of CEO Kevin Fordham, the business has refocused, modernised and adopted a more ambitious vision for growth.

Older DPUs have entered a refit programme and two brand-new machines were ordered. It signals our commitment to improving fleet performance, reliability and availability for clients across the region.

Expanding our US-based fleet ensures we can:

• Support more clients with their maintenance schedules

• Respond quickly to urgent work

• Deliver consistent performance across a wider geographic area

• Strengthen our long-term presence in key energy hubs

This DPU will be stationed permanently in Houston and deployed wherever required across North and Central America.

A Confident Investment in the Future

For our teams on both sides of the Atlantic, this project represents more than a new piece of equipment – it reflects the strength of collaboration within Cokebusters and our shared commitment to continuous improvement.

We look forward to seeing this DPU enter service in the New Year and to continuing to invest in the tools, people and technology that help us support energy operators around the world.