Careers Eliminating Oxide Debris Risk in New Gas Turbine Casings
Plant and Challenge Description
A leading U.S.-based turbine manufacturer operates a state-of-the-art facility that plays a central role in delivering advanced gas turbine systems to power producers globally.
In one such application, a new turbine combustor casing destined for a combined cycle unit required protection against high-temperature oxidation and scale spallation.
Oxide debris from combustor casings can damage downstream hot gas path components, driving unplanned outages and costly repairs. These casings operate in demanding thermal environments where temperatures above 500°C / 932°F cause low-chrome steels to oxidize, forming scale on internal surfaces. Over time, this scale can lose adhesion and spall, releasing oxide flakes that migrate downstream and threaten cooling passages, coatings, and other critical turbine components.
The plant’s objective was to prevent oxide spallation and preserve the long-term integrity of this critical asset.
T25-42239
Evaluating Options to Prevent Scale Spallation and Downstream Damage
As a new-build component, the casing arrived without protective cladding or an internal coating. Historically, the plant had not applied internal protection to similar casings, relying instead on bare metal surfaces. However, growing awareness of oxidation risk, combined with recent IGS projects at other facilities in the U.S., prompted reconsideration.
Oxidation-driven spallation can occur even when turbines are not active, as daily thermal cycling from daytime heating and nighttime cooling can trigger oxide formation and flaking. This highlighted the need for a preventive solution to eliminate oxidation risk before the asset entered service.
First full-scale OEM-aligned shop application of HVTS® on a new-build casing
This project marked the first full-scale, OEM-aligned shop application of HVTS® on a new-build combustor casing, establishing a new standard for pre-service oxidation protection. The appointment was based on:
- Proven success during other deployments and OEM-verified technology
- Speed and repeatability of the HVTS cladding process
- Low-temperature application with no impact on substrate properties
- Global expertise and ability to execute within tight lead times
The plant recognized HVTS® as a strategic upgrade that would not only repair damage but also prevent future degradation with a protective system engineered for long-term durability.
“Our client needed confidence that their turbine casings would perform reliably from day one. This application gave them a scalable, OEM-aligned solution they can now apply across future builds with reduced risk and greater certainty.”
– Mike Strom, Business Development IGS
On-Time Delivery of a Specialized HVTS® Cladding Solution
IGS applied a proprietary HVTS® cladding designed to withstand high-temperature oxidation and repeated thermal cycling. The application was performed using a proprietary application system, achieving a uniform thickness across both upper and lower casing halves and five manway covers.
Key HVTS® cladding features
The cladding, which met all required specifications, was executed under IGS’s strict quality management system.
| Feature | Description |
|---|---|
| Bond type | Mechanically bonded, non-diffusion superalloy |
| Barrier performance | Dense, low-porosity protective layer |
| Heat input | None introduced to the substrate |
| Dimensional impact | Maintains casing geometry and material integrity |
| Post-treatment | No heat treatment required |
| Protection mechanism | Blocks oxidation and erosion at the surface |
| Spallation control | Prevents initiation rather than mitigating effects |
Measurable Outcomes
The project successfully protected the combustor casing without welding or heat input, avoiding delays and ensuring OEM compliance.
| Metric | Result |
|---|---|
| Risk Elimination | Eliminated the risk of early-life oxide spallation and downstream damage to critical hot gas path components. |
| Cost Avoidance | Avoided potential rework, production delays, and warranty exposure associated with unprotected casings. |
| Lifecycle Reliability | Enabled long-term asset performance under high-temperature and cyclic operating conditions. |
| Execution Certainty | Completed without welding or heat input, maintaining material integrity and OEM compliance. |
| Application Quality | Uniform cladding thickness and surface finish confirmed through post-application inspection and testing. |
| Future Value Creation | Established a repeatable solution, with additional casings and follow-on applications already identified. |
Enabling Long-Term Reliability Through Repeat Applications
The project successfully demonstrated a full-scale HVTS application on a combustor casing. The project received strong positive feedback, with IGS recognized for its professionalism, flexibility, and ability to integrate seamlessly into the plant’s operations.
Based on the successful outcome, similar approaches are being considered for future projects, including additional applications, potential field deployments, and further technical evaluations.