PTQ Q2 2026 Issue

Figure 6 Corrosion barrier provided by HVTS cladding

Figure 4 Mechanical repair phase: EKT quench column

Figure 5 HVTS application: EKT quench column

barrier proactively, operators can significantly reduce the probability of unplanned shutdowns, extend run lengths, and defer the capital expenditure associated with full-pres- sure part replacement or repeated weld overlays. The rela- tively low direct cost and reduced downtime also enhance ROI and lower total cost of ownership (TCO) for critical assets. Integration within RBI frameworks RBI frameworks are designed to prioritise inspection and maintenance activities based on the likelihood and conse- quence of failure, particularly for ageing assets operating in aggressive service. In this context, mitigation measures that reduce corrosion uncertainty and stabilise degradation mechanisms provide significant value beyond immediate repair. The application of cladding directly supports RBI objec- tives by addressing localised corrosion mechanisms at their source. By establishing a stable, corrosion-resistant barrier between the process environment and the pressure-retain- ing substrate, HVTS cladding reduces the progression of metal loss and limits development of new damage sites. This allows corrosion rates to be treated as effectively dormant for RBI modelling purposes, subject to verification of cladding condition. Following this specific type of cladding application, inspection strategies can be adapted to focus on cladding integrity rather than ongoing wall thickness loss. Inspection activities typically shift from frequent thickness monitoring to periodic confirmation of coating continuity, adhesion, and absence of under-cladding degradation. This approach simplifies inspection planning while maintaining confi - dence in pressure boundary integrity, particularly for assets previously identified as high risk due to localised corrosion. HVTS also improves the predictability of asset perfor- mance in services characterised by variable chemistry or intermittent corrosive conditions. By decoupling short-term process fluctuations from substrate exposure, the technol - ogy reduces uncertainty in degradation behaviour, which is a key input to RBI decision-making. This increased pre- dictability supports more stable inspection intervals and facilitates longer-term maintenance planning. Overall, incorporating the technology into an RBI-based

Figure 7 Final inspection: EKT quench column

effectively acting as a corrosion barrier, preserving the orig- inal substrate (see Figure 6 ). The turnaround duration was met, with no extension for cladding work. From an operational impact perspective, full unit re-commissioning remained on schedule. An early service performance evaluation showed no vis- ible signs of delamination, cracking, or corrosion under the lining after several months in service (see Figure 7 ). Going forward, scheduled future inspections were planned as per RBI intervals. These outcomes validate HVTS’s technical and operational feasibility for asset integrity preservation applications, with more than 6,000 projects completed to date. Technical implications The successful deployment confirms that HVTS is an effec - tive metallurgical upgrade option for pressure vessels, particularly where schedule constraints make weld over- lay impractical. The low heat input and mechanical-bond nature preserve base metal properties and avoid HAZ/ PWHT issues. Furthermore, high-nobility CRAs used in these claddings provide long-term resistance to organic acids, chlorides, CO₂, and other corrosive condensates typical in refinery units and petrochemical plants, making this type of clad- ding a robust barrier against both general corrosion and localised pitting or under-deposit corrosion. From a maintenance strategy perspective, HVTS aligns strongly with predictive and RBI-based maintenance phi- losophies. By proactively applying a long-term corrosion

PTQ Q2 2026