Thermax’s remaining life analysis enables an oil and gas major to plan 20 years ahead with confidence

Project overview

An oil and gas company operating ageing industrial boilers faced growing concerns around safety, reliability, and regulatory compliance due to frequent breakdowns and high utilisation levels.

Thermax partnered with the customer to deliver a structured assessment approach that provided clear insights into asset health and remaining life. The engagement enabled informed long-term planning, improved operational confidence, and optimised lifecycle decision-making.

Challenges

An oil and gas company was facing recurring operational challenges and unexpected breakdowns because its six industrial boilers had been in operation for over four decades. The boilers were running at nearly 80% capacity, raising serious concerns around safety, reliability, and compliance. Without a precise understanding of the boilers’ remaining life, the company risked significant downtime costs, safety hazards, production losses, and regulatory non-compliance. To mitigate these risks and plan proactively for replacements, they sought a comprehensive Remaining Life Analysis (RLA) from an experienced and trusted partner.

Solution

Thermax conducted a detailed Remaining Life Analysis (RLA) of the six boilers. The project involved a hybrid assessment approach, combining an on-site visit with an exhaustive desktop study of over 30,000 pages of inspection data spanning 40 years. Using its deep OEM expertise and Babcock & Wilcox (B&W) proprietary RLA software, Thermax meticulously analysed the inspection history and provided data-backed recommendations for boiler pressure part replacement and burner management systems. While peer consultants had previously attempted the study, the company was not fully satisfied with their findings. Thermax’s technical precision, structured methodology, and adherence to international codes and standards distinguished the study from others.

Result

Thermax’s recommendations provided the company with a highly accurate prediction of boiler health and clear timelines for replacement and refurbishment. The study offered the confidence to plan long-term—up to 20 years ahead—with improved asset reliability and operational assurance. Thermax enabled the company to make informed maintenance and investment decisions, optimising lifecycle costs while prioritising safety and compliance.

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