IGS launches Rovex robotic cleaning technology

A new advanced robotic technology from IGS, a provider of asset integrity and energy efficiency solutions for energy, power and heavy industry, is revolutioning fired heater maintenance

The company has launched Rovex, a compact remotely operated vehicle (ROV) specifically developed for fired heater convection sectrions. It is designed to improve access to complex tube geometries and remove heavy fouling with precision, enabling operators to maintain output, reduce costs and extend asset life.

Heightened focus on energy security, coupled with continued investment in refining and petrochemical capacity across the Middle East, is driving greater attention towards efficiency and reliability across critical assets. Fouling is a persistent challenge across refineries, restricting heat transfer and reducing efficiency. In steam crackers, even a 1% efficiency loss can cost operators several million dollars annually. In large crackers, the impact can exceed US$10 million annually when yield, energy, and lost production are included.

Savings and benefits

At a time when the industry is under significant cost pressures, the technology can drive significant savings. Rovex’s fully remote operation eliminates the need for confined-space entry, reducing exposure to
• High-temperature environments
• Hazardous combustion residues
• Risks associated with confined-space entry
• Respiratory hazards from airborne particulate matter

High-definition cameras provide operators with continuous visual feedback throughout operation, ensuring operational precision and confidence. Proprietary articulation systems allow the ROV to navigate between tube banks and access all convection section surfaces, including those previously considered unreachable by conventional methods. Integrating robotic mobility, patented lance technology, and digital performance verification, the system supports measurable improvements in efficiency, reliability, and emissions reduction through effective cleaning of stubborn deposits on furnaces and fired heaters.

Compared to traditional water jetting or manual techniques, which typically access 20-30% of fouled surfaces and can risk asset damage, Rovex enables consistent cleaning coverage over 90% of the surface area.

Each Rovex deployment is supported by a thermal performance evaluation, enabling IGS engineers to quantify efficiency losses and target cleaning activity. This approach allows performance improvements to be measured and verified.

“Rovex reflects our continued focus on combining engineering and robotics to improve maintenance outcomes,” said Eric Duvekot, VP Engineering at IGS. “It provides a practical way for operators to address fouling safely, before it leads to lost revenue, while achieving consistent and measurable performance improvements.”

Success story

Recent field applications have demonstrated the system’s impact. At Oman Methanol Company, Rovex restored convection section performance, reducing stack temperature by 93.2°F / 34°C and improving fuel efficiency by 1.8%, enabling a return to full production capacity while reducing fuel consumption and associated emissions.