Careers H2S Corrosion in Upstream Flow Splitter Vessels Permanently Stopped
In 2020, the client, in collaboration with Integrated Global Services (IGS), developed and finalized the technical specification for High Velocity Thermal Spray (HVTS®) cladding to address severe corrosion challenges in its critical process vessels. This collaboration marked the beginning of a highly successful partnership that has since expanded based on demonstrated results. The specification was first implemented on a flow splitter vessel, setting a benchmark for corrosion mitigation in the client’s assets.
T24-13477
Corrosion Found in Separator Vessel
Deep pitting corrosion, reaching depths of up to 8 mm, was identified in the bottom third (liquid zone) of the separator vessel shell, circumferential welds, drain nozzles, and manholes. The corrosion was caused by an acidic process feed consisting of hydrocarbon gas, liquid, and water, combined with high operating temperatures.
Without addressing the underlying corrosion mechanism, the vessel’s containment would eventually be compromised, necessitating complete replacement.
2020 HVTS Project – High Velocity Thermal Spray Technology
IGS HVTS technology was selected to upgrade the carbon steel internal surface metallurgy of the vessel in-situ with a high-nobility alloy, effectively arresting further metal degradation caused by the corrosive environment. This solution substantially extended the asset’s service life, eliminating the need for costly and time-consuming vessel replacement.
Project Summary
Scope of Work:
IGS applied protective HVTS cladding to the bottom half of the vessel’s internal surface and multiple internal nozzles, effectively halting corrosion and restoring the vessel’s operational integrity.
Material Used:
A proprietary HVTS cladding system was utilized to deliver long-term corrosion protection in the harsh service environment.
Execution Timeline:
The project was completed in September 2020, during the height of the global COVID-19 pandemic. Despite widespread logistical and travel challenges, IGS successfully mobilized, executed, and demobilized on schedule—a significant achievement under those conditions.
Key Challenge:
The vessel exhibited extensive internal corrosion, including deep pitting and weld degradation, which required thorough surface repair and preparation before HVTS cladding could be effectively applied.
2023 Inspection Results
In January 2023, the asset owner’s maintenance team, together with IGS, conducted an inspection of the Flow Splitter and confirmed that the H₂S corrosion mechanism had been permanently mitigated through the application of IGS’s proprietary HVTS technology. This inspection represented a crucial milestone in the validation process of the HVTS solution. As a result, the asset owner decided to adopt IGS HVTS technology more broadly to permanently prevent metal degradation in high-temperature, acidic environments across its field equipment.
Client Endorses HVTS with Second Flow Splitter Cladding in 2024
Flow Splitter Vessel – 2024 Project
Following the successful 2023 inspection of the first HVTS-clad flow splitter vessel, the asset owner validated the performance of IGS HVTS technology in permanently mitigating H₂S corrosion. Building on these proven results, the client decided to proceed with the application of HVTS on a second flow splitter vessel in 2024.
For this project, IGS applied HVTS cladding to 158 m² of the vessel’s internal shell, covering the bottom half from the 3 to 9 o’clock positions, as well as multiple internal nozzles within the designated HVTS cladding zone.
Results
The project was completed ahead of schedule and without any safety incidents, underscoring IGS’s strong safety culture and commitment to operational excellence. The quality of the HVTS application matched that of the successful 2020 project, further reinforcing the client’s confidence in the reliability and long-term effectiveness of IGS HVTS technology.
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