Careers 6+ Years of Reliability - Amine Regenerator H₂S Corrosion Protection
HT H₂S Corrosion Attack Identified After 2 Years of Commissioning – Mitigated with no PWHT
IGS has maintained a long-standing relationship with this Saudi Arabian energy company, successfully completing projects across numerous downstream refining and upstream gas processing facilities since 2013. Throughout these projects, IGS has demonstrated its ability to provide effective, long-term corrosion protection solutions, particularly for challenges encountered in desulfurization and sulfur recovery processes, among others.
Project Summary:
- Location: Rub’ al-Khali desert, Saudi Arabia.
- Facility Type: Natural Gas Liquids (NGL) Recovery Plant.
- Processing Capacity: 2.4 billion standard cubic feet per day (BSCFD) of natural gas.
- NGL Recovery Capacity: ~275,000 barrels per day.
Due to H2S corrosion affecting the base material near the tower’s top section, IGS applied HVTS® cladding to the interior surfaces to prevent further deterioration of the vessel’s internal diameter.
While traditional welding repairs would require Post Weld Heat Treatment (PWHT) of the heat-affected zone – leading to complex and time-consuming repairs – IGS’s HVTS® technology provides the required protection without PWHT requirements. Additionally, the HVTS® cladding offers temperature resistance comparable to the nickel-based alloy itself, making it suitable for high temperature service conditions.
Scope of Work (2017):
IGS provided HVTS® cladding to the interior of the Amine Regenerator:
- Shell section (trays 16–21).
- Top and bottom surfaces of tray rings.
- Downcomers, nozzles, and manways.
Completed in 7 shifts with zero safety incidents.
Scope of Work (2019):
HVTS® cladding applied to the stripper column:
- Tray support rings 16–21, downcomers, and interior surfaces of nozzles and manways.
Project completed in 7 shifts (1 shift ahead of schedule) with zero safety incidents.
2023 Inspection
An inspection conducted in October 2023 during a planned turnaround on the ID of the equipment revealed excellent condition of the HVTS® cladding. Key inspection details:
- Inspection methodology: Thickness gauge measurements and visual inspections for cracks, breakthroughs, and irregularities
- Findings: HVTS® cladding was found in excellent condition after 6 years in operation; thickness measurements
- Compliance: Inspection conducted according to IGS Quality Control Standards
Inspection Results
After 6 years of operation, the HVTS® cladding maintains excellent condition within the amine regenerator. All protected surfaces—including shell surfaces, downcomers, and tray support rings—show continued optimal performance and functionality. People are the core of our business. We pride ourselves in doing things the IGS Way, focusing on our four core values: Excellence, Reliability, Respect and Innovation.
Technical Recommendations
- IGS will be inspecting the HVTS® cladding condition at each next scheduled turnaround with the client.
- Monitor condition of shell areas below existing HVTS® cladding.
- Inspect uncladded areas (trays 15 to 1) for deterioration or corrosion.
- Consider extending HVTS® cladding to all severely affected areas for permanent asset integrity preservation.
Next Inspection
This proven track record of performance has positioned IGS as a trusted partner. Moving forward, the recommendation is to maintain regular HVTS® cladding inspections during scheduled turnarounds, while evaluating uncladded areas for potential protection expansion as needed.
HVTS® Technology Advantages
- Proprietary Superalloy Cladding: IGS’s patented HVTS® material was specifically designed for high-temperature environments and validated through multi-year testing in collaboration with OEMs.
- High Velocity Thermal Spray (HVTS®): The technology ensures dense, impermeable cladding with minimal stress on the substrate material.
- Custom Protective Isolation Tooling: Designed to shield areas not being treated and maintain critical tolerances during application.
Related Case Studies:
- Ethylene Quench Tower Corrosion Mitigation Saves $1.8Mil
- Cracker Quench Column Corrosion Stopped with IGS HVTS Cladding
- A Short-term Saving has a Long-term Cost!
- Column Shell Corrosion Protection Verified
- HVTS Prevents Corrosion Attack in a Regenerator Column at LNG Plant
- Severe Amine Column Corrosion Permanently Frozen
- Amine Regenerator Column Pitting – On-Site Shell Alloy Upgrade Stopped Column Corrosion
- IGS HVTS Mitigating CO2 Corrosion in Main Amine Column
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