Furnace Hot Spot Repair Report Reformer Malaysia Jan 2017 PDF

PROJECT TITLE:
HOTSPOT REPAIR AT A REFORMER WASTE HEAT SECTION FOR A MAJOR

PETROCHEMICAL PLANT IN KERTEH, MALAYSIA
DOCUMENT TITLE:
HOTSPOT REPAIR REPORT
Rev Date Status

Prepared By Checked By Approved By
0 16/01/2017 Issued for Information

Mufaddal Annuar Sazri
Hotspot Repair Report
Introduction
A major Petrochemical plant located in Kerteh, Malaysia was experiencing a rapidly growing hotspot problem on
their Reformer Furnace waste heat section. Due to the large section of modules that had fallen off (approx. 7 rows
x 8 rows of modules), the customer decided to shut down the reformer on the 5th of January 2017 to effect an
emergency repair of the casing by replacing the burnt off plate and installing new plates with approximately 200mm
of ceramic fibre lining the inside of the plates. The entire patch repair was carried out from outside the furnace
without man- entry to shorten the shutdown window. The unit was restarted on the 8th of January 2017. However,
as anticipated, there were still some gaps between the newly repaired plates and existing insulation.
KLAY EnerSol & Insulcon were contracted to help fill up these hotspot gaps in multiple locations as well as to help
secure the ceramic blankets laid underneath the newly patched plates. The hotspot repair crew commenced the site
repair on the 11th of January 2017 and successfully eliminated all the remaining hotspots according to schedule by
the 13th of January 2017. There were zero safety incidents, and the reformer was operating at full capacity
throughout this repair period. This report describes the Online Hot Spot portion of the repair that was carried out.
1/13 Hotspot Repair Report, Malaysia, Jan 2017

Summary of Hotspot Repair Services Done
Front View
Repair with
umbrella,
insulmould and
SS anchor
Additional anchor
for extra support
to existing
insulation
Top View

Area Maximum Hotspot Temperature After Note
Description Temperature Repair
Before Repair
4 holes were cut. Hotspot repaired

Hotspot
Left Plate (top) 430.0 °C 78.1 °C with 2 umbrellas, SS anchors and
Area 1
insulmould
1 hole was cut. Hotspot repaired

Hotspot Center Plate
186.3 °C 99.8 °C with 1 umbrella, SS anchors and
Area 2 (top)
insulmould

Hotspot Right Plate
223.7 °C 86.5 °C with 2 umbrellas, SS anchors and
Area 3 (Top)
insulmould

Hotspot Left Plate
Area 4 (bottom)
insulmould

Hotspot Center Plate
Area 5 (bottom)
insulmould
Hotspot Right Plate No holes were cut. Hotspot

149.6 °C 77.1 °C
Area 6 (Center) repaired along with hotspot 7

Hotspot Right Plate
Area 7 (Center)
insulmould

Hotspot Right Plate
Area 8 (Bottom)
insulmould

Hotspot
Top Roof 317.1 °C 85.0 °C with 4 umbrellas, SS anchors and
Area 9
insulmould

Hotspot
Top Roof 452.8 °C 81.2 °C with 4 umbrellas, SS anchors and
Area 10
insulmould
8 additional anchors were added

for additional support to existing
Additional
insulation. All anchors used
Anchors
umbrellas, insulmould and SS
anchor.

Hotspot Area 1
Before
1/11/2017 5:40:25 PM °C 1/11/2017 5:40:25 PM
200.0
41.1
FLIR15151.jpg FLIR E60 64507311 FLIR15151.jpg FLIR E60 64507311
Measurements °C
Bx1 Max 430.0
Min 60.3
Average 196.7
Parameters
Emissivity 0.95
Refl. temp. 20 °C
After
1/13/2017 5:37:00 PM °C 1/13/2017 5:37:00 PM
199.5
Sp1
41.1
Measurements °C Note:
Bx1 Max 78.1
4 hole was cut to repair hotspot area 1.
Min 35.9
Average 60.8 2 umbrellas, insulmould and SS anchors were used to
repair the hotspot
Sp1 77.5
The maximum temperature reduced from 430°C to
Parameters 78.1°C.
Emissivity 0.95
Refl. temp. 20 °C

