Unlocking New Possibilities in Steam Reformer Maintenance
In the world of ammonia, methanol, and hydrogen production, steam reformers are critical—but their convection coils often go overlooked due to the difficulty of inspecting and maintenance challenges. That’s where a new approach is making waves: ultrasonic smart pigging combined with advanced mechanical cleaning.
The Challenge: Hidden Risks in Convection Coils
While radiant tubes in steam reformers are routinely inspected, convection coils—especially those connected to common headers—are frequently left unchecked. The reasons? Limited access, complex coil configurations, and the impracticality of traditional inspection tools. As a result, many plants rely on conservative estimates of tube life, risking unexpected failures and inefficiencies.
The Breakthrough: A Case Study in the Middle East
A methanol plant in the Middle East decided to challenge the status quo. With 100 natural gas preheater coils that had never been cleaned and inspected, the plant partnered with Quest Integrity to implement the Heater Integrity Optimization solution to overcome these challenges with innovative technology that allowed the cleaning, inspection and assessment of the coils without removing the common headers thereby saving valuable time and costs.
The Results: Efficiency, Safety, and Profitability
The inspection revealed severe internal fouling in the coils, with some completely blocked, significantly impairing performance. Additionally, localized wall loss upwards of 40% was observed in the straight pipes, along with general thinning in the return bends. After cleaning and inspection, the plant achieved a remarkable 60% improvement in heat transfer efficiency. These efforts not only restored operational throughput but also provided assurances that the plant could operate the coils safely for the next four years.
Beyond Methanol: Applications in Fertilizer Plants
The same techniques are now being used in fertilizer plants to monitor flue gas cooler coils and feed gas coils. In one case, annual smart pigging inspections help track corrosion caused by intermittent water flow—preventing future failures and validating corrective actions.
A Smarter Way Forward
This case study proves that with the right tools and strategies, even the most inaccessible parts of a steam reformer can be effectively inspected and maintained without costly modifications. Smart pigging and mechanical cleaning not only enhance safety and reliability but also unlock hidden performance gains—turning maintenance into a strategic advantage.
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Tim Haugen
Director, Process & Refining
Quest Integrity
