Careers Sour Gas Corrosion Remediation at Qatar’s Largest LNG Producer
Extending Slug Catcher Life Without Replacement
At one of the world’s most advanced LNG production hubs, asset integrity is key. A critical section of the plant’s infrastructure, an extensive network of large-diameter finger slug catcher piping, was facing internal corrosion due to exposure to highly sour gas. This slug catcher corrosion had advanced significantly in several segments, posing a direct risk to operational continuity.
The plant’s objective was to preserve operational uptime while remediating compromised pipework, all under severe time constraints. Traditional replacement with Inconel-clad piping was ruled out due to long lead times. A high-performance, in-situ applied alternative was needed to extend asset life.
Problem:
Internal corrosion in critical 48-inch slug catcher piping threatened production uptime. Inconel replacement was not feasible due to long lead times and complexity.
Solution:
IGS delivered an in-situ, hybrid cladding solution combining HVTS and CRA weld overlay – achieving CRA-level protection without the extended delays of full pipe replacement.
Repurposing Carbon Steel with Engineered HVTS® and Weld Overlay
Scope
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708 m of new carbon steel pipe, 12 m each
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3,400 m² internal surface area for HVTS
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In-situ internal cladding of existing 48-inch pipes to a depth of five meters
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Inlet separation tubes (5–12 m) clad at Ras Laffan
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150 mm internal CRA weld overlay (Inconel 625) at each pipe end, fully automated
Technical Requirements
The solution had to:
- Replicate corrosion resistance equivalent to Inconel-clad pipe
- Withstand high H₂S levels
- Be applied rapidly on site
- Enable reliable joint welding during installation
- Integrate seamlessly between new and existing pipe sections
Integrated HVTS® and CRA Weld Overlay
The IGS solution involved three integrated technologies:
1. HVTS Internal Cladding
IGS selected a nickel-based HVTS alloy engineered for sour service. Its properties include:
- High noble content for corrosion resistance
- Low porosity and oxide content
- Strong mechanical adhesion without dilution
- Immediately ready for service, enabling rapid installation
White metal surface preparation (SSPC-SP5 / SA 3) was achieved using robotic blasting, ensuring maximum adhesion.
2. Automated CRA Weld Overlay
Each pipe spool end received a fully automated internal weld overlay of Inconel 625.
This ensured joint integrity and compatibility with field welds, eliminating inaccessible heat-affected zones.
3. HVTS Automation
The IGS system performed internal abrasive blasting, followed by real-time visual QA/QC and precise HVTS application. The automated process ensured consistent quality, minimized human error, and maintained safety throughout.
The system is designed and validated for 15+ meter access, providing future-ready capability.
CRA-Equivalent Protection Achieved Without Delay or Distortion
The execution phase followed a rigorous 12-month qualification program, including:
- Sour-service simulation and corrosion testing
- Cladding adhesion, bend, and metallography tests
- Robotic application trials in Richmond, VA
- Full-scale 48-inch demo at Ras Laffan
Final on-site demonstrations confirmed production-level quality, and IGS deployed with zero compromise on safety or performance.
Results:
- Avoided full pipe replacement and associated delays
- Matched Inconel-clad pipe performance
- Enabled safe, rapid deployment with in-situ application
- Protected hundreds of millions in asset value through uptime assurance
“Our focus wasn’t just on protecting pipes, it was about protecting LNG output, project timelines, and operational confidence. With HVTS and CRA overlay, we delivered a solution that this plant could trust for both safety and performance.”
– Rohit Kardile, Technical Business Development Manager, IGS
Proven Execution Led to Strategic Asset Protection
Following successful qualification and field deployment, IGS’s solution was integrated into the operator’s broader asset-integrity strategy.
The combination of manual and semi-autonomous HVTS and CRA overlay provided a repeatable, scalable method for remediating high-risk sour service piping, with zero compromise on safety or performance.
No delays. No replacements. Just lasting protection, delivered on time.
That’s Asset Vitality.
WATCH: Robotic WOL and HVTS Protection for Qatar’s Largest LNG Producer
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