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.