Custom Solutions Improve Quality and Slash Schedule and Cost
Plant type: refinery

Client Challenge

The client’s Methane Steam Reformer Furnace was cracking in the lower flange weld with cracking and corrosion present in the original weld. The location of the cracking provided limited access for manual welding.

The client’s options at the time were complete replacement of catalyst tubes or dismantling the lower furnace to create access for manual welding, both of which would have been expensive and labor-intensive.

Aquilex Solution

Aquilex WSI designed an alternative approach to the repair by developing an integrated tool that could perform the machining and the welding from inside the tube. With the proprietary ID machining tool and a consumable insert for the root pass, the craftsmen were able to cut the existing flange and perform the new weld prep in just one step. They were then able to install the new flange with auto GTAW ID weld head.

Results

Aquilex WSI performed all of the machining and welding for replacement of 77 flanges. Utilizing four integrated systems concurrently, Aquilex WSI was able to complete the entire job in four days with zero rejects.