Introduction
In the demanding world of power generation, maximising equipment lifespan and minimising downtime are the need of the hour. Boiler tubes, chimneys, and other structural components in power plants face intense environmental pressures, which often lead to costly shutdowns and frequent maintenance.
What if your equipment could handle these harsh conditions longer, with fewer interruptions?
Metatech offers advanced coating solutions specifically customised to the power industry, helping plants operate more efficiently.
Extending Equipment Life with Metatech’s Coatings
Metatech specialises in high-performance coating services for the power sector. With a focus on improving durability and operational efficiency, Metatech’s coatings offer protection, reducing the frequency of maintenance and associated costs. Our coatings play an important role in improving plant performance by simply extending equipment longevity.
Services Offered for the Power Industry
1. Boiler Tube Coating
Boiler tubes in power plants frequently face punctures and wear, leading to unplanned shutdowns and expensive repairs. Metatech offers two primary coating processes to solve these issues:
Coating Processes:
- Twin Wire Arc Spray Process
- Porosity: Less than 5-6%
- Adhesion: Up to 5,000 psi
- Hardness: 55-60 HRC
- Coating thickness: Up to 500 μm
- Quick application for minimal downtime
- High-Velocity Oxy-Fuel (HVOF) Process
- Low porosity (<1%)
- Superior adhesion (up to 10,000 psi)
- Hardness: 65-70 HRC
- Fine grain size and smooth finish for enhanced durability
2. Structural Steel Coating
Structural components in power plants, especially steel frameworks, face corrosion from high temperatures, moisture, and flue gases. Metatech’s corrosion-resistant coatings offer a lifespan three to four times longer than traditional paint, providing protection against the elements and extending the life of structural steel.
3. Chimney Coating
Chimneys in power plants endure extremely high temperatures and corrosive flue gases, leading to rapid corrosion if unprotected. Metatech’s high-temperature-resistant coatings are specially formulated to protect chimneys from harsh operational conditions, prolonging their service life.
4. Hydro Power Plant Coatings
Hydro turbines used in hydropower plants suffer from extensive wear due to high silt levels in water. Metatech applies tungsten carbide-based coatings through HP/HVOF systems, which reduce wear, improving the efficiency and longevity of turbines in hydroelectric plants.
5. Tungsten Carbide and Ceramic Coatings for Various Components
Metatech also offers versatile coatings for various high-wear components such as pump sleeves, shafts, textile mill rollers, and more. Tungsten carbide and ceramic coatings provide exceptional wear resistance, making them suitable for numerous applications across industries.
Why Choose Metatech?
- Advanced Robotic Coating Systems
Using 6-axis robotic systems, Metatech ensures precise and consistent coating application.
- Better Durability
Our coatings extend equipment life, reducing both maintenance frequency and costs.
- Expert Team
Our highly trained team is dedicated to providing the best quality coating solutions.
- Trusted by Leading Names
Metatech is a preferred partner for industry leaders, including NTPC, Jindal, Tata Steel, and Bharat Petroleum.
Conclusion
Metatech’s coating solutions help power plants to operate more efficiently and sustainably, protecting equipment against harsh environmental conditions. Companies are investing in longer-lasting, more reliable equipment and reducing unplanned downtimes by choosing Metatech.
For power plants facing demanding operational pressures, Metatech’s expertise in coating technology offers a solution to extend the life of components.
Contact us today at www.thermalsprayworld.com to learn more about how we can help.
For more details around the coatings, you can also follow our founder, Bhavik Patel on LinkedIn.