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Recent Episodes
EPISODE 59 - Restoring SCR Performance at Apex Four Corners Power Station
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…
EPISODE 58 - How a Large Refinery Achieved 9.8% Fuel Savings Through Fired Heater Optimization podcast
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…
EPISODE 57 - Restoring Reliability in a Supercritical CFB Unit
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…
EPISODE 56 - HVTS in Offshore Service: Slug Catcher Corrosion Case Study
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…
EPISODE 55 - Stripper Tower H2S & HCl Corrosion Protection at Gulf Coast Refinery
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…
EPISODE 54 - Refinery Tackles Declining Furnace Performance and Rising Stack Temperatures Without Shutdown
A refinery restored furnace efficiency and reduced stack temperatures through targeted maintenance solutions, avoiding costly operational downtime.
EPISODE 53 - Extending Reactor Lifespan with Targeted Cladding Solutions
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…
EPISODE 52 - What is Asset Vitality?
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…
EPISODE 51 - How a Canadian Refinery Overcame Metallurgy Challenges in Renewables Conversion
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…
EPISODE 50 - Recurring Corrosion Damage Threatens Amine Still Tower Integrity
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.
EPISODE 49 - Cleaning Fouled Convection Tubes at a US Methanol Plant
In this episode, we cover a recent project at a methanol plant in the US where fouling in the primary reformer convection section reduced efficiency. We explain how precision cleaning restored heat…
EPISODE 48 - Addressing Amine Stress Cracking in Critical Equipment
Amine stress corrosion cracking is a common issue in amine regeneration units, often leading to costly damage and downtime. This episode breaks down how it happens, why it matters, and what can be…
EPISODE 47 - Improving Radiant Tube Life and Efficiency at an Aromatics Plant with Ceramic Coating
A petrochemical aromatics plant faced scaling and oxidation issues that reduced radiant tube life and efficiency. By applying Cetek ceramic coating, the plant increased throughput, reduced fuel use,…
EPISODE 46 - HVTS® Protects Critical Refinery Assets Saving 10–12 Days of TA Time
In this episode of the Efficiency and Reliability Podcast, we dive into a Q4 2024 refinery turnaround in Saudi Arabia, where HVTS® technology helped overcome severe corrosion challenges, saving 10–12…
EPISODE 45 - How to Address Scaling and Efficiency Challenges in an Aromatics Plant
Learn how an aromatics plant tackled severe scaling and efficiency losses in its fired heaters. Discover the impact of oxidation on radiant tubes and the steps taken to improve performance and extend…
EPISODE 44 - High-Temperature Corrosion Issues in a GE 7HA Gas Turbine
This episode explores the high-temperature corrosion challenges faced by a U.S. power utility’s GE 7HA gas turbine and their impact on maintenance and reliability.
EPISODE 43 - Severe Corrosion Threatens Biomass Boiler Reliability
A biomass-fired boiler in Sweden faced escalating erosion and corrosion, risking unplanned outages and costly failures. Discover the challenges this critical energy facility encountered and their…
EPISODE 42 - How a Metallurgy Upgrade Restored a Fractionation Column
This case study highlights how HVTS metal alloy cladding provided a cost-effective and time-saving solution to protect a fractionation column, bringing it back into service without the need for a new…
EPISODE 41 - How a Petrochemical Plant Avoided $12 Million in Losses
A petrochemical plant battled over 10 hotspots on a roof-fired reformer, exposed flames, and the threat of a $12 million loss—see how they avoided a full shutdown.
EPISODE 40 - Improving Boiler Reliability at a Texas Power Plant
In this audio case study, we discuss how a Texas power plant with two CFB boilers overcame severe tube metal erosion and unpredictable wear rates by adopting IGS’ SMARTGard® High Velocity Thermal…
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Efficiency and Reliability Audio Case Studies has published 59 episodes since October 2023, covering topics in Technology.
Efficiency and Reliability Audio Case Studies is currently active with new episodes every 2 weeks. Average episode length is 4m.
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