asset integrity strategy enables a transition from reactive corrosion management to proactive risk reduction. By sta- bilising corrosion mechanisms and reducing uncertainty, the IGS technology based on high-velocity metallic alloy particles provides a practical means of lowering the likeli- hood of failure for critical vessels and columns while sup- porting disciplined, data-driven inspection programmes. Conclusion This case study demonstrates that HVTS technology can offer a practical, cost-effective, and technically sound solu- tion for corrosion mitigation in pressure vessels, towers, and columns, even under tight turnaround constraints. By enabling rapid, low-heat metallurgical upgrade with minimal operational disruption, the technology supports a proactive maintenance philosophy that balances asset integrity, operational uptime, and lifecycle cost. For refining and petrochemical operators especially in regions with aggressive acid/amine/chloride/caustic service, the cladding technology represents a mature and reliable option to extend asset life, reduce downtime risk, and opti- mise maintenance expenditure. As a broader implication, this project supports the case for integrating advanced surface engineering technologies into mainstream asset integrity strategies across downstream operations globally. Future recommendations place a priority on long-term monitoring, standardisation of specifications, and extended application scope: • Long-term monitoring: Continue periodic inspections (every three to five years within the RBI framework) to val - idate cladding integrity, measure thickness retention, and detect any potential degradation. • Standardisation of specifications: Development of a company-wide HVTS cladding specification covering sur - face preparation requirements, alloy selection principles, thickness criteria, quality assurance testing, and periodic re-inspection planning to streamline future deployments. • Extend application scope: Evaluate other assets (amine units, caustic service vessels, overhead exchangers) for similar durable corrosion barrier upgrades where corrosion risk is identified. References 1 Campideli V.C., Koga H.H., Sicupira D.C., Lins V.F.C. A review on corrosion protection of metals and alloys by thermal spray coatings. International Journal of Engineering Research & Applications , Vol. 15, No. 1, 2025. ijera.com 2 High Velocity Thermal Spray (HVTS ® ) – Technology Catalogue. tech- nologycatalogue.com . 2025. 3 IGS Global Services, On-Site Thermal Spray Cladding Prevents Internal Corrosion. integratedglobal.com . 2025. 4 IGS Global Services, Prevent Ethylene Quench Tower Corrosion – On Site HVTS ® Cladding. integratedglobal.com . 2025. 5 New metal alloy materials slow corrosion in process vessels. Materials Performance Magazine. 2020. content.ampp.org 6 High Velocity Thermal Spray – role of thermal spray coatings on erosion, corrosion, and high temperature oxidation. ScienceDirect.com, 2024.
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Hayden Hill is Asset Integrity Specialist, Integrated Global Services (IGS). Email: hayden.hill@integratedglobal.com
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