Corrosion Case Study

Amine Regeneration Column

Amine Regeneration
Column Repair with
High Velocity Thermal Spray

Reduced life cycle cost

and effective risk mitigation

TA impact - 65 hours
Life cycle saving – $65.3M

Process Overview
Amine plants employ a regenerative process to remove acid gas
components (H2S or CO2) from a gas or light hydrocarbon stream. A Shell, tray supports
counter current reactive absorption process is utilized with an aqueous and downcomer brackets
amine solution in a multistage absorber column. The amine process protected with HVTS metal
permits regeneration of the solution by counter current steam stripping cladding
at higher temperature in a multistage regeneration column.

Integrity Limiting Corrosion

Several potential corrosion mechanisms exist in amine process
equipment. In the lower section of a regenerator for example,
carbon steel surfaces not wetted by the amine solution may be
attacked by water vapor condensation and the formation of
carbonic acid. Acid gas ratio, choice of amine, contaminants, two
phase flow, flashing, high velocities, vessel design and insulation are
all factors at play.

Prior Mitigation Strategies

Aside from operational considerations, several mitigation or repair strategies have
historically been employed when shell loss occurs. Some mechanical options included
installation of temporary clamps and plugs, vessel section replacement and application
of weld overlay. The time required for these, together with post weld heat treatment
and structural support considerations has often required extended turn around
schedules and associated production losses. Temperature and chemical compatibility
limitations have prevented effective use of organic coatings.

Surface Protection Solutions for

Mission Critical Equipment
 Corrosion Case Study

High Velocity Thermal Spray (HVTS) – New Application Technology

Severe pitting to a shell in a regeneration column was identified in a 400 000 bpd refinery. In some locations, pitting
had penetrated through the shell wall. Temporary clamps and plugs had been installed, but loss of containment posed
a major safety and environmental risk. Multiple sections of the column were cut out and replaced by a mechanical
contractor. IGS was contracted to employ a newly qualified technology to apply a corrosion resistant metal coating to
the internal surface to stop further corrosive attack. 407sqft of column shell was protected, including horizontal and
vertical tray supports. The operation was completed with 3 technicians in 65hours. The column was handed back to
the client for scaffold removal and tray installation.

Turn Around Risk Mitigation

The column was turned over to maintenance by the operations department with the objective of having the equipment
back online as quickly as possible. Due to criticality of the process and opportunity cost, a HVTS coating solution was
chosen over a weld overlay solution due to significant TA impact in time savings and the lack of need for post weld heat
treatment with column stabilization during the process. As the application of a corrosion resistant metal cladding had
no impact on the pressure bearing material of the shell, the scope complexity was significantly reduced. This facilitated
a simpler qualification path for the repair procedure. Immediately after completion of the coating scope, the vessel
was cleaned, trays were reinstalled, and the unit was boxed up.

Inspection / Integrity Assessment

Final inspection of the work scope involved the generation of an electronic thickness record with mapped
electromagnetic stand-off gage readings on a defined reference grid across the area coated. This record would be used
for future inspection and verification of coating integrity. Additional inspection technologies have been developed for
external, on-line verification of the coating condition by through vessel wall scanning. HVTS coating systems can be
readily inspected visually for any signs of deterioration. There is no need to high pressure water blast, sandblast or
mechanically abrade coating for inspection purposes. Unlike organic coating systems, HVTS metal coatings are long
term durable solutions with high mechanical toughness, abrasion resistance and wide service temperature and
pressure ranges. This substantially decreases life cycle cost and can extend required inspection intervals.

Value Proposition
IGS’s ability to provide advanced protection to the vessel shell in 65 hours and limit production losses was a key cost
factor for the client. The use of a high velocity thermal spray process was deemed more economical when compared
to weld overlay and column replacement strategies due to this time sensitivity. Total savings of $17,400,000 were
realized with HVTS application as compared to weld overlay, factoring in opportunity cost savings for the first year.
Costs saving of $64,500,000 were realized over a 3 year period versus mechanical section replacement, which was the
incumbent repair approach. The duration of the repair solution and further maintenance due to recurring corrosion
were taken into the calculation. Non-metallic coatings were not considered due to their inability to reliably achieve a
3 year run cycle in this corrosive environment.

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