Careers Emergency Water Seal Drum Corrosion Repair in H2S Environment
A leading European refinery identified corrosion below a nozzle on the process water inlet of a water seal drum during the final stages of a scheduled turnaround (TAR). This component handles seal water and flare gas contaminated with H₂S, making it highly susceptible to internal corrosion and critical to process safety. With just days remaining in the TAR window, the plant required a reliable, fast, and permanent solution to prevent unplanned downtime and restore the drum to full operational capability.
T25-40792
T25-40792
Evaluating the Available Options
The maintenance team considered several options, including deferring the repair, applying a temporary fix, or a full weld overlay. However, each alternative either lacked long-term durability, posed safety and time constraints, or risked extending the TAR schedule. Ultimately, IGS’s HVTS® (High Velocity Thermal Spray) cladding technology was selected for its flexibility, quick application without heat input, and proven longevity even in the most corrosive/high-temperature environments. The decision was also driven by IGS’s ability to mobilize within hours and coordinate tightly with the plant’s mechanical teams.
IGS Solution Delivery
IGS applied its proprietary HVTS cladding solution, utilizing a specialized alloy, followed by a topcoat to enhance chemical resistance. The selected scope focused on a 1.5-meter circumferential area around the nozzle, the zone most critically affected. Mobilization occurred less than 48 hours after the request, beginning with site induction and preparation. The application itself was completed in four 12-hour shifts, and the asset was handed over well within the turnaround window.
“This wasn’t just an emergency repair; it was the start of a new reliability strategy. We proved to this refinery that HVTS could deliver both speed and integrity when it mattered most.”
– Wouter Luimes, Business Development Manager, IGS Europe11
Quantifiable Impact and Proven Results
-
Zero downtime extension
IGS completed the work entirely within the existing TAR schedule.
-
€2M+ risk avoidance
Full replacement or unplanned shutdown was avoided.
-
15+ year corrosion resistance
The HVTS system now protects the drum against H₂S and seal water-induced degradation, removing this vessel from short-term inspection cycles.
Emergency turnaround saved. Long-term asset integrity secured.
That’s Asset Vitality.
WATCH: HVTS: Protecting Boiler Tubes and Process Vessels
Free consultation with an IGS Subject Matter Expert
IGS is here to provide information, answer questions and create an effective solution for your needs.