Thermal spray as a cost-effective and reliable alternative to weld repair (C2026-00320)

Zubair Ahmad, Chukwugozie R Ikeagu

Thermal spray technology is increasingly recognized as a technically robust and economically viable alternative to conventional weld repair during planned shutdowns in refineries and petrochemical facilities. Historically limited to temporary restoration applications, recent advancements in coating metallurgy and application techniques now position thermal spray as a credible means of permanent repair for static equipment. It offers significant advantage by eliminating the need for post-weld heat treatment (PWHT), reducing thermal stresses, and avoiding mechanical disassembly of critical components.
Field implementations demonstrate that thermal spray can restore structural and surface integrity with minimal downtime and labor, even under demanding process conditions. Notably, the technology has shown proven durability in extreme pH environments, making it suitable for equipment exposed to both highly acidic and highly alkaline services. Key case studies on heat exchangers and column inlets confirm not only corrosion resistance but also sustained performance under operational loads.
This abstract presents a framework for evaluating thermal spray as a scalable, efficient, and permanent repair methodology. The presented paper will delve deeper into the technical performance metrics, economic analysis, and long-term service validation across multiple turnaround scenarios.