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European countries lead the wave of Biomass energy. While some operators build new biomass-fired boilers, others retrofit old coal-fired units to burn biomass. Although this is a more environmentally friendly fuel, related Alkali- and Sulfide-induced corrosion of boiler tubes has become a problem.  Integrated Global Services (IGS) Inc. developed and field-tested a new metal alloy to cope with both corrosion and erosion in these aggressive environments. Recent, flawless results have shown that the high velocity thermal spray (HVTS) cladding in a large E.ON Biomass boiler in Sweden has delivered the desired benefit of lower operational expenses.

Integrated Global Services (IGS) is an international company with a 35+year history in providing on-site corrosion protection for power boilers, oil and gas pressurized vessels, and heat recovery boilers.  IGS surface protection solutions have been applied to 2,500 industrial boilers worldwide. Over 500 of these are Circulating Fluidised Bed (CFB) and Bubbling Fluidised Bed (BFB) boilers. The IGS engineering team have the benefit of a well-staffed and superbly equipped Technology Center. This large laboratory has advanced analytical tools and specific performance prediction capabilities that are used to develop and evaluate proprietary metal alloys and ceramic claddings, to provide reliable corrosion and erosion solutions for mission-critical equipment.

Biomass Corrosion Resistant Cladding

A recently developed material, IGS 5470, is a high velocity thermal spray (HVTS) applied metal alloy cladding shown to provide unprecedented corrosion resistance at the high temperatures found in Biomass boilers. This cladding is also designed to provide ease of on-site application. IGS CTO, Iain Hall, comments: “Merely specifying a corrosion resistant alloy does not ensure that the applied cladding system, with that alloy, will perform well in service. Very specific modifications are necessary to the material composition, process equipment and the application procedures, with additional post-treatment, to ensure that the as-sprayed cladding is resilient and capable of delivering an effective long-term corrosive and wear resistant barrier. Not all cladding systems are equal.”

IGS Global Presence

Having operational centers in strategic locations in North America, Europe, Asia and Africa, IGS provides its services worldwide. That said, each market is unique. Sören Stutin, General Manager at IGS Scandinavia, comments: “Scandinavia is a highly educated market in both CFB and renewable fuel thermal power and steam generation. Our boiler engineers have a deep understanding of metal wastage problems in boilers and years of experience in using thermal spray solutions. An important attribute is that even with this experience, Scandinavian engineers are open to innovation and once vetted, readily absorb the best available technology to improve operations. This combination of well-educated, curious, and savvy engineers is what makes our boiler industry so advanced.”

Large-Scale Application

The IGS Europe s.r.o. Operations team performed a high velocity thermal spray (HVTS) application at Eon Värme Sverige AB Åbyverket, Örebro Sweden steam boiler 5 during the August to September 2017 maintenance period. ÅP5 is a 170 MW biomass-fired CFB boiler built in 1988 by Götaverken-Generator (currently Valmet Technologies Inc.) The steam conditions are 150 bar/540° C.

Åbyverket wanted to upgrade the existing surface protection system that was previously installed in preparation for a future change in fuel composition during the boiler revamp in 2017.  In addition a height of 24 m of boiler tubing was changed on all 4 walls.

Alloy Cladding Protects Boilers From Biomass Corrosion

Biomass fuel is often multi-sourced. It may originate from virgin wood, plants or animal residue and may also contain recycled material like demolition wood. This uncertainty in the feed composition results in variations in the combustion process chemistry and gives rise to significant changes to the corrosion dynamics on water wall tube surfaces. In the case of fluidized bed boilers, this fuel mix together with changes in the bed material, adds an erosion/corrosion component to tube damage mechanisms.

Best Available Technology

While more aggressive fuels certainly increase tube material loss rates, this is not an entirely new problem. A number of other technologies have been employed to combat these problems. A subject matter expert for IGS in Waste to Energy and Biomass boilers, Cyril Narjoz says, “Some boiler operators believe that weld overlay is the only solution to protect boiler walls from biomass-induced corrosion safely. This was true some years ago, but now that IGS 5470 has proven its performance in several independent tests and practical applications. Being a faster, lower cost and more easily applied on-site technology, the IGS HVTS cladding with IGS 5470 is a great alternative for corrosion protection.”

