Integrated Global Services (IGS) has delivered major gains in reliability, efficiency and long-term asset integrity for one of India’s largest private-sector energy operators, reinforcing its growing footprint across the country’s rapidly expanding refining sector.

 

As India emerges as one of the world’s fastest-growing oil markets, refiners are facing intensifying pressure to maximise efficiency, extend asset life and minimise downtime. Ageing infrastructure and harsher operating conditions mean even minor failures can escalate quickly, driving operators to adopt proven technologies and proactive maintenance strategies that safeguard critical equipment.

 

The refinery—one of the world’s largest integrated refining and petrochemical complexes—processes more than 1.2 million barrels of oil per day and operates more than 20 fired heaters across India. Like many large-scale facilities, it was confronting refractory degradation, process tube oxidation, carburisation and declining heat-transfer efficiency, all of which threatened performance and reliability.

 

Partnering with IGS, the operator deployed advanced surface-protection and performance-enhancing technologies designed to extend asset life and improve operational stability.

 

“Our long-term partnership with this refinery is focused on unlocking sustained efficiency, reliability and reducing operational risk across their mission-critical equipment. By combining technologies such as ceramic coatings for fired heaters and HVTS alloy cladding for process vessels, we are helping them operate cleaner, longer and more reliably,” said Ed Griffith, Managing Director, APAC at IGS.

 

IGS supported the refinery with online Hot-tek service repairs and the application of Cetek high-emissivity coatings to improve fired heater performance. The upgrades delivered productivity gains of up to 10%, a payback period of less than six months and more than US$ 4 million in annual energy savings, leading the operator to expand the programme across additional units.

 

Early inspections have confirmed the upgrades are performing as intended. The refinery is now planning to deploy HVTS alloy cladding during upcoming turnarounds, further extending asset life and reducing future downtime.

 

The project highlights a wider industry shift toward proven, high-impact solutions that enable refiners to boost energy efficiency, protect critical assets and remain competitive in an increasingly demanding market.