Tubular Reactor Specialist

SAFETY, SPEED AND ACCURACY are key when performing a tubular reactor change out. It is vital that you partner with a company that has the expertise and latest technology to manage the job. Extended downtime, equipment damage or poor load quality will significantly impact your bottom line.

Maviro is a specialized service provider that is continuously developing and incorporating technology to improve safety, provide consistent results and reduce downtime.  By pairing Maviro’s wisdom with proven technology, like the SODI loader clients are experiencing a reduction in maintenance costs and are seeing higher production rates with improved yields.

The data collected and provided by Maviro during the turnaround gives the owners the confidence to maximize throughput while extending run lengths.

Maviro provides a ONE STOP TOTAL SOLUTION for your Catalyst Change out. Maviro catalyst's  bundled approach, which includes pre-planning – unloading – cleaning – loading and testing delivers a more consistent, predictable result with minimal downtime.

STEP ONE - UNLOADING

Fleet of modern, Tier 4 final high-volume vacuum units with electronic grounding systems. Depending on the customers specification or request we employ a number of techniques to efficiently remove the catalyst while protecting the integrity of the tubes. Air lancing, fish taping or stiff lances are methods used, by which catalyst particles are loosened with pressurized air and removed by vacuum.

If required by the customer, Maviro can screen, package, weigh the spent catalyst for disposal, reclamation or regeneration.

STEP TWO - CLEANING

Once the catalyst has been safely removed and contained, the inside of the reactor is inspected cleaned of deposits corrosion and other materials. Depending on the material, and client specification we will use specially designed wire brushes, abrasive blasting or high-pressure water blasting. Our teams are cross trained with our water jetting group and use the latest hands free multi tube jetting technology.

STEP THREE - LOADING

The most critical component of the process is the reloading of the catalyst. Maviro can utilize several techniques from manual to machines and has secured the exclusive rights to use the SODI tubular loading system. When using this system over 120 tubes can be loaded at a time with each unit. Not only does this provide a significant time savings – the technology results in an unprecedented level of accuracy, has a 2 stage de-dust eliminates a blow down step, accurately logs tube counts minimizes deviation and subsequent corrections. We also address and handle the mechanical components including support plates and springs

STEP FOUR - VERIFICATION/TESTING

Maviro uses a variety of techniques and technologies to inspect and verify the load quality and ensure no bridging has occurred. We will check the tubes (all or a percentage specified by the client) for differential  pressure drops (dP).  The system was developed in house uses flow controllers to allow for reliable air flow measurements. The data is transmitted to a computer that records logs and maps the tube sheet for quality control and analysis. The dP measurements shall not exceed +/- 3% of the average differential pressure of all measured tubes. Tubes that are out of spec will be corrected until they meet this tolerance criteria. Because of the accuracy of the SODI technology we are seeing results better than 2% with minimum corrections.