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HVTS – Thermal Spray Cladding

Introduction to High Velocity Thermal Spray

IGS’s High-Velocity Thermal Spray (HVTS) alloy cladding solutions upgrade existing metallurgy to higher alloys that provide a barrier to mitigate corrosion and/or erosion in mission-critical equipment around the world.

IGS HVTS solution prevents extended or unplanned shutdowns, reducing critical path and ensuring lasting integrity and reliability.

HVTS alloy cladding is recognized as an optimum solution for corrosion and erosion protection applied on-site by Malaysia’s refineries, agrichemical sites and power plants.

Features of HVTS

HVTS is made up of high-grade alloys such as Inconel® 622, Inconel® 625, Inconel® 825 and Hastelloy® C276, and modify them to provide optimal material characteristics for your specific equipment and environment. 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 is used as an alternative to weld metal overlay (WMO) and organics by Malaysian refineries, power plants and agrichemical sites since the IGS technology is more flexible and cost-effective. IGS HVTS is a robust solution that can extend the life of existing equipment.

HVTS Application

IGS HVTS does not require any curing time or bake out. It 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.

High Velocity Thermal Spray (HVTS) Alloy Cladding for process vessels, towers, columns and boilers can offer a long-term barrier (typically in excess of 10 years), freezing the internal metal condition of the asset. As a result, future shutdowns and maintenance requirements are reduced, increasing process productivity and availability. Rapid mobilization is also available in emergencies.

HVTS Application Areas

  • Process Vessels
  • Towers
  • Columns
  • Heat Exchangers
  • Piping
  • Boilers
  • Tanks

High Velocity Thermal Spray Benefits

IGS HVTS solution prevents extended or unplanned shutdowns, reducing critical path and ensuring lasting integrity and reliability. In erosive environments, HVTS cladding becomes a controlled protective sacrificial barrier that eliminates metal wastage and replacement indefinitely.

HVTS vs Weld Metal Overlay

The HVTS application is significantly faster than the 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.

HVTS vs Organic Coatings

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.

HVTS vs Other Thermal Spray Coatings

HVTS is “similar” to TWAS – twin wire arc spray. It is, however, very different in performance characteristics; TWAS has been around for almost 100-years, it atomizes material in a sub-sonic gas stream. HVTS atomizes in a super-sonic gas stream producing particles ~100X smaller, which are very flat. TWAS = large round particles; HVTS = tiny flat particles. The performance of HVTS cladding is in a completely different category as compared with TWAS in corrosion and / or erosion environments. Note, many TWAS equipment companies sell attachments to TWAS systems claiming them to be high velocity. They are not as is evidenced by the particle sizes only being marginally smaller than TWAS without such attachments.

HVTS Specification Compliance and Performance Testing

HVTS alloy cladding goes through rigorous testing within IGS’ in-house Technology Solutions Laboratory.

This State-of-the-Art Laboratory features:

  • Scanning Electron Microscope (SEM)
  • Laser surface profilometer
  • Potentiostatic testing
  • Heat transfer analyzer
  • High temperature erosion tester
  • Liquid and steam impingement tester
  • Salt Spray Chamber
  • Anaerobic chamber
  • Microvickers hardness tester
  • Metallurgical microscope
  • High Pressure Corrosion autoclaves
  • Blast and spray booths
  • High temperature thermal cycling furnaces
  • High temperature corrosive gas test chamber
  • Chemical exposure and immersion testing

“This is the way IGS operates. By making sure we understand our customers’ problems right from the get-go. We develop technologies that are going to give us the solutions and performance that we need down the line. We do that by operating side-by-side with asset owners and operators to achieve our joint mission – the reliable and safe operation of your equipment.”

Iain Hall, IGS Chief Technology Officer

Case Studies

Case Studies
Dissimilar Weld Corrosion in a Gas Line Prevented Hex Galvanic Corrosion Eliminated with HVTS
Hex Stress Corrosion Cracking Stopped 3 Years Maintenance-Free Specification
How a Plant Stopped CFB Boiler Tube Repairs Preventing Another Service Failure of the Sour Water Stripper
Column Shell Corrosion Protection Verified Putting a Stop to HFO Boiler Emergency Shutdown

 

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