Upgrading the R501-C Reactor at Bandar Imam Petrochemical Complex: A Remarkable Achievement by Sheghafzar Company
Sheghafzar Company, a leading engineering and industrial equipment maintenance firm, successfully executed a major project to upgrade the R501-C reactor at the VC unit of Bandar Imam Petrochemical Complex. This project aimed to enhance performance, increase efficiency, and reduce maintenance downtime. Through collaboration with international partners and the use of advanced technologies, Sheghafzar achieved outstanding results. Below are the key details and outcomes of the project:
1. Procurement of High-Quality Bare Tubes
Sheghafzar, in collaboration with TUBACEX Spain, procured Bare Tubes made of A347H superalloy with a diameter of 127 mm and a thickness of 12 mm. This superalloy was chosen for its exceptional resistance to corrosion and high temperatures, making it ideal for the reactor's harsh operating conditions.
2. Upgrading Fin Tubes with Advanced HF Welding Technology
In partnership with Delfin Spain, the design of the Fin Tubes was upgraded from spiral elongated type to HF Welded type This innovative method involves welding the fins to the tube surface, significantly improving heat transfer efficiency and reducing energy losses.
3. Precision Manufacturing of Elbows and Return Bends
Elbows and Return Bends were manufactured from A351-Cf8c superalloy byFASER Italy using advanced casting techniques. To ensure quality and integrity, 100% radiographic testing was performed on all components.
4. Domestic Production of Tube Sheets and Baffles
To support local manufacturing and reduce dependency on imports, tube sheets and baffles for the convection section were produced domestically using A351-Cf8c superalloy This initiative not only reduced costs but also demonstrated the capability of local industries to produce world-class components.
5. Professional Assembly of the Convection Section
The complete assembly of the convection section was carried out by Sheghafzar using a specialized fixture for transportation and installation. This precise and professional process significantly reduced overhaul time and extended the reactor's operational life.
Key Achievements of the Project
60% Reduction in Overhaul Time: The project drastically cut down maintenance and repair time.
More than Double the Operational LifeSince 2016, the R501-C reactor has been operating without any issues.
Improved Heat Transfer Efficiency: The upgraded Fin Tube design and HF Welding technology significantly enhanced the reactor's performance.
Sheghafzar's Pivotal Role
Sheghafzar Company played a critical role in managing and executing this complex project. From procuring components to final assembly, the company demonstrated exceptional technical expertise and professionalism. This success highlights Sheghafzar's capabilities in industrial equipment maintenance and sets a benchmark for similar projects nationally and internationally.
This project marks a significant step forward in improving efficiency and reducing costs in Iran's petrochemical industry. It showcases how collaboration between domestic and international companies can lead to remarkable achievements in the oil and gas sector.