Efficiency and Reliability Audio Case Studies

Integrated Global Services (IGS) has acquired Flamsprutarna AB, a provider of turbine maintenance and thermal spray services with over 40 years of experience. This acquisition expands IGS’s capabilities across gas turbines, steam turbines, and nuclear assets, strengthening its ability to support power generation operators with integrated, multi-technology solutions. In this episode, we cover what...

A case study outlining performance challenges at the 1040 MW Apex Four Corners coal-fired power station, where ash buildup, failed LPA screens, and degraded air cannon systems led to rising differential pressure, reduced output, and catalyst damage within the SCR system. The study explores the operational impact of ineffective cleaning and component failure, highlighting how these issues increased...

A case study on fired heater performance challenges at one of the world’s largest integrated refining and petrochemical complexes in India. The episode explores how refractory degradation, tube oxidation, and declining heat transfer efficiency impact fuel consumption, emissions, and long-term reliability, and why a holistic approach to fired heater integrity is critical for sustained efficiency at...

A multi-year case study of how HVTS cladding transformed a European biomass power station, from quarterly outages and recurring tube failures to predictable annual inspections and zero failures in protected zones.

An offshore platform faced pitting corrosion on stainless steel–clad slug catchers. HVTS was applied as a weld overlay alternative, achieving reliable corrosion protection under sour service conditions and delivering significant cost savings.

This episode explores a Gulf Coast refinery’s battle with severe H2S and HCl corrosion in critical stripper towers and a debutanizer. We cover the risks to reliability and safety, and how the refinery addressed these challenges during a major turnaround.

A refinery restored furnace efficiency and reduced stack temperatures through targeted maintenance solutions, avoiding costly operational downtime.

In this episode, we examine how a Middle Eastern petrochemical plant reduced costly shutdowns and improved reliability by applying IGS cladding technology inside a reactor for the first time. A practical look at implementation, challenges, and long-term results.

In this episode of The Efficiency and Reliability Podcast, we unpack Asset Vitality: IGS’s integrated approach to improving performance in power, petrochemical, and process industries. Discover how companies are cutting fuel use, boosting uptime, and extending asset life—without costly shutdowns or replacements. Real results, proven technologies, and global impact—this is Asset Vitality in action.

This episode explores how a Canadian refinery addressed complex corrosion and metallurgy challenges during its shift to renewable fuels using a faster, cost-effective thermal spray alternative to welding.

Severe corrosion was found in the amine still tower at P66 Giddings. Past fixes like coatings and weld buildup kept failing, causing recurring maintenance issues and rising costs.

In this episode, we cover a recent project at a methanol plant in the US where fouling in the primary reformer convection section reduced efficiency. We explain how precision cleaning restored heat transfer, improved steam output, and cut emissions—saving the plant up to $500,000 annually.

Amine stress corrosion cracking is a common issue in amine regeneration units, often leading to costly damage and downtime. This episode breaks down how it happens, why it matters, and what can be done to prevent it.

A petrochemical aromatics plant faced scaling and oxidation issues that reduced radiant tube life and efficiency. By applying Cetek ceramic coating, the plant increased throughput, reduced fuel use, and extended tube lifespan—achieving ROI in just six months and setting a new standard for heater maintenance.

In this episode of the Efficiency and Reliability Podcast, we dive into a Q4 2024 refinery turnaround in Saudi Arabia, where HVTS® technology helped overcome severe corrosion challenges, saving 10–12 days of turnaround time and providing a more cost-effective, long-term solution compared to traditional repair methods.

Learn how an aromatics plant tackled severe scaling and efficiency losses in its fired heaters. Discover the impact of oxidation on radiant tubes and the steps taken to improve performance and extend equipment life.

This episode explores the high-temperature corrosion challenges faced by a U.S. power utility’s GE 7HA gas turbine and their impact on maintenance and reliability.

A biomass-fired boiler in Sweden faced escalating erosion and corrosion, risking unplanned outages and costly failures. Discover the challenges this critical energy facility encountered and their impact on operations.

This case study highlights how HVTS metal alloy cladding provided a cost-effective and time-saving solution to protect a fractionation column, bringing it back into service without the need for a new column.

A petrochemical plant battled over 10 hotspots on a roof-fired reformer, exposed flames, and the threat of a $12 million loss—see how they avoided a full shutdown.

In this audio case study, we discuss how a Texas power plant with two CFB boilers overcame severe tube metal erosion and unpredictable wear rates by adopting IGS’ SMARTGard® High Velocity Thermal Spray solution.

Explore the 18-year impact of IGS Cetek dual emissivity coatings on coker heater tubes at a leading German refinery. Learn how these coatings optimize efficiency, extend run lengths, and enhance reliability, with insights on their application and ongoing benefits.

In this episode, Chris Landers of IGS discusses how the AirCannon Multiplier System improves material flow and enhances plant efficiency. Discover the key benefits and real-world applications of this innovative technology.

HVTS cladding helped a biomass power plant improve boiler efficiency, reduce maintenance costs, and extend equipment lifespan

Discover how Fireside ceramic coatings improve boiler protection by enhancing thermal spray performance, reducing porosity, sealing microcracks, and boosting wear resistance in high-temperature environments.