Careers Extending Column Integrity Across Two Turnarounds With HVTS® Cladding
At a major integrated refinery in the Middle East, the Main Fractionator Column in the Residue Fluid Catalytic Cracking (RFCC) unit plays a critical role in overall plant throughput. In 2019, advanced corrosion was identified in the pressure boundary between trays 30–33 — a degradation that risked both safety and schedule.
The operator partnered with IGS to restore column integrity and eliminate repeat corrosion without disrupting the turnaround critical path. IGS delivered a proven HVTS® (High Velocity Thermal Spray) solution designed to protect reliability, minimize intervention, and extend the column’s service life by multiple turnaround cycles.
Speed of Execution and Long-Term Value Outperformed Other Options
Before engaging IGS, the plant considered multiple alternatives, including weld overlay and partial replacement. However, these options introduced significant risks related to safety, schedule, and cost.
IGS was selected for its proven HVTS (High Velocity Thermal Spray) cladding technology, capable of providing 15+ years of corrosion protection with minimal disruption to plant operations. The client had confidence in IGS’s ability to meet the tight turnaround window while delivering a turnkey, high-performance solution — without the thermal stress, risk of distortion, heat treatment requirements, or schedule implications of welding.
Reliable Delivery Through Two Phases of HVTS Cladding
In 2019, IGS completed HVTS cladding of 125 m² of the Main Column pressure boundary (trays 30–33), applying an IGS proprietary high-nobility alloy system as a robust protective barrier to prevent further internal metal wastage and maintain the asset’s integrity. The cladding was subsequently inspected in 2021 and found to be in excellent condition.
As a result, in 2023, the project scope was extended to protect an additional 239 m², covering the zone between trays 16–23. The scope included internal shell areas of the column and all welds on the pressure boundary, excluding tray rings and bolted internals. IGS completed the main scope 2.5 shifts ahead of schedule, reinforcing its reputation for reliable, efficient project execution.
Internals Protected In Situ
The lower section of the column, from the bottom up to tray #29, was originally lined with OEM-applied SS410 weld overlay. While this metallurgy provides baseline corrosion protection, any attempt to upgrade or restore it — especially across a surface exceeding 200 m² — would be highly complex, time-consuming, and costly. Such work would require full removal of the existing weld overlay, new welding procedures, and would introduce potential risks of distortion under time-critical turnaround conditions.
HVTS offered a faster, more flexible solution. With minimal thermal stress impact on the substrate, HVTS cladding can be applied directly over carbon steel and existing weld overlays. IGS provides high-performance protection without major intervention, preserving the column’s integrity while adhering to the turnaround schedule.
Quantifiable Impact and Proven Results
- 6 years of proven performance on trays 30–33, validated by inspections in 2021 and 2023.
- 100% cladding acceptance achieved in 2023.
- Reduced critical path — the 2023 scope was completed ahead of schedule.
- Zero downtime due to rework — every HVTS applications passed final QA/QC inspection.
Operational Confidence Delivered
This outcome demonstrates how IGS’s HVTS® technology safeguards reliability and execution certainty, supporting both turnaround contractors and plant teams to maximize uptime, maintain safety, and extend asset life across multiple cycles.
“Our goal wasn’t just to protect one vessel — it was to help our client create predictability in their operations. HVTS gave them the confidence to extend run lengths, reduce maintenance interventions, and plan with certainty. That’s the value of an asset integrity partner like IGS.”
Shyam Barshikar, Regional BD Director, IGS
IGS HVTS extended the life of a process-critical main column with zero rework, completing two scopes of cladding, four years apart, with inspection-proven results.
That’s Asset Vitality.
Integrity Sustained. Service Life Extended. That’s Asset Vitality.
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