Case studies

Power Generation Industry

Corrosion and erosion by high temperature gas

Equipment details

Type: 60 MW gas turbine

Location: Barge – Seashore, Dominican Republic

Problem description

Issue: severe erosion and corrosion observed on the main turbine casing.

Cause: continuous exposure to high-temperature, high-velocity combustion gases.

Impact: degradation of casing integrity, resulting in reduced turbine performance and elevated risk of unplanned outages or catastrophic failure

Proposed solution

Apply a thermal spray cladding of 200–500 μm Aluminum Grade 1100 to the affected casing surfaces.

Outcome

Enhanced resistance to corrosion and erosion, extended service life of the casing, and reduced frequency of maintenance interventions.

Oil & Gas Industry

Corrosion by harsh environment

Equipment details

Type: offshore platform base plate

Location: Norway, North Sea

Problem description

Issue: accelerated corrosion of carbon steel base plates due to the severe marine environment.

ImContributing factors: continuous exposure to a saline atmosphere, splash zones, and cyclic temperature fluctuations.

Impact: increased corrosion rates, leading to potential structural degradation, elevated maintenance requirements, and risk of equipment failure.

Proposed solution

Apply 300 micron of TSA + anti-corrosive sealer to the exposed base plate surfaces

Outcome

Significant reduction in corrosion rates, improved structural integrity, and extended service life under offshore operating conditions.

Heavy Manufacturing Industry

Erosion by industrial production fumes

Equipment details

Type: steel foundry flue gas cooling duct

Problem description

Issue:

The client operates a flue gas cooling system that extracts heat from steel furnace fumes.

Fumes are highly abrasive and erosive, causing severe wear on the pipes.

Every 3 months, the client was forced to stop production for crack welding and leak repairs. Partial replacement of damaged sections

Full duct replacement was prohibitively expensive, leading to unsustainable maintenance costs and frequent downtime.

Proposed solution

Apply a 3-coat thermal spray cladding system: bond coat + anti wearing coat + Corrosion Resistant Alloy coat

Outcome

Maintenance interval increased from 3 months to 18 months, Reduced Downtime: Significant decrease in unplanned shutdowns, lower maintenance labor and welding costs, avoided costly replacement of flue gas duct.