Efficiency and Reliability Audio Case Studies

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Listen to our case studies that focus on challenges and innovative solutions for combating corrosion and erosion issues in industrial plants.

  1. 14 JAN

    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 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.

    3 min

  2. 15/12/2025

    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 protected zones.

    5 min

  3. 16/10/2025

    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 conditions and delivering significant cost savings.

    3 min

  4. 01/10/2025

    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 refinery addressed these challenges during a major turnaround.

    3 min

  5. 14/08/2025

    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.

    2 min

  6. 11/07/2025

    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 practical look at implementation, challenges, and long-term results.

    4 min

  7. 23/06/2025

    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 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.

    4 min

  8. 05/06/2025

    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 welding.

    5 min
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Listen to our case studies that focus on challenges and innovative solutions for combating corrosion and erosion issues in industrial plants.

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