OPERATIONS & MAINTENANCE
CLADDING BOOSTS EFFICIENCY How cladding can help manage boiler corrosion
I
n waste-to-energy (WtE) plants, operational efficiency and minimal downtime are crucial for both environmental
and financial reasons. A recent case study from Turin, Italy, demonstrates how innovative technology can significantly improve plant performance and extend maintenance intervals.
THE CHALLENGE The WtE plant in Turin, commissioned in 2014, faced a common problem: corrosion of boiler pressure parts. After several years of operation, water wall pressure part metal wastage was identified in the second pass of the boiler. The plant needed a solution that would protect the carbon steel tubes without causing extended outages or delays in their turnaround schedule.
FINDING A SOLUTION: HVTS CLADDING High Velocity Thermal Spray cladding, provided by IGS, emerged as the preferred solution. Unlike traditional weld overlay methods, HVTS is not a welding process and doesn’t require the same rigorous approvals. This meant the plant could proceed with its planned outage without delays. In 2019, IGS Europe was contracted
on an emergency basis to apply their proprietary HVTS alloy cladding to a 159m2
area in the second pass of the
boiler. The application covered four water walls, including the division wall, providing a protective barrier against degradation.
UNEXPECTED CHALLENGES AND QUICK SOLUTIONS During a follow-up inspection in 2020, while the HVTS cladding was found to be in good condition, the plant identified degradation in the unprotected pendant screens in the same area. IGS quickly mobilised to protect these hanging panels, according to the company, This
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High emissivity coating was applied to refractory lining
demonstrated the flexibility and rapid response capabilities of the HVTS solution.
IMPRESSIVE RESULTS The implementation of HVTS cladding, along with other strategic measures, led to significant improvements in the plant’s performance between 2019 and 2023:
1. Extended maintenance cycles The interval between turnarounds increased from 12 to 18 months, reducing downtime and enhancing operational continuity.
2. Improved plant availability Overall plant availability rose from 88% to 93%, representing a crucial 5% increase in operational capacity.
3. Cost efficiency Despite inflationary pressures, maintenance costs decreased, contributing to improved financial performance.
4. Increased waste processing The 5% boost in availability translated to an additional 18 days of operation
annually, enabling the facility to process an extra 10,000 tons of waste through the boiler.
This case study highlights the potential of HVTS cladding as a preventative maintenance solution in the power industry. By protecting critical components from corrosion and degradation, HVTS technology allows plants to optimise boiler performance, extend operational periods between planned maintenance interventions, and enhance overall efficiency. In conclusion, the Turin case study
serves as a compelling example of how targeted technological interventions can yield significant improvements in plant performance. The rapid application of HVTS cladding, compared with the time- consuming process and approval of weld overlay, proved crucial in minimising downtime and maximising operational efficiency.
For more information visit:
www.integratedglobal.com
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