| HRSGs and boilers
● Overcrowded outages and co- ordination challenges
Attempting to execute multiple activities simultaneously in confined boiler environments can compromise safety, quality, and productivity. Effective planning and contractor co-ordination are essential to avoid delays and rework.
Welding execution and outage delivery While material selection is important, field experience shows that execution quality, especially under outage conditions, is the key determinant of long-term performance.
High-quality weld overlay depends on:
● precise control of welding parameters; ● consistent bead geometry and full overlap; ● proper surface preparation (eg, SA3 cleanliness); and
● controlled heat input to avoid distortion and defects.
Automated welding systems, combined with experienced operators, enable consistent quality and efficient execution within tight outage windows. However, European waste-to-energy plant outages are highly constrained, often involving multiple contractors in confined spaces.
Success, therefore, also depends on:
● detailed pre-outage planning; ● adequate resources and skilled personnel; ● right-first-time execution to minimise rework; and
● effective co-ordination on site. Ultimately, the ability to maintain quality under pressure and to stop and correct issues early is what separates durable repairs from short-term fixes.
How to achieve long-term reliability
In summary, waste-to-energy boilers operate in uniquely aggressive environments driven by chlorine chemistry, fuel variability, and demanding efficiency targets. In this context, long-term reliability
requires a combination of: ● deep understanding of corrosion mechanisms;
● structured inspection and monitoring programmes;
● strategic selection of protection methods; and
● high-quality execution of welding processes. Weld overlay, when properly designed and executed, provides a powerful tool for managing corrosion and extending asset life. However, its success ultimately depends on expertise in both materials and field application. As European waste-to-energy plants continue to evolve, operators who adopt a proactive, lifecycle-focused approach, supported by high-quality welding capabilities, will be best positioned to maintain reliability and optimise performance over the long term. .
Visual inspection of failed boiler tube protection. Photo: IGS
www.modernpowersystems.com | October 2026 | 21
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