Case study

Thermal and Refractory Monitoring Strategy for Adsorber Vessels

A structured inspection and monitoring strategy was established to manage thermal and refractory condition across operating cycles.

Key Outcomes

  • Established monitoring strategy for thermal and refractory condition
  • Enabled ongoing condition tracking
  • Improved visibility of degradation mechanisms
  • Supported proactive maintenance planning

Project Overview

Asset
Adsorber Vessels
Facility
Gas processing facility
Scope
Strategy development and engineering close-out
Inspection Type
NII and monitoring strategy

The Challenge

Thermal and refractory degradation posed risks due to:

  • Cyclic operation
  • Limited internal visibility
  • Difficulty detecting early damage

Existing approaches did not support proactive decision-making.

The Solution

  1. Planning

    • Identification of thermal and refractory degradation mechanisms
    • Definition of monitoring objectives
    • Selection of inspection techniques

  2. Execution

    • Targeted inspection of critical zones
    • Data capture aligned to degradation behaviour
    • Establishment of baseline condition

  3. Close-Out

    • Engineering assessment
    • Development of monitoring framework
    • Integration into maintenance planning

Technical Detail

  • Strategy aligned to thermal fatigue and refractory degradation
  • Focus on high-risk thermal zones
  • Data structured for trend analysis
  • Integration with operational data
  • Outputs supporting condition-based decisions

Outcome & Impact

  • Improved condition visibility
  • Early degradation detection
  • Better maintenance planning
  • Reduced failure risk

Key Takeaways

  • Monitoring is critical for cyclic assets
  • Early detection improves outcomes
  • NII enables ongoing visibility
  • Strategy improves lifecycle management