Project Overview
Industry: Renewable Energy
Location: NSW
Duration: 10 days
Types of Laser Used: 1000W Jango & 300W Needle
Summary: In September 2024, Precision Laser Cleaning (PLC) was engaged by a nationally significant asset owner to evaluate the feasibility of in-situ paint removal within key internal areas of a spiral casing during a scheduled outage. The objective was to prepare the surface for Non-Destructive Testing (NDT) and subsequent repair works.
Following a highly successful on-site delivery, PLC continues to be engaged to perform this work during scheduled shutdowns. Using Netalux laser technology in compliance with AMPP SP21511-1-2024 standards and applicable Worksafe legislation, PLC’s solution ensures safety, compliance, and environmental responsibility. By eliminating the need for component disassembly, the methodology drastically reduces downtime that previously lasted for months, establishing a significant milestone for both the project and the client.
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The Challenges
Traditional Methods: Spiral casing paint removal typically required full turbine and rotor disassembly to protect sensitive, high-tolerance components.
Confined Space & Limited Access: Minimal clearance at the trailing edge of stay vanes and tight gaps between guide vanes made alternative approaches extremely difficult, leaving full removal as the only previous option.
Dust Control Risks: In-situ cleaning increased the risk of dust and debris entering critical areas, including labyrinth seals, necessitating strict mitigation measures. Traditional removal methods made dust management easier but were time-consuming and costly for the asset owner.
Equipment Access: All personnel and equipment had to be mobilised through restricted manhole points, limiting operational flexibility.
Time Constraints: The project had to adhere to strict outage schedules to minimise turbine downtime and ensure timely recommissioning.
First-Time Execution: As the first in-situ laser cleaning project undertaken in these difficult-to-access areas, it required thorough planning, close coordination with the asset owner, and meticulous attention to detail to ensure successful execution
Material Preservation: Surface preparation had to avoid altering or degrading the underlying metal substrate, adding an extra layer of complexity.
The Solution
Deployment of Multiple Laser Systems:
Netalux Jango 1000W Systems – Utilised or bulk paint removal from the stay vanes. Positioned outside the spiral casing, the systems leveraged a 50m fibre cable to provide precise access to internal areas.
Netalux Needle 300W Systems – Mobilised internally through manhole access points for detailed cleaning of hard-to-reach trailing edges. The compact design and rotatable heads, exclusive to Netalux laser systems, were critical in delivering the required outcome and ensuring operator ergonomics and comfort.
Advanced Dust Control Measures: Industrial HEPA extraction systems, equipped with inline particulate and charcoal filters, were deployed to capture all paint fumes and dust directly at the source. This prevented contamination of sensitive areas and eliminated the need for post-cleaning site cleanup.
Specialized Team and Continuous Operation: A team of five highly trained operators worked in shifts, utilising multiple laser systems to maintain continuous operation. The project was completed ahead of schedule while fully complying with AMPP and Worksafe standards.
Precision Surface Preparation: The pulsed laser technology selectively removed the paint layer without impacting the underlying metal substrate. The process preserved the original surface profile while eliminating residual coating and contaminants from within surface cracks, without modifying the defect geometry or structural integrity, the inspection results accurately represent the true condition of the asset enabling reliable real-time defect assessment
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The Results
PLC’s pulsed laser cleaning methodology enabled paint removal to be carried out within a tight outage window while allowing critical internal turbine components to remain in place. By eliminating the need for full disassembly, minimising dust generation, and supporting parallel maintenance activities, laser cleaning provided the future only practical solution to meet the project’s operational, safety, and scheduling requirements.
This project demonstrates pulsed laser cleaning as a highly controlled, low-disruption solution capable of reducing downtime and costs while preserving sensitive assets in complex, confined industrial environments.
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