The Hidden Truths Of Heat Treatment

A Smart Approach to a Refinery-Wide Turnaround Saved 36%

Introduction

Superheat was founded in 2000, with the idea of a safer and more efficient way to provide heat treatment services. Today, Superheat is leading the heat treatment industry by integrating emerging communication technology, equipment advancements, and innovative software solutions. Through our Superheat SmartWay™ approach, control of your heat treatment process is consistent at all levels. Superheat manages on-site quality via remote monitoring technology, eliminating the need for non-productive monitoring personnel on the job site. This, in turn, reduces on-site labor requirements by up to 40% while mitigating safety concerns.

Background

Superheat performed heat treatment services during a refinery-wide turnaround for one of the largest petroleum companies in the United Kingdom. During planning stages, the project posed serious issues as the client had a limited knowledge of the work scope, due to the majority of the work being inspection-driven. This presented problems for the company’s work timeline during the turnaround.

Smart Solution

Using the Superheat SmartWrap™ program, 6 Superheat supervisors from the UK were on-site with 24 contracted insulators. The insulators underwent Superheat’s 16-hour Heat Treatment course prior to the turnaround. Combining training with Superheat SmartCenter™ monitoring, allowed for further reductions in on-site labor, with Superheat remotely overseeing the process. Using Superheat SmartView™ to provide project data in real-time, technicians were able to troubleshoot heat treatment cycles in-progress while maintaining a high level of quality. The insulators were only utilized for the wrapping and stripping of welds, which accounts for 33% of the heat treatment procedure.

Results

By utilizing these contractors on an as-needed basis, our client obtained a labor cost savings of 36% overall. The adjusted “wrench time” for the general insulation contractor was increased by only 3%. The Smarter Way to do heat treatment is here.