IGS High Alloy Coating for Biomass Boiler  Corrosion PreventionIGS applied IGS 5470 to 993.5 m2 to the ÅP5 unit for erosion and corrosion protection in a 3-week period working 24 hours a day, 7 days a week, with eight spray units and technician rotation. The director of Operations for IGS Europe, Petr Sovadina, a boiler engineer with many years of thermal spray experience, commented, “We have an experienced and well-trained team, but it was our first large project in Scandinavia. The E.ON engineers were attentive and supportive, their close communication and collaboration with IGS mitigated many obstacles in the execution phase. As we understand that operators need to squeeze the critical path for boiler operations, IGS’s ability to mobilize 8 application teams enabled us to complete the application to the 993.5 m2 of water walls in 21 days. We are proud of our quality and glad to provide a warranty behind our work.”

Flawless Corrosion Protection

The first annual inspection of the IGS HVTS application was conducted in August 2018. The result was as expected; there was no degradation or thickness loss of the applied thermal spray cladding. The ceramic top coat system, IGS 6022, indicated the areas with the heaviest erosion. A cladding thickness mapping inspection was performed, as usual, and a full report provided to the customer,. The E.ON site manager Ingrid Bogren commented, “Our work is extremely important, that is why we choose the best services for our boilers. We closely monitor projects performed in our boilers, IGS has an experienced and quality-oriented team that listens to customer needs and delivers according to their promises.”

As the European energy market develops and uses more widely varying biomass fuels, facilities will face more difficult corrosion conditions than they have experienced before. IGS is well equipped to provide effective long-term surface protection barriers on existing tube water walls, stopping tube leaks and effectively eliminating the requirement for panel replacement by preserving the existing water wall tube condition.

Now in Turkey: Integrated Global Services (IGS) is a global industry leader in the development and on-site application of emissivity coatings, and metal spray cladding mitigating corrosion and erosion problems in challenging operating environments. IGS specializes in serving a global customer base with on-site technical solutions. The company’s Technology Research Center in Richmond, Virginia partners with some of the largest energy companies in the world to understand and solve difficult metal wastage problems, improve operating efficiencies, improve coating and welding techniques, and evaluates material performance.   See more at https://integratedglobal.com

IGS’s objective for this project was to identify a strong local partner to market the company’s products to the large potential market of industrial facilities and energy providers in Turkey and Azerbaijan.

Assistance Provided

In September 2017, CS Richmond consulted with CS Ankara Senior Commercial Specialist Serdar Cetinkaya regarding IGS and was advised that the market did hold some promise for these product offerings.  At that point, CS Richmond and CS Ankara held a market assessment call with IGS management in October 2017 to discuss the client’s prospects for garnering interest in the Turkish market.

Following the market assessment, IGS engaged with CS Ankara to conduct an International Partner Search, which resulted in several Turkish firms expressing strong interest in representing IGS in the market.  Following the delivery of the final report, IGS staff visited Turkey in June 2018 and met with the final shortlisted Turkish firms.  CS Ankara was able to provide value-added support in the final stretch of these considerations by sharing additional insights and knowledge of the firms’ experience and viability. IGS partnered with ENPRO to be their selected representative in the region. ENPRO (http://www.enpro.com.tr/) has been serving the power plant engineering and construction industry since 2003.

Description of Results

Due to the assistance provided by CS Anakara, the representation from ENPRO, and the deep knowledge and relationships in the energy sector held by Serdar Cetinkaya, IGS was afforded the opportunity to present their company to a range of qualified potential partners in Turkey and to receive market insights and guidance throughout the process.  This new foothold in Turkey builds upon previous CS support provided to IGS in the Czech Republic, which is the location of the IGS regional office that will also manage this new business in Turkey.

