Careers Internal Corrosion Protection for Amine Regenerator Towers in Sour Gas Service
At a high-throughput sour gas processing facility in Canada, two amine regenerator towers play a critical role in acid gas removal, maintaining treated gas quality, process safety, and continuous plant reliability. Operating in severe amine service, these towers are exposed to corrosive process conditions that can lead to internal corrosion, surface pitting, and long-term pressure boundary degradation.
While one newly installed regenerator tower had not yet entered service, the second tower had experienced years of internal corrosion damage typical of sour gas and amine environments. The plant required a proven internal corrosion protection solution to ensure long-term asset integrity, reduce recurring maintenance, and prevent premature tower replacement.
T25-40848
Choosing a Long-Term Corrosion Barrier Without Welding
The plant evaluated traditional internal protection approaches, including repeated epoxy applications and weld- based repair methods. These options raised concerns about PWHT, extended schedules, and recurring maintenance exposure.
IGS was selected for its ability to:
- Provide a fast-application HVTS cladding system
- Facilitate effective application within restricted vessels
- Remove the need for welding, and as a result, heat-affected zones (HAZ), and post-weld heat treatment (PWHT)
- Ensure schedule reliability and lower operational risks
- Offer long-lasting dependability in amine service
Deploying Alloy Cladding in Confined Process Vessels
IGS installed HVTS cladding on both amine regenerator towers. The surface preparation involved abrasive blasting to meet white metal standards, followed by profiling to guarantee optimal mechanical bond strength. Even with the restricted geometry of the vessels, IGS carried out the work with minimal disruption and no safety incidents.
Tower #1 was primed for immediate application because of its new condition. In contrast, Tower #2 required additional mechanical preparation to address pitting and sharp surface transitions. The work was carried out in collaboration with the plant’s mechanical contractor before cladding could be applied.
HVTS Cladding Scope Summary
| Parameter | Value |
|---|---|
| Asset Type | Amine Regenerator Towers |
| Number of Assets | 2 |
| Total Cladded Area | 154 ft²/14.3 m² |
| Application Duration | 6 days |
| Welding/thermal work required | None |
Delivering Repeatable Results in Amine Environments
| Tower | Initial Internal Condition | Preparation Requirement |
|---|---|---|
| Tower #1 | New, clean surface | Minimal |
| Tower #2 | Heavy pitting and profile damage | Mechanical grinding and surface conditioning |
IGS adapted execution sequencing to ensure productivity was upheld while adhering to all quality and safety standards.
Establishing Long-Term Corrosion Resistance in Amine Service
The HVTS cladding system creates a robust, corrosion-resistant internal barrier tailored for harsh amine environments. By removing permeation pathways, this solution effectively enhances asset longevity and ensures reliable operation.
Technical Performance Outcomes
| Performance Attribute | Result |
|---|---|
| Corrosion Barrier Integrity | Dense, low-permeability alloy cladding |
| Heat Input to Vessel | None |
| Vessel Distortion Risk | Eliminated |
| Safety Performance | Zero incidents |
Benefits & Results
As demonstrated in this project, IGS provides quantifiable outcomes in terms of speed, quality, and reliability, with significant advantages that include:
- World-Class Quality and Global Agility in One Team:
On-time delivery with global-standard QC processes and responsive site adaptation. - Application Completed 3× Faster Than Welding:
Full scope completed in 9 calendar days for both towers. - No Vessel Distortion or PWHT Required:
Eliminated risk of structural impact or thermal damage during application. - HVTS Achieves <1 mil/year Corrosion Rates in Amine Environments:
HVTS selected specifically for alloy composition and high PREN value. - Enables Predictable Turnaround Schedules:
Surface profiling and cladding processes followed strict QC and SEE mapping procedures, enabling confident schedule planning.
This project wasn’t just about addressing corrosion inside two vessels. It was about giving the client confidence that their amine system is protected for the long term. By applying HVTS cladding before and after years of service, we helped them reduce future maintenance exposure and plan their operation with certainty.
– Mike Place, Business Development Manager, IGS
Future Recommendations and Next Steps
Based on the observed internal corrosion mechanisms in amine service, IGS recommended applying the same HVTS® cladding system to future amine regenerator towers and corrosion-sensitive process equipment prior to commissioning. Implementing internal corrosion protection before start-up in sour gas and acid gas removal service provides a proactive corrosion mitigation strategy, protecting the pressure boundary from day one of operation.
This proactive approach enables corrosion protection from day one, minimizing lifecycle maintenance costs and inspection findings associated with internal corrosion and pitting in amine environments. The effective execution and teamwork on this project have established a strong technical foundation for continued collaboration on future internal corrosion protection upgrades across the facility’s amine and sour gas processing assets.
Long-term internal corrosion protection delivered without welding or schedule risk.
That’s Asset Vitality.
WATCH: High-Velocity Thermal Spray, HVTS Solution Alloy Cladding
Free consultation with an IGS Subject Matter Expert
IGS is here to provide information, answer questions and create an effective solution for your needs.