Careers Stripper Tower H2S & HCl Corrosion Protection at Gulf Coast Refinery
Plant Profile
- One of the largest refineries in the United States
- Located in Houston, Texas
- Processing capacity: 585,000 barrels per day
- Strong emphasis onmechanical integrity and preventative maintenance
H2S & HCl Corrosion
The refinery was experiencing significant corrosion issues in two critical stripper towers and later discovered similar problems in a nearby debutanizer.
The primary damage mechanisms were hydrogen sulfide (H2S) and hydrochloric acid (HCl) corrosion.
These corrosion issues threatened operational efficiency and posed potential safety and compliance risks.
Initial Scope
- Two stripper towers requiring corrosion protection
- Combined surface area of approximately 2,400 ft²
- Existing condition included:
- Previous weld buildup in some areas
- Heavy erosion and scale
- Weld splatter
- Various pit defects
Solution Development
Upgrading the material with HVTS® will freeze the condition preventing further thickness loss and avoiding the need for further build-up in the future. The IGS team worked closely with the refinery to develop a comprehensive solution:
Information Gathering
- Collected detailed process media chemical composition
- Analyzed maximum operating temperatures
- Reviewed previous inspection reports
- Shared data with metallurgy team in Richmond, Virginia, for analysis
Expanded Scope
- During the planned maintenance, corrosion was discovered in a nearby debutanizer
- Added this 860 ft² vessel to the project scope
- Created a series workflow to maximize efficiency with one mobilization
Implementation
- Applied HVTS® cladding system
- Worked in series across all three vessels
- Operated on a 24-hour schedule with two shifts per day
Timeline and Efficiency
- Original timeline: 12-day critical path duration for both stripper towers
- Additional 5 days for the debutanizer work
- Project executed during peak season (Fall 2023)
- 50% faster and more economical than traditional weld overlay alternatives
- The metallurgy of internals upgraded with no need for replacement
Quality Assurance
- Conducted thickness measurements at approximately one-foot intervals
- Performed salt reading tests
- Created detailed surface thickness maps
- Ensured homogeneous and uniform application across all vessels
Results
- Successfully maintained planned turnaround schedule despite expanded scope
- Provided stress-free maintenance solution
- Enhanced long-term equipment reliability
- Eliminated the risk of pressure boundary failure
- Eliminated the risk of distortion
Conclusion
This case study demonstrates IGS’ ability to execute both planned maintenance and handle emergent discovery work efficiently. By implementing HVTS® corrosion protection solution, IGS provided the refinery with a faster, more economical alternative to traditional weld overlay while maintaining exceptional quality standards.
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