Impact – IGS serves many valued customers worldwide, including Europe and Middle East, providing metal coatings that increase service life of upstream and downstream vessels, coal boilers, as well as emissivity modifying coatings to improve efficiency of fired heaters. IGS evaluates market demandas 3-4 projects per year, totaling ~$1 mln with ROI for the customers frequently being less than a year. Turkey and Azerbaijan lacked this kind of service which provides multi-million dollars operating savings for refineries and power plants.

Acquisition Creates Clear Global Leader in Engineered Maintenance Coatings Industry

RICHMOND, VA, 10/31/17 – Integrated Global Services, Inc. (IGS) has acquired Cetek Ltd., merging two of the world’s most experienced and technologically advanced critical asset maintenance and coating solution providers. Cetek is the market leader in the evaluation and performance optimization of critical fired heaters and boiler equipment in the global downstream oil & gas and power markets. Cetek’s key offerings include Ce-Coat high emissivity ceramic coating services performed during scheduled customer plant turnarounds, and Hot-tek high temperature maintenance services performed while the refinery is still operating to minimize costly downtime of process equipment. Cetek’s unique solutions enable customers to improve the throughput, longevity, fuel consumption and emissions of their critical process equipment, typically resulting in a rapid return on investment for customers. Cetek brings more than 40 years of experience in servicing equipment to IGS.

“The biggest winners here are our customers,” said Rich Crawford, President and CEO of IGS. “The addition of Cetek—including its full team of subject matter experts and suite of innovative technologies—will allow IGS to offer an even wider array of solutions, expertise and resources to our clients who want better performance, reliability and longevity out of their mission critical equipment.” Crawford also referenced the two companies’ complementary business models and cultures. “Cetek and IGS are incredibly similar. We are both undisputed technology leaders in our markets, and our customers depend on us for ensuring their equipment performance and reliability.”

Integrated Global Services

Based in Richmond, VA, IGS is an international private equity backed company with over 30 years of experience in providing in-situ internal thermal spray surface protection solutions and environmental products that focus primarily on metal wastage reduction, corrosion mitigation and emissions reduction. Specializing in customized, engineered solutions, IGS is the largest world-wide provider of in-situ metal spray surface protection in the market.

The Cetek ltd. acquisition contributes additional lines of ceramic coating technology and maintenance services to IGS’s already extensive array of surface protection tools. Cetek’s solutions offering consisting of technical heater evaluations, advanced ceramic materials, high temperature online maintenance, and other turnaround services have earned a loyal customer base that Crawford says will be even better serviced because of the new partnership.

“Not only will Cetek customers experience the advantages of significantly expanded operational capacity and our ISO certified technology solutions laboratory, but we’ll be able to introduce a wide range of new, innovative services relevant to our current customers,” Crawford said. “We’re going to share Cetek’s technology and expertise with our clients all over the world.”

IGS  and Cetek ltd Global Service

IGS has operations in multiple locations across the U.S., Canada, Europe, the Middle East, Africa, and Asia, and will now expand into an even greater global presence in the U.S., Western Europe, India, and Southeast Asia with the addition of Cetek ltd.
For more information on our global service capabilities, along with details on how to contact IGS personnel who can support your needs, refer to the IGS website at www.integratedglobal.com/contact-us/ or through email to info@integratedglobal.com.

RICHMOND, VA.–(BUSINESS WIRE)–Integrated Global Services (IGS) is pleased to announce the opening of its newest operational center of excellence, IGS Europe s.r.o in Brno, Czech Republic. IGS is the global leader in the development and application of high velocity thermal spray solutions to combat corrosion and erosion problems in mission critical equipment.

Numerous factors contributed to IGS’s decision to open a dedicated office for serving Europe; including IGS’s current and prospective customer demand, power generation and energy industry trends, and the need for a more experienced and operationally capable solutions provider with specific focus on providing high quality, on-site metal coating services.

“As the global leader in surface technology solutions, establishing a dedicated presence in Europe is a key part of our strategy to better service the European market and enhance our global capabilities.  We believe we have partnered with the most talented, experienced, and focused team in Europe in our area of expertise—solving customers’ metal wastage issues, primarily on-site.  Combined with IGS’s unparalleled application references, technical know-how, and track record of solutions, we are extremely well positioned to provide a unique service to the European market,”  states Richard Crawford, CEO.

