Careers Quench Tower Organic Acid Corrosion Mitigated with HVTS®
This Singapore Chemical Plant is one of the largest integrated chemical facilities globally. Operating since 2001 and significantly expanded in 2014, the plant produces over 2.5 million tonnes of petrochemicals annually and integrates with the parent company’s refinery operations.
Project Context
During September 2024, the Quench Tower required intervention due to organic acid corrosion. The facility follows a Risk-Based Inspection (RBI) approach to maintenance, with scheduled turnarounds every 4–5 years.
Challenge:
Stainless steel lined equipment experienced organic acid infiltration behind protective plates/strips, leading to shell corrosion.
Solution:
IGS applied specialized HVTS cladding to both failed lining areas and unprotected base material.
Results:
Through detailed inspection and surface preparation, IGS created a robust protective barrier preventing organic acid contact with base metal.
Technical Scope
The scope of work included a 240 m² area of the tower bottom section and adjacent nozzles.
The upgraded metallurgical specification was chosen based on:
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Previous corrosion patterns
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Operating conditions
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HVTS versatility, applicable both on existing linings and bare metal
Corrosion Mitigation Option Comparison
Cost and schedule savings comparison of various options for this project.
| Corrosion Mitigation Option | Estimated Cost (USD) | Cost Variation % | Mechanical Work Duration (Days) | Schedule Variation % |
|---|---|---|---|---|
| CS tower replacement with SS316L | 657K | X + 105% | 18 | X + 51% |
| CS internal weld overlay with SS316L | 730K | X + 130% | 27 | X + 170% |
| HVTS® with Modified Hastelloy C276 | 321K | X | 10 | X |
A commercial viability study was conducted by the asset owner comparing corrosion mitigation options applicable in this situation.
Solution Provided
The plant commissioned IGS to perform their HVTS base alloy upgrade. HVTS doesn’t require PWHT (and involves no HAZs). It provides a metallurgical upgrade with high nobility modified alloys ensuring a permanent impermeable barrier is in place.
Execution
Phase 1: Mechanical Work
IGS teams worked 24/7 for 9 days, completing the project (shell and nozzles) within the planned turnaround window.
Alternative welding solutions would have required full original lining removal and would cause delays extending the turnaround.
The application of organic coatings would only be a temporary solution and require cure time, further impacting the TA schedule.
Results
Success factors included:
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Planned TA schedule maintained
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No need for full SS lining removal (only badly affected areas were addressed)
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Metallurgy upgrade completed without welding/hot work
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No curing time
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No distortion
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Cost effectiveness
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.
Benefits of Applying HVTS
Cost and schedule savings comparison of various options.
| Mitigation Option | Estimated Cost in USD | Cost Variation % | Mechanical Work Days Duration | Schedule Variation % | |
| 1 | CS tower top replacement with alloy 825 cladding | $290K | X + 111% | 10 Days – | X + 43% |
| 2 | CS internal weld overlay with alloy 825 cladding | $256K | X + 86% | 12 days – | X + 71% |
| 3 | HVTS with Modified Hastelloy C276 | $137K | X | 7 days | X |
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