Careers HVTS Protects Critical Heat Exchanger Tube Sheets in Demanding Petrochemical Service
During a planned turnaround, IGS was engaged to protect the inlet tube sheets of two critical PDH heat exchangers affected by significant corrosion. A durable metallurgical solution was required to stop further degradation, protect the existing equipment and support reliable long-term operation.
T26-44844
Plant Background
| Plant / Location | Petrochemical facility, Jubail Industrial City, Saudi Arabia |
| Process | Propane dehydrogenation (PDH) |
| Equipment | Second-stage trim cooler and compressor effluent chiller |
| Affected areas | Inlet tube-sheet faces |
| Primary concern | Corrosion and metal loss |
| Solution | IGS HVTS alloy cladding |
The Challenge
The heat exchangers operate with compressor effluent gas on the tube side, and propane refrigerant on the shell side, exposing the inlet tube-sheet faces to demanding process conditions.
Inspection identified:
- Severe corrosion of the tube-sheet faces
- Localized pitting and metal deterioration
- Risk of continued metal loss affecting equipment integrity and availability
The plant needed to address the existing degradation while upgrading the exposed surfaces to a more corrosion-resistant metallurgy, without replacing the existing heat exchangers.
The Solution
IGS applied its proprietary HVTS corrosion-resistant alloy cladding to the inlet tube-sheet faces of both heat exchangers, providing a targeted in-situ metallurgy upgrade over the existing carbon steel.
The HVTS system creates a dense, low-permeability metallic barrier that isolates the substrate from the corrosive process environment. Applied using engineered alloy materials and qualified procedures, the technology allowed IGS to upgrade the metallurgy precisely where protection was required.
Compared with conventional weld overlay, HVTS also offered a faster, less invasive application, making it well suited to execution within the planned outage.
“Not every integrity challenge requires large-scale replacement. This project shows the value of targeting the areas that need protection most, helping plants make smarter use of turnaround time and existing assets while strengthening long-term reliability.”
– Annas Alraigi, Business Development Manager, IGS
Results & Impact
HVTS was successfully applied to both heat exchangers within the planned outage, with the completed work meeting the required quality criteria.
The project delivered:
- Corrosion-resistant protection of the degraded tube-sheet faces
- Retention of the existing heat exchangers, avoiding tube-sheet or equipment replacement
- Protection against continued localized corrosion and metal loss
- Reduced turnaround impact compared with more invasive repair alternatives
- Greater confidence in the long-term integrity and reliability of the exchangers
Conclusion
By applying HVTS to the degraded tube-sheet faces, IGS delivered a targeted corrosion-resistant metallurgy upgrade while preserving the existing heat exchangers.
The project demonstrates how HVTS can protect critical exchanger components while balancing long-term integrity, asset preservation and turnaround efficiency.
Targeted protection, lasting performance.
That’s Asset Vitality.
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