The Hidden Truths Of Heat Treatment

A Smart Approach to a Refinery-Wide Turnaround

Introduction

Superheat was founded in 2000 on the idea of a safer and more efficient way to provide heat treatment service. Today, Superheat is leading the industry by integrating emerging communication technology, equipment advancements, and innovative software solutions.

Through Superheat SmartWay™, we were able to control the heat treatment process at all levels. Superheat was able to manage the on-site quality by remote surveillance, allowing the elimination of non-productive on-site heat treatment cycle monitoring personnel. This, in turn, reduced on-site labor requirements by up to 40%, while mitigating safety concerns.

Background

Superheat performed Heat Treatment services for a refinery-wide Turnaround at a British refinery in the United Kingdom. During planning stages, the project posed a problem as the client had a limited knowledge of the work scope due to the majority of the work being inspection driven.

Smart Solution

Using Superheat’s Installing Partner Program, 6 Superheat Supervisors from the UK were on-site with 24 incumbent insulators. The insulators were given Superheat’s 16-hour Heat Treatment Installation course prior to the turnaround. Combining training with our Superheat SmartCenter™ allowed for further reductions in on-site labor, with Superheat remotely monitoring the process as a whole. Using Superheat SmartView™ to provide project data in real-time, technicians were able to troubleshoot the heat treatments in-progress while maintaining a high level of quality. The insulators were utilized only for the wrapping and stripping of welds, which makes up 33% of the heat treatment procedure cycle.

Results

By utilizing these nested contractors on an as-needed basis, our client obtained a labor cost savings of 36% overall. The adjusted “wrench time” for the nested insulation contractor was increased by only 3%.

The Smarter Way to do heat treatment is here.