More information on our global service capabilities, along with details on how to contact IGS personnel who can support your needs, refer to the IGS website at: www.integratedglobal.com/contact-us/ or through email to info@integratedglobal.com

About Integrated Global Services

IGS is the industry leader in the development and application of high velocity thermal spray solutions for corrosion and erosion problems in challenging operating environments. IGS specializes in serving a global customer base with on-site technical solutions executed from operational centers throughout the world. The Company’s industry leading Technology Research Center in Richmond, Virginia, USA partners with some of the largest energy companies in the world in order to understand and solve difficult metal wastage problems, improve coating and welding techniques, and evaluate material performance.

RICHMOND, VA.–(BUSINESS WIRE)– Integrated Global Services (IGS), the industry leader in the development and application of high velocity thermal spray solutions for corrosion and erosion issues in mission critical equipment, is pleased to announce the hiring of two industry leaders – Colin Bateman and Jeff Shelton.

Colin Bateman brings nearly 20 years of engineered solutions expertise to IGS and will serve as the Business Development Manager for Europe, the Middle East and Africa. Previously, he served in leadership, business development and technical service and solutions roles for Belzona Polymetrics, Ltd.

“I am very pleased to be joining IGS a company focused on high quality, highly reliable solutions, states Colin. “Customers are increasingly turning to IGS technologies to solve metal wastage problems that have gone unaddressed by preexisting or underperforming technologies and solutions. I am excited to contribute to this growth.”

Jeff Shelton will serve as the VP – SCR Solutions and has more than 30 years of experience in the power, paper, environmental and NOx control industries. Most recently, he served as Managing Director of the Power Generation division at Martin Engineering. Jeff provides a strong technical background in the design and supply of engineered solutions for addressing critical maintenance and reliability issues for coal fired power plants, including ash piling, flue gas redistribution, and large particle ash prevention and remediation. .

“We are excited that Colin and Jeff have joined the IGS team,” said Rich Crawford, CEO of Integrated Global Services. “Both are incredibly talented and well respected professionals who bring a wealth of experience helping plants solve their asset performance issues. They will be instrumental in expanding our customer base and ensuring that IGS maintains its market leading position of providing high performing engineered solutions.”

More information on our global service capabilities can be found on the IGS website at: www.integratedglobal.com/services , by dialing +1 804 794 1646 or through email to info@integratedglobal.com

About Integrated Global Services

IGS is the industry leader in the development and application of high velocity thermal spray solutions for corrosion and erosion problems in challenging operating environments. IGS specializes in serving a global customer base with on-site technical solutions executed from operational centers throughout the world. The Company’s industry leading Technology Research Center in Richmond, Virginia, USA partners with some of the largest energy companies in the world in order to understand and solve difficult metal wastage problems, improve coating and welding techniques, and evaluate material performance.

RICHMOND, VA.–(BUSINESS WIRE)–Integrated Global Services (IGS), the industry leader in the development and application of high velocity thermal spray solutions for corrosion and erosion issues in mission critical equipment, is pleased to announce the opening of regional operations centers in Houston, Texas, USA and Edmonton, Alberta, Canada.

Among the leaders in IGS’s Houston office are Wesley Cowley, Vice President – U.S. Business Development, and Johan deVos, Manager – North American Project Execution. Both executives, as well as a team of experienced project managers, supervisors, and technicians, have recently joined IGS from Alstom’s thermal spray division. Michael R. Place, General Manager – IGS Canada, Inc., is leading the company’s efforts in Canada.

“We are pleased to have built out our regional capabilities to efficiently serve our key customers in Alberta and along the Gulf Coast. Our services extend the lives of our customers’ assets with proprietary, high performance, alloy upgrade systems. Investing in these two regions helps us to strengthen our global execution platform to best serve those who trust their assets to our team and technology to achieve their production standards,” states Brian Simer, VP – Corporate Development.

