On August 20, 2025, BIC Magazine hosted a webinar, "Advanced unheading system installations: Reducing downtime, enhancing coker safety," which brought together industry experts to share insights on delayed coker turnarounds and the challenges of lifting, installing and maintaining equipment under demanding conditions.
Sponsored by TF Companies and DeltaValve, the session offered valuable insights from refiners, contractors and engineers.
The panel, consisting of Chad Beckemeyer with TF Companies, Pablo Gonzalez and Brian Liccioni with DeltaValve focused on execution: planning, experienced crews and proactive coordination driving successful outcomes. Attendees asked about common field challenges such as drum deformation, concrete damage, crane logistics and maintenance cycles.
"We try to stay on a five to seven-year rework plan because of life cycle fatigue on wear components. Some refiners push further, but staying ahead is key to reliability," noted Brian Liccioni, emphasizing the need of maintenance planning.
Chad Beckemeyer stressed constructability noting that "you only have a few inches to play with when removing these valves… that’s where we concentrate early. If you don’t plan for those inches, you risk days of delay." Beckemeyer also highlighted size and weight considerations as the parts are not everyday valve replacements. It is an extraordinary challenge to move an 80,000-lb, 30-foot-long valve, by lifting it with a crane and maneuvering it into a structure with only inches of clearance.
He added, "Retrofits demand that we verify headroom, orientation and rigging plans well in advance." He also said, "Preturnaround planning is about reducing surprises. By preparing as much as possible ahead of the outage, we can focus on installation rather than troubleshooting once the turnaround begins."
Pablo Gonzalez stressed precision: "Before installation, check the runout. Eighty percent of the time, the drum is not flat. If you skip that step, you create problems that ripple through the entire installation."
The discussion covered retrofits and new installations. Older drums may shift, warp or erode, complicating the job. Pre-turnaround preparation — modular piping, foundations, staging — keeps outages on schedule. Adaptability was key. "No two turnarounds are alike. The field will always throw you a curveball. The team’s experience allows us to adjust quickly and keep things moving," said Beckemeyer. Environmental factors, crane reach and tight workspaces were also highlighted as points of interest in turnarounds.
Size and logistics matter. "Everything depends on site logistics, tonnage and the distance drums must be moved. That’s why meticulous planning and experienced field execution are crucial to control costs and schedule," Beckemeyer noted. Attendees also learned about spare valves and on site vs. shop-based maintenance to reduce critical-path delays.
Key lessons for refiners and contractors:
• Early evaluation of drums, cones and concrete conditions
• Detailed rigging and lift planning in constrained spaces
• Pre-turnaround preparation of modular components and foundations
• Maintenance planning with spares and shop/on-site service strategy
• Flexible execution to handle unforeseen field conditions
Technology sets the stage, but field experience delivers results. The right contractor brings decades of practical experience, proactive problem-solving and seamless coordination between engineering, construction and maintenance teams. Working with an experienced team like TF ensures turnarounds run safely, efficiently and on schedule. Refiners considering unheading system installations or upgrades can reduce downtime and risk with proper planning and hands-on expertise.
For more information, visit tf-companies.com.
