Careers Proven HVTS® Performance in Amine Service at a Major UAE Gas Processing Complex
At a large onshore gas processing complex in the UAE, amine sweetening and regeneration units handle wet H₂S and CO₂ at elevated temperatures. These conditions can drive localized corrosion on the pressure boundary (vessel shell, heads, and nozzle/penetration welds), especially at vapor–liquid interface elevations and in the hottest sections of the unit, where acid-gas breakout and high velocities can intensify corrosion. To mitigate these risks and maintain pressure boundary integrity, the operator adopted High Velocity Thermal Spray (HVTS), a dense, low-permeability corrosion-resistant alloy cladding applied with true high-velocity equipment. Over multiple project executions since 2014, HVTS has consistently demonstrated predictable and reliable in-service performance at this site.
T21-14485
Corrosion Mechanisms Addressed in These Projectst
Wet H₂S and CO₂ at elevated temperatures resulted in localized attack on the pressure boundary (vessel shell, heads, and nozzle/penetration welds).
Within amine absorbers and regenerators, common damage modes include pitting, crevice corrosion, flow-enhanced corrosion, and general metal loss. Most corrosion is linked to acid-gas (H₂S/CO₂) breakout attacking steel at elevated temperature, with a significant share of incidents occurring in the hottest sections of the unit (for example, regenerator bottom and reboiler circuits).
Contributing factors, such as the acid-gas ratio, amine selection, contaminants, two-phase flow, flashing, high velocities, vessel design, and insulation, influence the severity and location of attack. An HVTS metal cladding applied in-situ at true high velocity establishes a durable CRA barrier without HAZ or PWHT, and offers superior longevity versus organic coatings, helping maintain long-term vessel integrity in amine service.
Case History
(Three Separate Project Executions)
2014 – Initial HVTS Adoption
(Absorber)
Project Context
Localized corrosion in sour amine service. HVTS was selected to protect targeted internal shell zones on pressure vessels.
Outcome
Work executed under site HSE systems and closed out with client inspection and acceptance.
2015 – Follow-on HVTS
Application (Absorber)
Project Context
Building on the prior year’s outcome, the operator extended HVTS to a second absorber during the next turnaround.
Outcome
Mobilization was completed safely and within the planned window; the project was closed out with a site inspection.
2020/21 – Expansion to High-Pressure Absorbers (Three Units)
Project Context
With HVTS established at the complex, the operator expanded coverage to additional absorbers in the amine unit.
Outcome
Project execution conducted to site standards with formal QA/QC and completion documentation.
Technology qualification for deployment
A comprehensive pre-qualification program at the IGS Richmond, Virginia laboratories, witnessed and verified by an independent third-party inspection company, assessed adhesion/bond performance and microstructural characteristics to confirm suitability in sour amine environments. The qualification was subsequently accepted for use by the operator, supporting formal approval of IGS HVTS for the UAE onshore gas processing complex.
Why HVTS – anchored in five pillars
- High-velocity process: Produces a dense, low-permeability metallic cladding with strong mechanical bonding; low heat input and no PWHT make it well-suited to pressure vessels and tight turnaround windows.
- Material modifications for large-scale in-situ use: Engineered alloy feedstock limits in-flight oxidation and residual stress, delivering durable, field-applied cladding for H₂S/CO₂ amine service.
- Qualified procedures: Defined, repeatable parameters, validated through pre-qualification testing, ensure consistent outcomes across units and outages.
- Dedicated, trained execution resources: Specialized crews and supervision experienced in confined-space, turnaround environments, and the nuances of amine equipment deliver safe, predictable execution.
- Over-arching Quality Management System: Integrated QA/QC, documentation, and inspection hold points provide end-to-end traceability from surface preparation through cladding and close-out, ensuring seamless continuity.
Reinforced by track record
These pillars are validated by a demonstrated history of success across multiple mobilizations and units at this site, as well as by extensive HVTS deployments in gas-processing equipment worldwide and across the Middle East with major oil and gas companies.parameters, validated through pre-qualification testing, ensure consistent outcomes across units and outages.
“In environments where corrosion risk is non-negotiable, reliability and predictability are key. These projects demonstrate what proven HVTS can deliver – long-term integrity of the pressure boundary.”
– Dennis Snijders, Sr. Director – Middle East, IGS
Performance on subsequent inspections
Across the 2014, 2015, and 2020/21 project executions, follow-up inspections have consistently supported stable, in-service performance of the HVTS-protected pressure boundaries, underpinning the operator’s decision to extend and standardize HVTS for at-risk locations in amine service.
Conclusion
Over three separate project executions spanning a decade, HVTS has delivered predictable, reliable integrity of the pressure boundary in harsh amine (H₂S/CO₂) service at a major UAE gas processing complex. This track record has reinforced HVTS as the operator’s preferred approach for protecting critical column shells while supporting safe and efficient turnaround execution.
IGS HVTS restored long-term reliability across three absorber columns in harsh amine service, with no heat treatment of the parent substrate, no vessel distortion, and fast execution.
That’s Asset Vitality.
WATCH: How Does HVTS Perform in Aggressive Environments Like Sour Gas or Amine Service?
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