*êftglH3gtf,

Special Focus: Wear Protection >

Fig.4. Âr{spriyiilg ùii laf!e b0!lerTiltce pàne! iiwerkihop.

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ûr nl;l$v 'r'ears eflerglr rl*manrj has

besn stronglv grcninq and'wi!i

co*tllue.'l]te insr:riiatii:ir *1r trerç'

plant capacitlt calr Itrlre vtals sÛ there

is ;ln ei:*ilnous pt{issurr {lri polver

plants tr: imprcvc aprlâtional $l-ltJ]11r, cfÏlcietrci'

anii :rvrrilai:ilir,,'. Fltrther, there is the coilsttint

recluirrr*enr t+ rc,.luce operating co.srs and the

environ:nenral impact *f achi*r'ing th*sc t:rrgets.

ï:e maintr:nancr: department can plai' a critical

rclc b,v seleering 1*rger-1*stira key cnnrpone:rts

ro r:xrend ûntâqe irltcfïals and aiso reducc:

unplanneti citrvn-time ariL!. in','enl orl'"

i)r:r-rpcnent repair rtthe r than rrplacenlr:ni

prciluccs imnrediare c*sts savings anri illsa

r*duc*s dre irse ci:n:a{.erials, r:ncr;1' ancl t:"ansporr

in producing tlres* ncrn' cûinpûnettts"

.Aftri: years t{reseirrch, ficki lests and

;"tv.t;.qTllflit O" pO\\'L! pla:ri rnli ir\'rs. lr-JIi\'

inncvarivt prot-im:rs hirv* b*en dcvcloped t<;

suilpiirt the rnaittenance dc;-:artmenrs in *reirdaiir' fighi agaitrsi r.r''e...t and corrcsii;n. Fr*nr

-rveléin* anrl br;r;zir:g thrr:ugir to thern:al spr;:yicu

and rn'err pri)-recti{ln pârtsl i1iâl),- .sr:iuricns h:rve

be*n e{r*-elope,l ic extencl tlre i!f* Êf *r'irica!

pûwfr piant comli*nînr:s {Lti'as rnucir as fir'c

':'nc.l. ,\ '. l, r'' iun .rl tiit.; ^ . l- .! 5irrJrii

rei:hnakigies anrl thcir le}:rtcd ni,-piicatici:s are

highlighted.

Wear resistant plate solutionsT{/eful o.l,r:lay ',vear ;-latr':s ;rre bec*r:rin51 ptpr.:iar

firi ch* prorecri** olti*ige surlhces agairlsr

w'ear in **al/alternatir'* ir-itl :;r:r{ ash handling.

Llol-re'ç'el, rheir usefr-rlnrss ili a };olvtr pianr can be

restrict*{i in some applicati*ns"tr,r, rhe mirinumplatr: thici<nes*., s*i:1icc raughness, laci< *l*hrasii;r ansi erûsiûn resisrani:e. {-Jne t-.ithe m,lst

corn;:rclensive and sucr:essilll rangcs af iii;lteproducts er* calli:tl {,,astr:l}r-ir l}iam*nd lllate:

(Cl]?i *,hich inchicle specific plaies ancl a]l,;r-s to

rcsist abrasi*r-i, etosicn, in:pacr tnd coltt;siçn.'Ih* letclt dcvci*rpmeni are tl-re uniq'"ie Lll)F

Polvder rvear plates. The use o|-oupr:r hard'Iungsten Carhiries l]àrt;dirs offcr- high ahrasion

and r:rosii:l r*sisianc* in c*inbinati*n r-,.iih iightrvcighr, r;rinimai rhick;lfss {as k:rv as 3inn'j ':nd

$moûrh srirfar:e. ,'\ nerv varilr!on whii:l-, ules a

Srairles-. Steel base fir*iai all*r,vs these piafi:s toplovide *ptimal ."r"ear- resistauc* in aggressi'.re

cr:rrosi*n cnvironm*uts.'Iyplcai :r.'Éplid:3tifi ns

include fa:rs, cyr:lonr:s, chures, li:rers, *tc.

Nano structural engineering"Ilie',oro rid's flrs t l.lan +Ai J il,' i'crmt llttion rvas

dcv*is lrred ti: pr *:,i rie r:u rsr a nditt g ab ras ion

.,1'1,r.'rinn,rri'l..ntr,.it,Ë.in i:ltlJ\1ii,.Êâ!rû stlrlcrural tngin**rinu approac*-r t* aii+;'

de""eioprnetrt b:s,ecl on a l*w iast f *rrt;us b;rse.

