In 2024, one of the large-scale renovation works within the technological infrastructure of the Heydar Aliyev Oil Refinery was the comprehensive repair and modernization of reactor and piping systems successfully carried out by Caspian Engineering Solutions. This project aimed not only to address the refinery’s critical process lines but also to renew the internal protective coatings of the R-301 series reactors and enhance their technical durability.

Within the scope of the project, extensive technical inspections were conducted on the internal and external pipes related to product, steam, technical water, fire water, cooling water, and furnace systems. As a result, segments that had reached the end of their service life and posed potential risks were dismantled and replaced with new materials amounting to a total of 18,000 WDI (Weld Diameter Inch). The pipe replacements were executed with on-site welding, leakage tests, and supervised by Non-Destructive Testing (NDT) methods.

The most technologically complex part of the work was the replacement of protective metal coatings located inside the R-301.1/2/3/4 reactors and their bunkers. Within the reactors, 25 m², and in the bunkers, 250 m² of damaged bimetal and stainless steel layers were completely removed. New metal layers resistant to high temperatures and chemical loads were welded and installed in their place. These coatings play a critical role in maintaining both the reactors’ internal structural integrity and the stability of operational processes.

All stages of the project — inspection, dismantling, installation, and testing — were completed within a total of 30 calendar days. This achievement once again demonstrated the agility, technical expertise, and coordinated teamwork of the Caspian Engineering Solutions team.

This repair process is not only a restoration of existing systems but is also regarded as a strategic modernization measure that ensures the refinery’s long-term technological sustainability.