Careers Maximize Uptime Through Smart Inspection
Real-time insights to avoid unplanned repairs and reinforce boiler reliability.
Location: Power Plant, Philippines
Application: Drone inspection in 150MW circulating fluidized bed (CFB) boiler
Proactive Insight During Unplanned Downtime
Taking Advantage of an Outage to Safeguard Future Operations
When an unavoidable ID fan issue forced an unexpected shutdown of one of the client’s CFB boilers, the team saw an opportunity to gain valuable insights into the boiler’s internal condition.
With no other major work scheduled inside, full scaffolding wasn’t justified—but the team still wanted a clear view of key components, including the refractory and tubes.
IGS proposed a drone inspection, marking the first time this technology was used by IGS in the Philippines. The plant had previously received IGS HVTS® cladding in 2022, and both parties were eager to verify its performance.
Inspection Objectives
- Evaluate the performance of previously applied High Velocity Thermal
Spray (HVTS®) cladding installed in 2022 - Identify any other anomalies while the boiler was offline
Efficiency Without Compromise
Full Visibility Without Delay or Disruption
The inspection utilized a high-performance drone – the first of its kind used by IGS in the Philippines. By accessing the boiler through two entry points, the drone achieved complete internal coverage within just 4 to 5 hours.
This innovative approach eliminated the need for scaffolding and enabled the inspection to begin almost immediately, saving the plant 2–3 days compared to traditional methods.
Findings Confirm Long-Term Protection
Validation of cladding performance and risk mitigation
The visual review confirmed the HVTS cladding remained in excellent condition, validating its protective integrity nearly two years after application. Areas with visible erosion outside the clad zones were noted but did not require immediate intervention. Other findings revealed cracks in the refractory material, which were promptly addressed by the plant team to prevent potential future boiler tube failures.
The drone inspection showed the HVTS cladding applied in 2022 to be in excellent condition.
The inspection revealed some cracks in the refractory, which were promptly addressed by the plant’s maintenance team.
Delivering Strategic Value Beyond Protection
Trust Built Through Performance and Partnership
IGS’s inspection emphasized its ongoing commitment to client success. It reinforced the performance of the cladding and provided SMC engineers with timely, decision-driving insights during a critical outage.
Precision insights. Proactive partnership. That’s Asset Vitality.
“We expected the cladding to be in good condition, having been in service for only two years, and having undergone one previous inspection. What really mattered was giving the client real-time, actionable data during a critical moment, helping them avoid a potential future shutdown.”
– Rohit Katarnaware
Country Manager – Philippines, IGS
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