Tiris science rç:rs trar:slareri into ;r ru,'*iciing rvire

r'vhi,'h coujc! i:e çser.l ra'ith nr:rmal r'v*Liing

*riuipillr:nt in rh* ;:cra,ei pi::ni bt:r produr:ing

a protecrive cverlal' with a bnik hardne ss oyerrl {lHi. \1p1., ari,,:'' irr'. "b.r',,

l};1,\in r r

ihe i:*x,"er iudr-rstr,,-- in r*al" ask a*d abetnadvc

iirei rr;ir-ispr:i"r and grinclitg ri,!'sttûlii. lJsf illc*al erin*iing s.-v$tems have sl:or,'n a i tirnes

irnpi*vcrnerti în r,r,'t;rr iifi: i* krr' a{lrn!-1i}i-ruj1i:s.

lncreasing power planteffi ciency whi le decreasi ngenvironmental impactlf the lifetime of a repaired part can be increased over that of a newpart, plant performance and availability can also be improved, leadingto significant energy savings and carbon generation. Dr Gary Heathreports.

Fig. 2. 5l

il;lri:i:-i

tig. 3. i

tig. 2. spe(jai Nàno s{rudure lndustry proven boiler tube protectionagainst corrosion and wear{l:rstolin llurectic rvâs ânrcng anc of ri:c first

compirnies to d*v.:lcp ilense, tl:ermeliy spravcd

coatings r() protect boiler tubes itt por';sr pianrs agair:st

r,veai and ccrroslon in thc 198{.}s artl liavc clcr'*ioped

a conside rable reputatinn a.ncl *x;rericncc 11: tiresc

cc-ratings. Success is bas*d û;r ;i coT]lLlination citli*1,deveiol:r:rent and also a speci:r1 ccarit-tg cleposition

process {Sprav anii i;use). é, novel high À4ol1,b{ç'ç11111,

nickel, siiicon allov rvas deveioocd ané p,rrcntrd {br

severe corrosirrc/wcar envi rr: nrernrs.

lh.is solution coirrbincd with thc ir*rcrent

properties of sLrclr Sprav and F-used coatinEs oin'retallursicai b<;n ding, zerc thr*trgh porosiLr' !rrooidcdimproved selvicr irelfcrrrnancc ovcr all oth*r sailitions

r:n ther r:arket is increasing the use ofihis apprtiacli.-lhe

increasi:rg usc cf al:ernativr: firls is cxtcndinsthe corrosion probkms in rùste to flnergy pla;rts an<i

i*atling to new developnc,rrts.

lhrough do.rlopnre rt in the e:rrly i !)9*s r:'ith

flttr...

Special Focus: Wear Protectior

Fig. 4. Ihe IDP :omple'e il eàrpldt€ rànge

ieaciir-rg Fiiwei cûnrFâirii:s and hlgh rempcratirr wfârinstir*tcs r lànil-; of ilo::i-t-aseti irieh tenrp*raiurc

alllvs n,as de ';eloped To Frot:.t 5oilrr tiibcs fr:*r:r

Itigh tcntperraiure crcsitti: *ear using thc arc lvire

spray dcp*rsitir)n plo.rss. 'ib.Jri1' thes: si:li<i industrialreferc:nces are bcilg uscri firr ncç,' ellov dcve:op:aent.

supported by lnrprovcrnclts in airplicatlrin rquiprncntrû lnlrer tiie incte:ising perlirrnl;rnce dcmands. tlt n-iant

ccll/1..'aste plants, iroilcr irr[ri: cûatinc is arr estriilis]:ed

rûutc ro e:<rcld tube iifi and prcgrcssive companics

ofier a rar.ge ofplotelticn aiioy: anri prûccsscs iailcrcci

Lo rhe spr:rilic'v\reâï alld corLosic;n denrarcls o1r thc

pl;rrr r.

Wear protection of transport tubing'1 he rn:r.jor lvcilr afeas outriclc the boiler arc concçrc:rirv!th the cnrsi-,ing and lransport ol carrl/{ircl al<-i ash

rei:tov;1.

A pleumnric ash tianspnrt iir:rn drc boilers to tLc

as!: cvilone ca*sej th; ùrisin:rl ciiror,v lif*time ter be

incrca.:erl by a {lcror i;f rhrce bv using a ncw design

and tir* usr of {ll}f '.r'earllat: sc,iuti*n.

Conclusions(lastoliu llutcctic's therrnal pcrver plaut lep:ir strviclr

pack;rge includcs: a widc range olrinlovative prtrlric:sto soh.e *.ear probicms; cr-siæ irnd il our w.olkshcp

rcfurbishl::rnt possi l:il i tics; incrcasr:ci ser.ii cc ii f e

over ccnve:rtir:nai *'eiiling ellcys; làst anrl efi:ectivc

ret$m to .rerv!rr'; aTlo,v de..clcpnreut llnci inior,isenra:rufàcruring.V,'iren a por,r,et pi;r:rt's crirical parts er*

{oc iarsc tc L,e inovcd tol exarnpil, C:rstr.-lin's C;stoi.al5ervlces maifitinalce cxp*rts * ill visii l custon-:er's

premises ro sclvc rirc probleur on-site. o

Enter 49 or @ at www.engineerlive.com/ip

,1,.i:Jil, t,;,rrlÈ.ilrllI È: I .'+:!rr:.=::

'1:

Fig.3. Dense roàting ûn lub€ panel ready pr0dçred by spray and luse prcress

Dr Gary Heath is with Castolin Eutectic, Lausanne, Switzerland. www.Gastolin.com

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