SMARTGard

The Smarter Way to Guarantee CFB Boiler Reliability

SMARTGard logo IGS

IGS’ SMARTGard solution has been developed by boiler maintenance experts. When you partner with IGS, our team integrates with yours to identify problem areas, protect your Circulating Fluidized Bed Boiler (CFB) (that’s where SMARTGard comes in), and implement a proactive maintenance program to guarantee boiler reliability.

If that’s not enough, we consistently deliver full ROI within an average of six months.

What is SMARTGard?

Essentially, SMARTGard is our proprietary High Velocity Thermal Spray (HVTS) alloy clad solution that is applied by IGS technicians to protect CFB boilers from fly ash erosion, fireside corrosion, and fouling.

However, SMARTGard is more than a protective barrier. It is a comprehensive maintenance service that starts with a detailed analysis of the boiler including previous maintenance and reliability history. After a full inspection, HVTS is applied which provides long-term protection from high-temperature corrosion and erosion of CFB boiler tubes. Finally, results are measured, documented, and monitored alongside a proactive maintenance schedule. SMARTGard is a complete service that guarantees boiler reliability.

 

CFB_boiler_corrosion_erosion

The 4 SMARTGard Steps to CFB Boiler Success

Step One: A Systematic Approach to Boiler Reliability

Our dedicated technicians spend time understanding the unique wear patterns and problem areas within the boiler by investigating the following:

Research boiler-specific information including:

  • Year commissioned
  • Size of boiler
  • Fuel blend
  • Nominal thickness
  • Previous UT data
  • Understand maintenance and operational philosophy
  • Consider past tube failures, type, and locations
  • Consider past solutions
  • Consider trends and wear occurrences
  • Documenting findings with images while accurately noting the location
  • Inspection and thickness mapping of existing cladding (if any), taking three readings looking out for preferential corrosion
CFB_boiler_SmartGard alloy Cladding
CFB_boiler_inspection
Step Two: Materials and Equipment Engineered for Specific Results

Typical IGS material includes high alloy steel specifically designed to protect Circulating Fluidized Bed Boiler tubes from high-temperature erosion and corrosion. IGS material recommendations for boilers often include both ceramic and metallic components to produce a homogenous, hard, and tough layer. The system provides optimal application and performance properties for CFB boilers.

We only use a true High Velocity Thermal Spray (HVTS) application process, where atomization of the material occurs in a super-sonic gas stream. HVTS process achieves optimal cladding properties needed for reliable and predictable long-term cladding performance.

Step Three: Material Application by Trained and Accredited Teams

We are proud to have a team of dedicated IGS technicians stationed in more than 15 countries around the world. Together, they perform more than 2300 hours of work every year during planned plant shutdowns and turnarounds.

With project managers for each SMARTGard client, we can coordinate projects with precision and respond rapidly to requirements, all whilst maintaining stringent safety procedures.

Our clients benefit not only from the provision of skilled personnel and our proprietary fit-for-purpose HVTS cladding solution but also through expert inspection and wastage modelling.

We specify the materials and application thickness both on the first project and during periodic refurbishment as part of our IGS Monitor and Protect service. These specifications ensure long-term dependable performance.

Step Four: Results are Measured, Documented, and Monitored

We maintain detailed records of all applications and inspections. This information includes:

  • Quality and completion documentation
  • Inspection reports and images
  • Cladding thickness maps

Reports are delivered after every project and these records are always available on-demand to monitor the condition of the cladding and to provide critical information for shutdown and maintenance planning and preparation.

 

35+ years’ experience

600+ boiler reliability projects worldwide

$3 million+ average customer payback

What do our Clients Say?

“We went from a varied scope and high man-hours to lower man-hours and a known scope, which is great for planning for an outage, especially for the budget. Because of our process and work with IGS we didn’t need to replace pressure parts. When you start doing pressure part replacement in circulating fluidized bed boilers, you run into all kinds of issues because you must do tube alignment. If the tube alignment is not done correctly, you’re going to end up with erosion or gouging issues for the rest of the life of those pressure parts, that’s extremely difficult to fix.”

Joel Taylor, Boiler Engineering and Maintenance Specialist. Joel has ensured the reliable operation of 7 Circulating Fluidized Bed Boilers between 4 Plants across his 15 Years of CFB Experience.

“IGS brings to the table the technical expertise, the understanding, the technical knowledge behind what the people in the field are doing and you’re seeing the results. IGS spends a fair amount of time making sure that they’ve got a good base material and they quantify the finish and document that to ensure a sound product, a sound solution, and a sound application. Cladding thickness measurements give you the ability to determine your wear rates and what millage you want to apply and need to maintain to be able to get you from one outage to the next.”

Pete Kline, Plant Manager with 28 years CFB Experience, beginning with the initial utilization of CFB boiler Technology.

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