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 the acquisition means, how the combined capabilities enhance outage execution and asset reliability, and what this signals for the future of global power plant maintenance.

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 maintenance demand, safety risks, and emission compliance pressure over time. PHL

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 scale.

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.

In this podcast, we explore how Cementos Panam improved production efficiency by overcoming raw material humidity issues with IGS air cannons and multipliers.

Learn the latest materials and techniques that combat internal pipeline corrosion, including IGS's Metalspray Pipe ID cladding, which enhances durability, safety, and cost-effectiveness across oil and gas infrastructure.

In this episode, we explore the importance of high emissivity coating durability for fired heaters and how it enhances process efficiency while reducing fuel consumption. Join us as we discuss key factors such as surface preparation, application techniques, and quality control measures that ensure long-lasting performance in extreme operating environments.

Discover how IGS played a key role in the success of the Ras Tanura Refinery 2024 Mega Turnaround.

This episode discusses an ethylene furnace's declining fuel efficiency and increased emissions over six years due to fouling, with limited options for cleaning.

This audio case study highlights the importance of treating vacuum heater systems as a single unit to optimize refinery operations, addressing the impact of phase separation and tube coking on efficiency and safety.

The copper smelter’s waste heat boilers, used to recapture heat, faced significant issues with corrosion, erosion, and accretion due to SO2 and other contaminants. The previous coatings, while somewhat protective, exhibited cracking and spalling, necessitating an effective solution to mitigate these problems and reduce maintenance costs.

Discover how a petrochemical plant struggled with persistent erosion and frequent costly shutdowns, leading to significant production losses and safety issues, and how they turned to IGS for a custom solution to tackle these challenges.

Chief Technical Officer Iain Hall discusses how IGS's technology addresses energy companies' biggest challenges around reliability, efficiency, and reducing fuel consumption.

In this audio case study, Nugen Energy faced a significant challenge when their facilities began experiencing refractory failures, requiring extensive downtime for repairs. This downtime not only halted production but also led to substantial financial losses, nearly $6.59 million per incident.

Integrated Global Services (IGS) deployed Tube Tech’s engineered VCFE cleaning solution to remove fouling from 2688 tubes across two Texas Towers. 100% of tubes were cleaned to a production standard and 10% of tubes received enhanced cleaning for IRIS inspection.

This episode explores the issue of oxidation scale formation on steel tubes in fired heaters. This problem disrupts heat transfer, causing over-firing, high bridgewall temperatures, and reduced production rates.

Today, we'll delve into a case study surrounding the challenges faced by a plant due to erosion and corrosion in their waste heat recovery system, and how they tackled this issue without compromising plant availability or production.

This audio case study is about fouling challenges faced by a petrochemical company. There is a crucial need to restore heater efficiency and operational reliability, leveraging advanced robotic technology in alignment with the company's commitment to sustainability, this process generated minimal waste.

A refinery faced a challenge during a turnaround project in 2022, aiming to enhance hydrotreater efficiency with a unique convection section configuration dedicated solely to boiler feed water heating, lacking process coils. This setup presented an opportunity to maximize processing efficiency in the radiant section, which required an innovative approach to optimize radiant heat transfer efficiency.

A prominent player in the Japanese market, this energy company operates several refineries across the country, including Miyagi, Ibaraki, Chiba, Kanagawa, Okayama, Yamaguchi, and Oita, facing various corrosion and erosion challenges in critical refinery equipment, leading to premature deterioration and costly repairs or replacements during turnarounds.

In this audio case study, we discuss the corrosion challenges within a sulfolane unit, showing why it's important for proactive maintenance strategies to safeguard operations and reinforce commitments to process safety, efficiency, and environmental responsibility.

A critical issue arose during the construction of a groundbreaking direct air capture facility in the US Gulf Coast, risking the project timeline and costing over $500k per day in delays, as a particular coating specification for a vessel proved inadequate for the required environment and temperature ranges, requiring urgent intervention to prevent further setbacks. The urgency was heightened by the need to address the problem during the New Year holidays.

In this episode, Larry Emch, Furnace Efficiency Specialist from IGS, joins us again to discuss a project where his team audited furnaces and heaters at an oil and gas site, identifying inefficiencies and offering solutions for increased production, including a notable 13.5% improvement, and long-term efficiency.

In this audio case study, we discuss a situation at a Gulf Coast chemical plant where an ethylene furnace encountered a hot spot challenge, requiring prompt action.

In this episode, we're joined by Kevin Phillips, Director of Business Development for Integrated Global Services and a Thermal Spray expert. He discusses a Pulp and Paper CFB Boiler dealing with extreme erosion issues, worsened by the presence of plastics, resulting in corrosion problems. The boiler experienced forced outages due to tube leaks, leading to frequent mechanical repairs. Fast forward six years later, and there are no tube leaks or forced outages. Items discussed in the episode:   Difference Between High Velocity Thermal Spray and Low Velocity The True Cost of Metallurgy Cladding for Pulp and Paper CFB Boilers The Dangers of Continued Forced Outages for CFB Boilers What Is the Duration of the Agreement or Partnership Between IGS and Its Clients?

In this audio case study, we discuss how refineries can instantly reduce fuel consumption and save costs with the process tube Hot Tube Descaling process on their live heater.

In this audio case study, we'll talk about the changing maintenance strategy of the power plant operating two Circulating Fluidized Bed boilers. In 2015, they required 500 tube repairs across their units, leading to severe production disruptions. We'll explain why their boiler reliability was compromised and what they learned from it.

In this audio case study, we explore how a copper smelter addressed extensive downtime, high replacement costs, and logistical challenges associated with their waste heat boiler.

In this audio case study, discover how IGS's Hot Refractory Repair prevented a potential $156 million shutdown cost for a Central Asian oil and gas producer. It also highlighted the crucial role of proactive maintenance in sustaining uninterrupted energy production.