More information on our global service capabilities, along with details on how to contact these two locations, can be found on the IGS website at: www.integratedglobal.com/contact-us/, by dialing +1 804 794 1646 or through email to info@integratedglobal.com

About Integrated Global Services

IGS is the industry leader in the development and onsite application of high velocity thermal spray solutions for corrosion and erosion problems in challenging operating environments. IGS specializes in serving a global customer base with on-site technical solutions executed from operational centers throughout the world. The Company’s industry leading Technology Research Center in Richmond, Virginia, USA partners with some of the largest energy companies in the world in order to understand and solve difficult metal wastage problems, improve coating and welding techniques, and evaluate material performance.

Industrial Growth Partners Acquires Integrated Global Services, Inc.

Richmond, VA, May 15, 2014 – Industrial Growth Partners, in partnership with management, has completed the acquisition of Integrated Global Services, Inc.

On May 12, 2014, Industrial Growth Partners IV, L.P. (IGP), in partnership with management, purchased a controlling interest in IGS.  The transaction creates a platform for IGS to accelerate its international growth, enhance its selling capabilities and pursue selective acquisition opportunities. The acquisition is an ideal fit with IGP’s strategy of investing in niche industrial companies with leading market shares and outstanding management teams.

“IGP’s familiarity with IGS’s key end markets through its prior investments and the firm’s deep experience in the industrial sector made IGP an ideal equity partner for us,” commented Rich Crawford, CEO of IGS. “The IGS management team is excited about the opportunity to leverage IGP’s experience to help expand our business internationally and to strengthen our position in our core markets. We look forward to capitalizing on the resources this new relationship provides.”

IGP, founded in 1997, is a San Francisco-based private equity investment firm with $1.4 billion of equity capital raised since inception.  The firm invests exclusively in middle-market companies in the industrial sector in partnership with management teams.

To learn more about IGP, please visit www.igpequity.com

Integrated Global Services Opens New Global Headquaters and Achieves Record 2013 Results

RICHMOND, VA., January 10, 2014 –(BUSINESS WIRE)– Integrated Global Services (IGS) is pleased to announce the opening of its new global headquarters at 7600 Whitepine Road in Richmond, Virginia.  IGS will formally celebrate the opening of the new facility in a ribbon-cutting ceremony later this month.  The facility more than doubles the capacity of the company’s previous location in Midlothian, Virginia, where IGS was headquartered since 2003.

“Our new engineering, sales, maintenance, and production facility on Whitepine signifies our tremendous growth, and augments our ability to address the highly complex, metal wastage environments plaguing our customer base” said Rich Crawford, President of IGS.  Crawford indicated that IGS has more than doubled in revenue and headcount since 2009, and has added numerous marquis energy company accounts who recognize IGS as the global leader in on-site cladding for critical process equipment.  “Customers trust their mission critical equipment to IGS because they understand they need a partner that understands equipment wastage problems at the metallurgical level.  We are not simply an applicator – we’re a engineered solutions provider,” added Crawford.

The opening of IGS’s new global headquarters tops off the third consecutive year of record financial results for the company.

RICHMOND, Va., May 09, 2013 –(BUSINESS WIRE)– Integrated Global Services (IGS) is pleased to announce the recent hire of Tom Naughton, who joins the IGS team as the Vice President – Business Development & Welding Technology. Naughton will lead IGS efforts in terms ofglobal business development of weld overlay-focused opportunities. During over 30 years at WSI/Aquilex, Naughton served as a welder and worked his way up through the organization into a variety of roles, most recently VP-International Support and GM of their Arabian joint venture.

“Naughton’s depth of experience, leadership acumen and track record of success are exactly what the Company needs for its next major phase of growth.”

Additionally, IGS has hired Boady Stewart as a Mechanical Production Manager. Stewart comes to IGS with over 35 years of experience with companies such as Brahma Group, Foster Wheeler and TUV, performing construction and maintenance in power and paper plants throughout North America, with a particular specialization in circulating fluidized bed boilers. Recent key personnel hires include Rob Kappus and Tri Shrestha. Kappus joins IGS as Regional Sales Manager – Southeast U.S. from Alstom Power, where he worked as a field service engineer for seven years. Shrestha is joining IGS as Senior Materials Engineer within the IGS Technology Center, where he will support IGS in the development and application of technical solutions for customer problems around the world.

