Careers HVTS® Mitigates Gas Turbine Spalling at Mexico Power Plant
The power station in Mexico serves as a critical energy infrastructure asset in the region, supporting the electrical grid of central Mexico. The facility caters to growing energy demands from both industrial and residential sectors. The station’s management actively invests in equipment preservation to reduce long-term operational costs, extend equipment lifecycle, and maintain optimal power generation efficiency.
Facility Overview
- Unit Type: Combined Cycle Gas Turbine
- Capacity: 850 MW
- Fuel Type: Natural Gas
- Began Operating: 2021
- Components Treated: Unit 1 turbine components
Challenge Overview
The facility experienced persistent base metal spalling in its gas turbine components due to high-temperature corrosion. This led to several operational challenges:
- Increasing frequency of unplanned maintenance outages
- Accelerated wear of critical turbine sections
- Potential risk of premature equipment failure
- Damage to downstream components, including blades
Technical Solution: HVTS®
Integrated Global Services (IGS) implemented a comprehensive HVTS® (High Velocity Thermal Spray) cladding strategy that included:
- Full lower-half space coverage using IGS HVTS cladding
- Advanced masking and application techniques
- Total coating area of 458 ft²
- Nominal thickness of 12 mils
Project Implementation Timeline
- Team Mobilization: December 6th, 2023
- Equipment/Material Delivery: December 9th, 2023
- Set-Up Activities: December 10th-11th, 2023
- HVTS Activities: December 12th-15th, 2023
- Break-Down Activities: December 16th, 2023
- Demobilization: December 17th, 2023
Performance Validation – January 2025 Inspection
An inspection in January 2025 showed the cladding in excellent condition with the following operational metrics since application in 2023:
- Total Operating Hours: 34,000 hours since new
- Post-Cladding Operation Hours: 10,000 hours
- Total Start-Ups: 169
- Post-Cladding Start-Ups: 25
Technical Assessment
Thermal and Mechanical Stress Resistance
The HVTS cladding successfully withstood multiple startup cycles involving rapid temperature and pressure changes, demonstrating excellent adhesion and flexibility under thermal expansion and contraction conditions. During prolonged operation, the coating maintained its integrity despite continuous exposure to mechanical loads, high temperatures, and aggressive environmental conditions.
Creep and Fatigue Performance
The HVTS cladding showed exceptional resistance to fatigue during frequent cycling between operating and ambient conditions. The coating maintained its structural integrity through 25 startup cycles and sustained high-temperature operation.
Wear and Corrosion Protection
The cladding effectively protected against various wear mechanisms, including turbulent flow, erosion from particles, thermal shock during startups, and high-temperature corrosion during steady-state operation.
Project Outcomes and Recommendations
The implementation proved successful, with IGS confirming the viability of the full lower-half cladding strategy. No bypass was noted through any of the masking components, validating the expanded application approach. The project team recommended continuing the full lower-half cladding strategy for future installations, while noting the need to consider larger compressors for high-altitude installations to ensure sufficient airflow.
Conclusion
The IGS HVTS cladding has demonstrated its effectiveness as a transformative solution for this power plant, successfully addressing long-standing equipment reliability and maintenance challenges. The technology has shown exceptional potential for extending the operational life and performance of critical power generation infrastructure, with real-world validation through sustained operation and multiple startup cycles.
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