In the chemical industry, replacing or incorporating critical equipment such as a process furnace or steam boiler does not depend solely on the manufacture of the equipment. It also requires an execution strategy that reduces on-site risks, limits downtime and allows installation and commissioning to be carried out with the highest possible degree of control.

In this context, AITESA is making progress in the supply of two pieces of equipment for the same customer in the chemical sector: a process furnace and a saturated steam packaged boiler.

Although they fulfill different functions within the plant, both projects respond to the same execution logic: anticipate as much as possible in the workshop to reduce uncertainty on site, facilitate coordination during shutdowns and prepare each unit for a more reliable integration in the plant.

In projects of this type, the value is not only in delivering the final equipment. It is also in how each unit is designed, manufactured, inspected, documented and prepared before it arrives at the plant.

The process furnace has reached an important milestone: the unit is ready to leave the workshop and start its transport to the customer’s facilities.

This step comes after months of engineering, purchasing, manufacturing, inspections and coordination. Seeing the equipment assembled and ready for shipment is the visible part of a work sequence that demands technical precision, shop discipline and continuous follow-up.

During the final manufacturing phase, the focus has been on closing critical pre-delivery activities:

• Final dimensional checks;

• Verification of alignments;

• Non-destructive testing according to code;

• Revision of critical welds and pressure parts;

• Verification of the traceability of materials;

• Documentary closure;

• Preparation of the equipment for safe transport;

• Logistics and plant delivery coordination.

The shipment of such a process furnace is not just a logistical milestone. It confirms that an extensive engineering, manufacturing, quality and documentation phase has been completed before moving on to the installation stage.

In this project, the collaboration of Proincar during the manufacturing phase stands out. Its technical capacity, commitment and coordination with AITESA’s teams have contributed to reach this point successfully.

The furnace is now one step closer to installation, commissioning and plant operation.

In parallel, AITESA is also manufacturing a saturated steam packaged boiler for the same customer, within an EPC project for the chemical industry.

When a plant needs to replace a steam generation unit, one of the main constraints is often downtime. Every activity that can be resolved before arriving on site helps to reduce uncertainty, simplify installation and accelerate the plant’s return to operation.

For this reason, the boiler is being assembled and pre-assembled in the workshop as a single module ready for shipment. This approach reduces field work, limits assembly risks and facilitates faster commissioning.

The unit has been designed to operate at 256 °C and 44 kg/cm², and incorporates the main elements necessary for reliable saturated steam generation:

• Water wall with finned tubes for heat absorption in the radiant zone;

• Tubular screen as a transition between the radiant and convective sections;

• Upper boiler for steam and saturated water separation;

• Lower boiler for saturated water circulation;

• Convective tubular bundles;

• Support structure, gas ducts and sealing systems;

• Sight glasses and access doors for operation and maintenance.

Although the process furnace and the packaged boiler have different functions within the plant, both projects share the same execution philosophy: to resolve everything technically possible in the workshop before arriving on site.

This approach allows anticipating constraints from engineering, coordinating purchasing and manufacturing from early stages, inspecting components in the shop floor, properly closing the documentation and preparing each piece of equipment thinking about the real installation conditions.

In practice, it brings value to the customer at several key points:

• Less work during shutdown;

• Reduced risk of on-site interference;

• Greater control over quality and documentation;

• Better coordination between manufacturing, logistics and installation;

• More confidence before start-up.

In critical equipment such as process furnaces and industrial boilers, reliability doesn’t start when the equipment goes into operation. It starts much earlier: in every design review, every welding procedure, every inspection, every dimensional control and every decision made during manufacturing.

These advances are the result of the coordinated work of many areas: engineering, manufacturing, quality, purchasing, project management, logistics, suppliers and specialized partners.

In the case of the process furnace, the collaboration with Proincar has been important during manufacturing. In the case of the boiler, the work with ALMESA is reinforcing the manufacturing capacity and quality control of the project.

Both collaborations reflect an essential part of AITESA’s way of working: combining technical know-how, workshop discipline and close coordination to deliver reliable equipment in demanding industrial environments.

With the process furnace now ready for shipment and the packaged boiler advancing in fabrication, the project continues to take important steps towards plant installation and commissioning.

These are visible milestones, but they are supported by many less visible activities: design reviews, material control, welding, inspections, dimensional checks, documentation, planning and daily shop floor coordination.

In industrial projects of this type, a solid execution before arriving on site is what allows the work in the plant to progress with greater safety, less uncertainty and more control.

Thanks to all the teams involved in these projects.

If your plant is considering the replacement, incorporation or revamping of a process furnace, an industrial boiler or a critical heat transfer equipment, AITESA can analyze the technical scope of the project and help you define the most appropriate solution.