High Velocity Thermal Spray (HVTS) alloy cladding
IGS’s High Velocity Thermal Spray (HVTS) solutions upgrade existing metallurgy to higher alloys that provide a barrier to mitigate corrosion and / or erosion in mission critical equipment around the world. This alloy modification is essential to success of these material types when applied with thermal spray processes, as the materials are significantly changed through rapid heating, oxidation, and cooling. IGS modified alloys meet or exceed the performance characteristics of their wrought alloy analogs after application. HVTS can be used as an alternative to weld metal overlay (WMO) or organics since the IGS technology is more flexible and cost effective. IGS HVTS is a robust solution that can extend the life of existing equipment.
The HVTS application is significantly faster than weld metal overlay. Combine that with material and labor savings, and the HVTS solution provides excellent up-front cost reduction and long-term ROI. These time and cost savings are often as much as 50% compared to other technologies. Furthermore, HVTS doesn’t create a Heat Affected Zone (HAZ) and therefore will require no post weld heat treating (PWHT) as with weld overlay applications, saving more time and putting your equipment under less stress.
IGS HVTS has one major advantage against organic coating: HVTS does not require any curing time or bake out. HVTS is also insensitive to atmospheric temperature and humidity, this means HVTS application can reduce critical path turnaround time by up to ten days, bringing your unit back into operation that much sooner. HVTS does not have the low service temperature limitations that organic coatings do, as metal coatings can withstand much harsher environments, and are resistant to impact damage that may commonly occur during a turnaround.
IGS is the industry leader in on-site corrosion protection for mission critical equipment. Operating on site, in turnarounds and shutdowns and in confined spaces is a challenging requirement. This is the primary work of IGS.
We have performed over 4,000 site projects and installed millions of square feet of reliable surface protection with metal cladding for our customers, wherever they are around the world. Our ability to extend the life of existing equipment provides our customers with a great opportunity to protect their existing boilers and vessels and avoid costly replacement without sacrificing long-term reliability.
Excessive fouling in the convection section of fired heaters and furnaces results in higher fuel consumption to achieve the required output. This causes high stack temperatures, reduced heat transfer, and increased emissions, which can lead to government fines and environmental damage. Fouling occurs ...
Cetek’s patented Dual Emissivity Ceramic Coating technology manipulates and optimizes the heat flux distribution in DCU heaters which would otherwise be susceptible to coking inside tubes.
We designed the dual emissivity coating system to maximize benefits based on the coking pattern of ...
Occasionally, tube supports (wall and roof) in the radiant section of process heaters fail, allowing the process tubes to potentially get out of alignment (sagging or bowing) or even worse, rupturing.
IGS Hot-tek provides on-line repair service to stabilize the process tubes while the heater ...
Thermal Inefficiencies. In a high temperature environment, steel alloy process tubes will oxidize immediately and scale will develop. This oxidation scale layer acts as an insulator and will lead to a decrease in heat transfer as the scale increases in thickness. To compensate for the insulating effect ...
Hot Spot Repair in Live Heaters. Hot spots in the shell of the fired heater limit capacity and can cause a forced shutdown. Our experienced global team mobilizes at short notice to repair refractory online.
What is Refractory Failure?
The refractory may fail prematurely due to the ...
IGS’s High Velocity Thermal Spray (HVTS) solutions upgrade existing metallurgy to higher alloys that provide a barrier to mitigate corrosion and / or erosion in mission critical equipment around the world. This alloy modification is essential to success of these material types when applied with ...
How many times have you been reminded that fired heaters have the greatest running cost of fixed equipment on your site?
Most fired heaters experience a drop in thermal efficiency over time with degradation coming from both radiant and convective sections.
For many units that can ...
Is your fired heater limited by bridge wall temperature, or firing duty? Instead of a full scale revamp, we may address these issues may by the application of Cetek’s High Emissivity Ceramic Coatings to the refractory surfaces. Cetek High Emissivity Ceramic Coatings provide improved efficiency of ...