BOILER TUBE COATING/ THERMAL SPRAY

AOS Engineering provides in-situ coating services to enhance the life of boiler waterwall tubes in CFB and PC boilers. Our protective coatings significantly extend the service life of boiler tubes by providing a permanent barrier against ash erosion. AOS has developed the capability to offer thermal spray coating services using resources within the country, saving foreign reserves and providing a cost-effective solution for our customers. Our thermal spray coatings have helped customers prolong their boiler shutdowns from six months to two years, resulting in massive savings in production losses and maintenance costs

What is Thermal Spray Coating?

Thermal spraying is a coating technique in which melted wire consisting of Nickel and different alloys like Nickel chromium Moly Tungsten or Nickel Chromium Moly Niobium are sprayed onto a surface, forming a protective layer to shield the substrate from the surrounding atmosphere.

Thermal spray alloys are deposited onto the surface by melting a wire or powder (or a combination of both) feedstock in the spray gun and projecting them at high velocity onto a suitably prepared substrate where the droplets form splats and interlock with each other to form an impermeable barrier. There is no fusion between metal coating and the base metal. Unlike welding, there is no heat or thermal stresses that gets imparted in the base material.

Benefits of Thermal Spray Coating

• Protection against erosion- Our coating is tailor-made with high-nickel and noble alloys to protect the substrate from the surrounding atmosphere. AOS offers 50% more erosion-resistant coating than the equivalent products on the market and is 20 times more erosion-resistant than carbon steel.

• Protection against corrosion- Thermal spray coatings create a robust barrier against corrosion, significantly extending equipment life and reducing maintenance costs

• High-Temperature Stability. Thermal spray coatings provide exceptional thermal protection for components exposed to extreme temperatures.

• Significantly faster to apply than weld metal overlay, providing substantial up-front cost reduction and long-term ROI.

• Applicable to any fuel type.

• Significantly reduces the Equivalent Forced Outage Rate (EFOR).

• Measurable, scalable and repairable.

Why chose AOS Engineering Group's Thermal Spray

What makes AOS thermal spray unique is our combination of the right materials, the right equipment, the right people, the right training, the right experience, the right procedures and right project management to consistently deliver high-quality thermal spray applications for long-term performance.

• We are familiar with the most difficult conditions in the most extreme environments.

• A tailored solution to fit customer needs

• We work to reduce critical path schedule as much as possible and comply with the schedules we commit to.

• Proven technology. 50% more erosion resistant to carbon steel as per G65 test results.

• Increase component life.

• Allow predictable maintenance.

• Reduced Total Cost of Ownership (TCO).

• Skipped outages can increase profits up to 25%.

• Up to 75% faster than traditional cladding techniques.

• AOS Thermal Spray does not require any curing time or bake out. AOS Thermal Spray is also insensitive to atmospheric temperature and humidity, thus reducing critical path turnaround time.

• AOS Thermal Spray does not create a Heat Affected Zone (HAZ) and therefore will require no Post Weld Heat Treatment (PWHT), saving time and eliminating stresses.

• Ability to deploy on site within 24 hrs of notification.

• Our Thermal Spray cladding minimizes downtime and maximizes the reliability of your critical equipment.

• In conjunction with our Inspections Division, we can offer you a turnkey solution for identifying, evaluating,

  and repairing your pressure parts.

POWER GENERATION

Corrosion and erosion mechanisms are both major contributors to tube wastage in this CFB, PC & Wte/ biomass boilers. AOS is extensively working with our clients in the energy sector globally to resolve these issues in their plants

OIL & GAS

AOS thermal spray cladding has been successfully used to effectively eliminate internal vessel corrosion by applying noble alloys on top of the existing substrate, thus preventing long shutdowns and expensive vessel replacements.

PETROCHEMICAL

Refineries and petrochemical plants are prone to high-temperature corrosion. AOS thermal spray application can provide a permanent corrosion barrier, typically lasting 15 years, thus avoiding costly equipment repair and maintenance

Waste-to-energy (WtE) and biomass boilers are extremely prone to both erosion and corrosion mechanisms on their boiler tubes due to the presence of precipitated salts in the surrounding gases. AOS thermal spray coating acts as a barrier between boiler tubes and the surrounding gases, thus preventing the costly replacement of the tubes every two years.

WTE & BIOMASS