Naughton’s appointment and hire of these key personnel comes during another year of strong growth for the company. “IGS is experiencing double-digit growth and great customer interest from refineries, power plants and paper/pulp mills with the unique services and solutions we provide,” said Rich Crawford, President and CEO of IGS. “Naughton’s depth of experience, leadership acumen and track record of success are exactly what the Company needs for its next major phase of growth.”

To support future growth, Integrated Global Services recently acquired a 70,000-square-foot building in Richmond, Va., which will serve as IGS’s new global headquarters. “Our new, world-class facility will house our new metallurgical laboratory, greatly expanded operations center and shop production facility,” Crawford said. “That’s more than double the size of our current facility.”

IGS is the leader in the technological innovation and application of surface protection systems to solve corrosion and erosion problems in challenging operating environments. IGS designs solutions that increase plant reliability, increase equipment availability and reduce unplanned downtime. IGS has its own accredited Technology Research Center in Richmond, Va., USA, dedicated to the ongoing research and design of on-site and shop applied Metalspray®, ceramic coatings and automated weld overlay systems. IGS solutions are designed by coupling its extensive evaluation process with the largest database of erosion and corrosion test results in the world, unmatched global industry experience, and partnerships with some of the most advanced research and customer-sponsored laboratories in the world.

Contacts

Integrated Global Services
Ellen Costlow, 804-794-1646 x10
ellen.costlow@integratedglobal.com

RICHMOND, VA., March 29, 2013 /PRNewswire/ — Integrated Global Services, Inc. (IGS) helps major power companies like St. Johns River Power Park (SJRPP), jointly owned by Jacksonville Electric Authority (JEA) and Florida Power and Light, prevent Large Particle Ash (LPA) from interfering with the efficiency of SCR (selective catalytic reduction) environmental equipment. SCR equipment is used globally to reduce NOx emissions to meet environmental standards.

IGS designs, engineers, and manufactures the longest lasting large particle ash (LPA) filtration systems in the world and customers include Alstom, Southern Company, Babcock Wilcox, AES, Progress Energy, TVA and Duke Energy

Typical filtration screens protecting catalysts within SCR systems have proven to be short-lived and unreliable, resulting in frequent clogging of catalyst with LPA (or “popcorn ash”), decreasing NOx reduction performance. In contrast, over 60 IGS patent pending NoNOx Components™ systems have been in service for years in some of the most aggressively run SCR systems in the world.  By using NoNOx to protect their catalyst from popcorn ash, these plants have maximized catalyst run-time, decreased the likelihood of unplanned downtime, and significantly reduced the lifetime cost of their SCR systems.

St. Johns River Power Park (SJRPP) consists of two identical 640-MWnet coal-fired baseload generating units placed into service in 1987 and 1988.

Larry Bradley, SCR Project Manager at St Johns River Power Park said, “During each outage we inspect the screens but there is never any indication of damage or wear.  We have been very satisfied with this product.”

The NoNOx Components™ system features an optimized, custom-fit screen and support system design and proprietary erosion-resistant materials that outperform any other commercially available LPA screen system. Additionally, IGS’s in-house engineering, flow modeling, and system design experience provide SCR systems designers and owners the opportunity to maximize their systems’ open area ratio (OAR), decrease pressure drop, conserve fan power consumption, and improve ash collection.  This value proposition reduces localize erosion due to high velocities and improves the life and condition of the downstream equipment while reducing ammonia slip.  The end result is improved overall plant reliability, generation capacity and emissions output.

IGS has over 20 years experiencing solving customer problems of high temperature erosion and corrosion. NoNOx products benefit from IGS in-house metallurgical, engineering, and on-site experience and know-how. No comparable system outlasts NoNOx.

The IGS Technology Center continues to perform research related to the analysis of physical particle format across different SCR installations. By screening sample sections of these materials, IGS is able to optimize filtration materials and design parameters necessary to achieve a suitable acceptance-rejection characteristic with minimal plugging.