Careers Hydrogen Induced Cracking (HIC) Repair in an MDEA Regenerator Column
An oil and gas operator in Libya operates a critical gas processing facility where the MDEA Regenerator Column is essential for maintaining amine quality and overall plant reliability. Operating in continuous amine service, the column is exposed to corrosive process conditions that demand robust internal corrosion protection.
During a scheduled turnaround (TAR), internal corrosion was identified on the carbon steel shell between tray rings 5 and 7. Detailed inspection confirmed Hydrogen Induced Cracking (HIC). The column had previously undergone mechanical repairs, including external plate welding to address full-through leaks caused by corrosion damage.
If left unresolved, the HIC-related corrosion threatened pressure boundary integrity, run length, and maintenance predictability within the amine unit.
As a temporary mitigation measure, an internal organic coating was applied. However, due to the aggressive operating HIC-prone amine environment, this solution failed to provide long-term protection, requiring shutdowns every three months for inspection, monitoring, and repeated repairs. These frequent outages increased operational disruption and maintenance burden, highlighting the need for a proven, robust, long-term internal corrosion protection solution capable of performing in severe HIC-prone environments.
CS: T25-14406
Long-Term Internal Protection with HVTS® Cladding
IGS mobilized rapidly to site during the scheduled turnaround (TAR) and completed the full scope of work ahead of the agreed schedule. The HVTS® cladding solution was deployed as the internal corrosion protection upgrade for the MDEA regenerator column operating in HIC-prone amine service.
IGS Solution Scope
| Scope Element | Details |
|---|---|
| Protection Method | HVTS cladding |
| Application Area | Internal shell |
| Total Surface Area | 38.5 m²/414 ft² |
| Execution Method | Fully on-site, confined space |
All surface preparation, HVTS cladding application, inspection, and final acceptance were executed under approved IGS quality procedures, with continuous coordination alongside site operations and maintenance teams. The confined-space internal application was performed safely, minimizing disruption to amine unit operations and ensuring long-term corrosion resistance of the pressure boundary.
Quantifiable Impact and Proven Results
The HVTS cladding solution restored internal shell integrity and delivered measurable operational value aligned with the plant’s objectives.
Without HVTS cladding, the regenerator column would have required removal from service for three-monthly internal inspections, preventing sustained operation. The HVTS metallurgical upgrade addressed the identified integrity concerns. It also provided key technical justification for the granting of Fitness-for-Service approval, enabling safe, continuous operation of the column.
Safety And Quality Performance
| Metrec | Result |
|---|---|
| Safety Incidents | Zero |
| Schedule Delays | None |
| Scope Completion | 100% of planned scope |
| Quality Control | Executed under approved IGS QC and ITP |
This project wasn’t just about addressing corrosion in one area of the column. Our focus was delivering a solution that fit seamlessly into the client’s planned maintenance window, protected a critical asset long-term, and gave the operations team confidence in the reliability of their amine system moving forward.
– Mohamed Al Ahwani, Business Development Manager at IGS
Results Delivered
The HVTS® cladding solution restored the integrity of the MDEA regenerator column and provided long-term internal corrosion protection in a severe HIC-prone amine service environment.
| Outcome | Verified Result |
|---|---|
| Cladding Area Completed | 38.5 m²/414 ft² |
| Corrosion Resistance | Enhanced in WC7 amine exposure zone |
| Maintenance Performance | Completed within the planned window |
| Asset Life | Extended (10-15 years) through permanent internal protection |
| Maintenance Risk | Reduced future reactive intervention |
Post-application inspections confirmed that the HVTS® cladding thickness was fully compliant with the specified limits. Thickness measurements verified uniform application across the repaired area, ensuring effective corrosion mitigation and long-term pressure boundary protection within the amine regenerator column.
Asset Life Extension Delivered with Zero Downtime or Distortion Risk.
That’s Asset Vitality.
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