Careers Zero Shell Loss Verified After HVTS® Application in Quench Column
Plant and Challenge Description
A major U.S. refinery, recognized for its operational discipline and strong focus on reliability, encountered significant corrosion in a critical Quench Column during a planned turnaround. Severe internal corrosion, driven by sulfide and dew-point sulfuric acid attack, had compromised up to 50% of the vessel wall thickness in the liquid/vapor line area, with measured shell loss reducing thickness from the original 0.625″ to as low as approximately 0.3″.
With turnaround timelines fixed and increasing risk to run length, the plant’s reliability team required a permanent corrosion solution that could be implemented without extending the critical path.
T24-34683
Evaluating Corrosion Barrier Methods
Initially, conventional options were considered, including weld overlay and full component replacement. However, concerns around schedule delays, cost, and post-weld distortion led the team to reevaluate. IGS was initially brought in for consultation, though the client admitted to having doubts about HVTS effectiveness at the time.
The turning point came after seeing the condition of similar IGS applications and understanding the technical validation behind IGS alloy performance.
The speed of application, combined with IGS’s collaborative planning and integrity-based QA program, earned the team’s trust.
IGS Solution Delivery
IGS mobilized and applied its proprietary HVTS cladding system across 631 ft² of internal surface area within the 41-C-301 Quench Column. The solution was deployed from 25’ elevation to the bottom head, including nozzle ‘A’ and manways 1 & 3. All surfaces were blasted to IGS spec, with repairs coordinated by the plant’s team prior to application.
The HVTS cladding was applied at a nominal thickness of 20 mils, followed by an IGS surface conditioner to enhance corrosion resistance. The job was completed on schedule in under a week, despite delays from necessary weld repairs, and without safety incidents.
This project built on several previous engagements IGS had successfully completed across the client’s refinery network.
Quantifiable Impact and Proven Results
Nine months after application, IGS returned to perform an ultrasonic thickness (UT) inspection in July 2025. The goal was to verify system integrity and assess shell preservation.
The Results
- No cladding failure was detected across any of the 18 UT inspection points.
- Average HVTS thickness was measured at 21.2 mils, consistent with original as-applied values, confirming no degradation.
- Shell thickness remained stable, with multiple spot readings showing virtually no change from pre-application post-blast measurements (e.g., 0.278” vs. 0.275”).
- The plant’s integrity team corroborated these findings, noting no further wall loss since the HVTS was installed.
This level of asset preservation means the vessel, once at risk of near-future replacement, can now continue operating safely, without capital…
Partnership Evolution
Following this successful inspection, internal feedback at the plant shifted significantly. Plant personnel acknowledged that they were initially skeptical of HVTS, but seeing the results firsthand validated its value and effectiveness.
This project is now being positioned as a model solution to be shared across other Valero sites.
By demonstrating measurable performance and inspection-backed validation, IGS is now in discussion to support similar corrosion-critical assets at sister facilities.
The IGS HVTS cladding preserved critical vessel integrity with zero degradation and no shell loss. That’s Asset Vitality.
“Our goal wasn’t just to solve a corrosion issue; it was to give this plant the confidence to extend the life of a mission-critical asset, without compromise. Now that they’ve seen the results for themselves, we’re helping shape their long-term reliability strategy.”
Elizabeth Cano, Business Development Manager, IGS
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