Careers H₂S Corrosion Control in Oil & Gas
Protecting Amine Systems, Pipelines & Desalters with HVTS® Cladding
Proven Alloy Cladding Technology to Stop Hydrogen Sulfide Corrosion – No Weld Overlay. No PWHT. No Compromise.
Understanding the Risk: H₂S Corrosion in Oil & Gas Production
Hydrogen sulfide (H₂S) is among the most aggressive and costly corrosive agents found in oil and gas processing environments. From upstream pipelines to downstream amine regenerators and crude desalters, H₂S corrosion can compromise asset integrity, reduce equipment life, and cause unplanned shutdowns — often without warning.
At IGS, we understand the root causes and failure mechanisms behind H₂S corrosion. With more than two decades of experience applying in-situ High Velocity Thermal Spray (HVTS®) cladding to critical pressure vessels, we provide asset protection strategies that outperform traditional repair techniques and coatings.
Where H₂S Corrosion Strikes
H₂S corrosion mechanisms typically involve localized attack, particularly in areas with:
- High temperature gradients
- Acid gas breakout
- Two-phase flow or flashing conditions
- CO₂–H₂S mixtures, which amplify corrosivity
Key Areas Affected: Amine Systems, Desalters, Pipelines
- Amine regenerators and CO₂ strippers – Elevated temperatures in the reboiler and bottom trays lead to rapid pitting, crevice corrosion, and metal loss.
- Crude desalters – H₂S in the water-in-oil emulsion phase contributes to under-deposit corrosion and cracking, especially when chloride hydrolysis forms hydrochloric acid.
- H₂S pipelines and upstream vessels – Sour service lines face continuous exposure to H₂S, increasing the risk of general corrosion and sulfide stress cracking.
HVTS®: Field-Proven Barrier Against H₂S Corrosion
IGS HVTS® 5000 Series is a proprietary corrosion-resistant alloy (CRA) cladding system applied on-site to mitigate H₂S corrosion and prevent further metal wastage. Unlike weld overlays or organic coatings, HVTS® offers:
- No Post Weld Heat Treatment (PWHT)
- No Heat-Affected Zone (HAZ)
- No cure time or recoating cycles
- Fast, safe application – even in confined vessels
Our NiCrMo alloy cladding creates a dense, impermeable surface that resists chemical attack from hydrogen sulfide, carbon dioxide, water vapour, and cleaning chemicals.
Case Study: 6+ Years of H₂S Corrosion Resistance in an Amine Regenerator
A major gas processing facility in the Rub’ al-Khali desert, Saudi Arabia, experienced severe high-temperature H₂S corrosion in the upper trays of a 2.4 BSCFD Amine Regenerator column.
Rather than resorting to costly weld repairs, IGS installed HVTS® cladding across the affected shell, tray rings, downcomers, and nozzles in just 7 shifts — without PWHT. Six years later, inspection revealed no degradation, and the HVTS® cladding remains in excellent condition.
Key Outcome: Long-term protection, reduced downtime, zero safety incidents, and full structural integrity preserved.
H₂S Corrosion in Desalters: Why Coatings Fail
Desalters often suffer from severe pitting corrosion in the bottom third of the vessel — the liquid phase. This is where H₂S, residual chlorides, and cleaning agents combine to create highly corrosive localized conditions. Organic coatings, when used, tend to break down under steam-out, thermal cycling, or abrasive cleaning.
- HVTS® cladding offers a permanent solution, with:
- Robust performance in wet H₂S environments
- Steam-out resistance
- Compatibility with standard inspection techniques (no blasting or surface prep needed)
One client reported $75 million in combined savings across multiple desalters by switching from coatings to HVTS®.
H₂S Corrosion Mitigation in Pipelines and Sour Gas Units
For upstream operators facing H₂S pipeline corrosion or corrosion in high-pressure gas vessels, HVTS® provides the metallurgical upgrade needed to protect the base steel — without changing the substrate or incurring the delays of fabrication or weld overlay.
Our teams mobilise globally to apply HVTS® in the most demanding environments, ensuring your assets continue to operate safely, efficiently, and within specification.
Why IGS?
- Proprietary Alloy Chemistry – IGS 5XXX Series alloys are engineered to resist H₂S, CO₂, chloride, and acid gas corrosion, validated through rigorous lab and field testing.
- On-Site Application – No shipping. No hot work risks. HVTS® is applied in-situ, with custom tooling to protect tolerances and maintain vessel geometry.
- Verified Performance – All projects include electronic thickness mapping, visual inspection protocols, and ongoing support. Our claddings are designed to last entire inspection cycles, reducing the frequency and cost of future maintenance.
- Global References – With more than 3000 m² of internal surface protected in amine vessels alone, IGS is the trusted corrosion mitigation partner for top-tier operators worldwide.
Let’s Talk About Your H₂S Corrosion Challenge
Whether you’re planning a turnaround or responding to an urgent corrosion issue, IGS can help you evaluate your options and deliver a fit-for-purpose solution with proven ROI.
I’m here to help
Colin Bateman
IGS Subject Matter Expert
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