Challenge
A midwestern refiner was experiencing premature failure on the inlet ducting in the flue gas desulfurization unit (FDU). Unit efficiency fell. Heat and gases blanketed the area, creating a hazardous environment. Maintenance crews were kept out of the area due to safety concerns. An unscheduled outage was being hastily planned.
Technical Assessment
Phoenix High Temperature Repair crews were mobilized to the plant and immediately established control of the work area for FDU repair. Multi-gas and heat monitors were utilized to define the exclusion zones. Proprietary PPE was required of all Phoenix crew members during work site inspections. An engineered solution complete with risk assessment and mitigation was presented and accepted by the client. The PO was issued to commence work.
Solution
Leaking areas on the ducting were specially prepped to ensure proper sealing. Custom designed enclosures with relief valves were built to specs. Enclosures were welded on the ducting following approved welding procedures.
Results
Monitoring devices indicated leaks were successfully sealed and an improving environment. The FDU repair was completed and the boiler was cleared for normal operations and efficiency returned. Significant cost savings to the client resulted from Phoenix’s ability to work under pressure at temperature.