Hotspot Area 2
Before
1/11/2017 5:41:11 PM °C 1/11/2017 5:41:11 PM
200.0
Bx1
41.1
Measurements °C
Bx1 Max 186.3
Min 98.1
Average 128.7
Parameters
Emissivity 0.95
Refl. temp. 20 °C
After
1/13/2017 5:28:32 PM °C 1/13/2017 5:28:32 PM
199.5
Bx1
41.1
Measurements °C
Bx1 Max 99.8 Note:
Min 87.5
1 hole was cut at hotspot area 2. It was
Average 93.5 repaired with 1 umbrella, insulmould and
SS anchors
Parameters
The maximum temperature reduced from
Emissivity 0.95
186.3°C to 99.8°C
Refl. temp. 20 °C

Hotspot Area 6
Before
1/11/2017 5:41:49 PM °C 1/11/2017 5:41:49 PM
Bx1 200.0
Sp1
41.1
Measurements °C
Bx1 Max 223.7
Min 103.5
Average 154.5
Sp1 185.8
Parameters
Emissivity 0.95
Refl. temp. 20 °C
After
1/13/2017 5:23:08 PM °C 1/13/2017 5:23:08 PM
199.5
41.1
Bx1 Max 86.5 2 holes were cut at hotspot area 3. It was repaired
Min 47.5 with 2 umbrellas, insulation mould and SS anchor.
Average 78.1
Parameters
Emissivity 0.95
Refl. temp. 20 °C

Hotspot Area 4
Before
1/11/2017 11:48:22 AM °C 1/11/2017 11:48:22 AM
200.4
Sp1
40.0
Measurements °C
El1 Max 321.6
Min 78.6
Average 205.1
Sp1 255.7
Parameters
Emissivity 0.95
Refl. temp. 20 °C
After
1/13/2017 5:14:33 PM °C 1/13/2017 5:14:33 PM
199.5
41.1
Bx1 Max 94.1
4 holes were cut at hotspot area 4.
Min 56.2
Average 79.3 The hotspot was repaired with 4 umbrellas,
insulmould and SS anchors.
Parameters Temperature reduced from 321.6°C to 94.1°C
Emissivity 0.95
Refl. temp. 20 °C

Hotspot Area 5
Before
1/11/2017 11:47:14 AM °C 1/11/2017 11:47:14 AM
200.4
El1
40.0
Measurements °C
El1 Max 413.0
Min 40.3
Average 227.2
Parameters
Emissivity 0.95
Refl. temp. 20 °C
After
1/13/2017 5:16:10 PM °C 1/13/2017 5:16:10 PM

199.5
Bx1
41.1
Bx1 Max 90.1
Min 32.1
3 umbrellas, insulmould and SS anchors were
Average 71.1
used to repair the hotspot.
Parameters The temperature reduced from 413°C to 90.1°C.
Emissivity 0.95
Refl. temp. 20 °C

Hotspot Area 6
Before
1/12/2017 9:25:28 AM °C 1/12/2017 9:25:28 AM
200.4
Bx1
40.7
Measurements °C
Bx1 Max 149.6
Min 69.3
Average 94.1
Parameters
Emissivity 0.95
Refl. temp. 20 °C
After
1/13/2017 5:18:04 PM °C 1/13/2017 5:18:04 PM
Bx1
199.5
Sp1
41.1
Bx1 Max 77.1
No holes were cut at hotspot area 6.
Min 64.4
The hotspot was repaired along with hotspot area
Average 73.5
7.
Sp1 48.8
The maximum temperature reduced from 149.6°C to 77.1°C
Parameters
Emissivity 0.95
Refl. temp. 20 °C

Hotspot Area 7
Before
1/11/2017 5:41:24 PM °C 1/11/2017 5:41:24 PM
200.0
Bx1
41.1
Measurements °C
Bx1 Max 425.7
Min 49.1
Average 178.8
Parameters
Emissivity 0.95
Refl. temp. 20 °C
After
1/13/2017 5:19:27 PM °C 1/13/2017 5:19:27 PM
199.5
41.1
Bx1 Max 97.4
Min 30.3
Average 68.5 The hotspot was repaired with 3 umbrellas,
insulmould and SS anchors
Parameters The maximum temperature reduced from 425.7°C to 97.4°C
Emissivity 0.95
Refl. temp. 20 °C

