Facilitating reliable operation of the natural gas saturator at one of the largest Methanol Plants in the Middle East

Heat Exchanger Stress Corrosion Cracking

Corrosion was identified on the tube sheet and the cone during a planned turnaround.

Your Emergency is Our Routine

The problem was unexpected and required a prompt solution in order to not delay the shutdown. IGS assessed the issue, identified a lasting solution utilizing high nobility CRA alloys, and quickly mobilized a local team of specialized technicians.

IGS’ HVTS was applied following extensive surface preparation and successfully stopped stress corrosion cracking.
The heat exchanger was returned to service as planned with no delays or safety concerns.

PROBLEM

Internal surfaces of the heat exchanger had experienced micro Stress Corrosion Cracking (SCC) from Chloride or Sulphide attack or general corrosion mechanisms in the process stream. The plant maintenance team attempted grinding out some cracks but failed due to the complexity of crack locations (in between tubes) and fear of the cracks propagating further.

SOLUTION

The heat exchanger needed to go back into service within a matter of days. IGS quickly responded to this emergent need by utilizing in-country available resources. IGS HVTS cladding was applied onto the tube sheet and cone regions of the heat exchanger, facilitating its prompt return to service.

1 Situation Analysis

The plant maintenance team attempted grinding out some cracks but failed due to the complexity of crack locations (in between tubes) and fear of the cracks propagating further.

 

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hex-tube-sheet-before

2 IGS HVTS Solution

IGS quickly responded to this emergent need. IGS HVTS cladding was applied onto the tube sheet and cone regions of the heat exchanger, facilitating its prompt return to service.

 

 3 Ensuring Lasting Protection

Upon completion of the cladding application, IGS performed coating thickness and quality inspections. A complete thickness report was compiled for all applied cladding and the final ITP and Quality Control book was signed and shared with the asset owner’s inspection group.

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