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Corrosion protection with High Velocity Metal Cladding Iain Hall, Chief Technology Officer, USA

Corrosion protection with High Velocity Metal Cladding Iain Hall, Chief Technology Officer, USA Samat Mahmutov, Director Raim Group, KZ. Japan. Kazakhstan. United States. Canada. South Africa. China. Middle East. India. NACE Gold Member # 566576. Introduction :

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Corrosion protection with High Velocity Metal Cladding Iain Hall, Chief Technology Officer, USA

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  1. Corrosion protection with High Velocity Metal Cladding Iain Hall, Chief Technology Officer, USA Samat Mahmutov, Director Raim Group, KZ Japan Kazakhstan United States Canada South Africa China Middle East India NACE Gold Member # 566576

  2. Introduction : IGS History and experience – protecting critical assets Begins 15 years of service with TengizChevroil in Kazahkstahn Adds mechanical and weld overlay service capabilities Executes first in the world offshore cladding work for Total World first application of high velocity cladding on-site - Sasol 2007 2007 2003 1980 1991 1997 2000 1994 30 Years of “ Surface Protection of Mission Critical Equipment with on-site, Thermal Spray and Weld Overlay Technologies”

  3. When does this need for protection occur? • Usually when not expected or not initially expected. • Existing systems might not be effective. (paints, overlay, plating, cathodic protection.) • Process and feed changes make conditions different from the original design intent.

  4. Addressed problem: Severe corrosion mechanisms limiting vessel life Acid Attack :

  5. Pitting Corrosion: Mechanisms of Corrosion • Typically due to Chlorides in a system locally breaking down protective scale. • This can occur with droplets on a surface or in submerged systems.

  6. Hydrogen Blistering and Cracking: Mechanisms of Corrosion • This occurs in systems with high H2S content. Often at elevated temperature, sulphidation of steel liberates ionic hydrogen which penetrates metals and collects at localized discontinuities.

  7. Sulphide Stress Cracking: Mechanisms of Corrosion • This occurs in conditions where hydrogen sulphides are present in solution and can attack steel. Higher water content can introduce this failure mechanism where it didn’t previously exist.

  8. Stress Corrosion Cracking (SCC) Mechanisms of Corrosion • This is a cracking of shells due to high chloride content in susceptible alloys (such as stainless steels.) SCC also requires the presence of stress in the base material.

  9. Solution: Upgrading internal metal surfaces with highly corrosion resistant alloy cladding Research Testing Qualification Application

  10. Case Study 1 – Pitting protection - Slug Catcher - Off Shore • Customer : Total ABK – Off-shore HP Slug Catchers • Problem: Chloride pitting of internal shell • Scope: Internal Cladding – NiCrMoW • Qualification: Total, Pau, France • Alternatives: Weld overlay (40 days) • Replacement (2 years) • Scope Duration: 15 days • Cost saving: 6 Million USD • + Production losses

  11. Case Study 2 - Amine Regeneration Column - Qatar Corrosion Mechanism : Dissolved acid gas pitting Alternative : 60 Million USD – replacement cost Solution : High Velocity metal alloy upgrade Result : Three problem free inspections later, Vessel condition preserved

  12. Case Study 3 – MP/LP Separators and Flare Knockout Drums Substrate /Base: Paint system replacement – permanent solution Scope : Remove paint system and replace with HVAS alloy Location: TCO, Kazakhstan Chevron Qualification : Richmond, California Long term benefit: Reduced T/A load and costs

  13. Case Study 4 – Liquefaction trains – Adgas - UAE Corrosion Mechanism : Stress Corrosion Cracking, new train (2 years old) Scope : 6 vessels, condensate stripper and discharge drums upgrade alloy cladding.

  14. Case study 5: De-ethanizer Column - Saudi Aramco Corrosion Mechanism : Sulphide Stress Cracking Solution: Protection of entire internal surface with upgraded highly corrosion resistant alloy (20 days) Alternative: Vessel removal, rework, PWHT and reinstall (4 months)

  15. Thank you Iain Hall, Chief Technology Officer, USA Samat Mahmutov, Director RaimGroup, KZ www.integratedglobal.com Japan United States Kazakhstan Canada South Africa China Middle East India

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