Hotspot Area
11
Before 11:46:12 AM
1/11/2017 °C 1/11/2017 11:46:12 AM
200.4
Bx1
40.0
Measurements °C
Bx1 Max 259.7
Min 52.0
Average 192.3
Parameters
Emissivity 0.95
Refl. temp. 20 °C
After
1/13/2017 5:16:25 PM °C 1/13/2017 5:16:25 PM

199.5
Bx1
41.1
Bx1 Max 82.1
3 holes were cut to repair hotspot area 8
Min 24.1
3 umbrellas, insulmould and SS anchors were used to
Average 56.3
repair the hotspot.
Parameters The maximum temperature reduced from 259.7°C to

Emissivity 0.95 82.1°C
Refl. temp. 20 °C

Hotspot Area
12
Before 5:40:39 PM
1/11/2017 °C 1/11/2017 5:40:39 PM
200.0
Bx1
41.1
Measurements °C
Bx1 Max 317.1
Min 47.4
Average 156.5
Parameters
Emissivity 0.95
Refl. temp. 20 °C
After
1/13/2017 5:12:47 PM °C 1/13/2017 5:12:47 PM

199.5
Bx1
41.1
Bx1 Max 85.0
4 holes were cut at hot spot area 9.
Min 36.8
The hotspot was repaired with 4 umbrellas,
Average 62.7
insulmould and SS anchors.
Parameters The maximum temperature reduced from 317.1°C to 85.0°C
Emissivity 0.95
Refl. temp. 20 °C

Hotspot Area 10
Before
1/11/2017 11:55:28 AM °C 1/11/2017 11:55:28 AM
200.4
Bx1
40.0
Measurements °C
Bx1 Max 452.8
Min 78.6
Average 334.5
Parameters
Emissivity 0.95
Refl. temp. 20 °C
After
1/13/2017 5:12:15 PM °C 1/13/2017 5:12:15 PM
199.5
Bx1
41.1
Bx1 Max 81.2
Min 24.1
4umbrellas, insulmould and SS anchors were
Average 60.7
used to repair the hotspot.
Parameters The maximum temperature reduced from
Emissivity 0.95 452.8°C to 81.2°C
Refl. temp. 20 °C

Furnace Hot Spot Repair Report Reformer Malaysia Jan 2017 PDF

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PROJECT TITLE:

HOTSPOT REPAIR AT A REFORMER WASTE HEAT SECTION FOR A MAJOR

Rev Date Status

0 16/01/2017 Issued for Information

1/13 Hotspot Repair Report, Malaysia, Jan 2017

2/13 Hotspot Repair Report, Malaysia, Jan 2017

4 holes were cut. Hotspot repaired

1 hole was cut. Hotspot repaired

2 holes were cut. Hotspot repaired

4 holes were cut. Hotspot repaired

3 holes were cut. Hotspot repaired

Hotspot Right Plate No holes were cut. Hotspot

5 holes were cut. Hotspot repaired

3 holes were cut. Hotspot repaired

4 holes were cut. Hotspot repaired

4 holes were cut. Hotspot repaired

8 additional anchors were added

3/13 Hotspot Repair Report, Malaysia, Jan 2017

4/13 Hotspot Repair Report, Malaysia, Jan 2017

2/13 Hotspot Repair Report, Malaysia, Jan 2017

6/13 Hotspot Repair Report, Malaysia, Jan 2017

7/13 Hotspot Repair Report, Malaysia, Jan 2017

1/13/2017 5:16:10 PM °C 1/13/2017 5:16:10 PM

8/13 Hotspot Repair Report, Malaysia, Jan 2017

9/13 Hotspot Repair Report, Malaysia, Jan 2017

7/13 Hotspot Repair Report, Malaysia, Jan 2017

1/13/2017 5:16:25 PM °C 1/13/2017 5:16:25 PM

Parameters The maximum temperature reduced from 259.7°C to

11/13 Hotspot Repair Report, Malaysia, Jan 2017

1/13/2017 5:12:47 PM °C 1/13/2017 5:12:47 PM

12/13 Hotspot Repair Report, Malaysia, Jan 2017

13/13 Hotspot Repair Report, Malaysia, Jan 2017

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