When refinery outages cost millions of dollars per day, there’s no room for delays or quality compromises. A recent emergency coating project put our rapid response capabilities to the ultimate test – and demonstrated why proper planning and execution matter when time is critical.
The High Cost of Refinery Downtime
Industry studies reveal sobering statistics about refinery outage costs. Research conducted from 1999-2005 in the Gulf Coast Region found that production losses during outages ranged from 8.2% to 33% annually.
For perspective, consider a refinery producing 100,000 barrels per day:
- Minimum daily loss: 8,200 barrels
- Maximum daily loss: 33,000 barrels
With crude oil prices, these numbers translate to millions in lost revenue every single day of extended outage time.
An Unplanned Emergency During Routine Maintenance
During what should have been a routine plant maintenance outage, engineers discovered a serious problem: aggressive galvanic corrosion attacking cooling water heat exchanger components.
The damage was extensive and immediate:
- Mild steel components showed severe corrosive attack from galvanic coupling
- Four brass tube heat exchangers required immediate protective coating
- 17 additional exchanger head components needed emergency treatment
The Challenge: Five Days or Millions in Losses
This “repair” work was completely unplanned, but the plant’s outage schedule was fixed. The requirement was absolute: all equipment had to be coated, cured, and ready for reinstallation within five days.
Missing this deadline would extend the outage and cost millions in lost production.
received at Curran shop.
Our Emergency Response: Systematic Excellence Under Pressure
As trucks loaded with damaged exchangers rolled into our shop, Shop Manager Richard Rodriguez and his crew immediately began comprehensive evaluation and planning.
Initial Assessment and Problem Identification
Visual inspection revealed multiple serious issues:
- Crevice corrosion on carbon steel tube sheets at brass tube joints
- Corrosion pitting on channels, primarily affecting divider plates
- Failed previous coating showing blistering, cracking, and adhesion failure
- Galvanic coupling damage between dissimilar metals
Critical Surface Preparation Steps
Pre-Blast Preparation Protocol
Before any grit blasting begins, we follow strict preparation procedures:
- Surfactant rinsing of all equipment to remove surface contaminants
- Complete equipment evaluation for substrate abnormalities requiring special attention
Advanced Contamination Testing
After grit blasting, we conduct C S N testing (Chlorides – Sulfates – Nitrates) to detect soluble salts on surfaces.
This step is critical because grit blasting alone doesn’t remove these contaminants – even when achieving “white metal” cleanliness. Chloride salts remaining on white metal surfaces can promote under-coating corrosion and eventual coating failure.
NACE 1 “White Metal” Standard
Our standard blast cleaning achieves SSPC-SP 5 / NACE 1 White Metal Standard, ensuring:
- Excellent coating adhesion through proper surface profile
- Extended coating life through complete contamination removal
- Documented quality control with all results recorded in Job Quality Control Logs
Precision Coating Application
Protective Masking and Preparation
Before coating application:
- Gasket surfaces on flanges and tube sheets protected from blast and coating
- Tube internals masked to prevent contamination
- Strategic taping and plugging ensures only intended areas receive coating
High-Build Application Technique
Our Curran 500™ coating system application process:
- Generous application in heavily corroded areas for high-build protection
- Spatula application forces coating deep into crevices and pits
- 3-inch brush smoothing creates uniform coverage and finish
- Light sanding between coats for optimal surface geometry
Final Finish for Performance
The final coating application creates:
- Smooth, high-gloss finish that reduces drag and fouling buildup
- Temperature-resistant properties that maintain finish integrity
- Easy-clean surface for more efficient future maintenance
Controlled Curing Process
Proper curing is essential for coating performance:
Natural Gas Fired Oven System
- Precise temperature control ensures optimal curing conditions
- Force-cured process eliminates variables and accelerates timeline
- Uniform heat distribution through large oven capacity
Protective Transportation Preparation
- Plastic and cardboard wrapping protects finished surfaces
- Road debris protection maintains coating integrity during transport
- Ready-for-installation condition upon arrival at refinery
Project Success: Delivered Early with Quality Excellence
The project planned for four days was completed with time to spare.
When the coated equipment arrived at the refinery, it was immediately ready for service – no delays, no quality issues, no extended outage costs.
Key Success Factors
Systematic Approach
- Immediate mobilization of experienced crew and resources
- Comprehensive quality control at every step
- Proven processes adapted for emergency timeline requirements
Quality Standards Under Pressure
- No shortcuts in surface preparation or contamination testing
- Full NACE standards maintained despite time constraints
- Complete documentation of all quality control measures
Economic Impact
Our rapid response and quality execution helped the client:
- Meet critical outage timeline without costly extensions
- Avoid millions in lost production from delayed restart
- Extend asset life through proper protective coating application
Why Emergency Response Capability Matters
This project demonstrates several critical capabilities:
Rapid Mobilization
- Immediate resource allocation when emergencies arise
- Experienced personnel who can work effectively under pressure
- Complete shop facilities capable of handling large emergency projects
Quality Under Pressure
- Proven processes that don’t compromise under tight deadlines
- Advanced materials and methods that deliver long-term performance
- Complete quality control maintained even in emergency situations
Economic Value Delivery
Our emergency response capabilities help clients:
- Minimize outage extensions and associated costs
- Maintain production schedules through reliable service delivery
- Protect asset investments with quality protective coatings
Ready for Your Next Challenge
Whether it’s planned maintenance or emergency response, our systematic approach to protective coating delivers the quality and timeline performance your operations demand.
Contact us at (281) 339-9993 or reach out to David Lopez at dlopez@curranintl.com to discuss your coating requirements. Our proven methods and emergency response capabilities ensure your critical equipment gets the protection it needs, when you need it.
When refinery downtime costs millions per day, quality coating work on aggressive schedules isn’t just a service – it’s an economic necessity. We deliver both.
