Revamps 2026 Issue

preparation was performed to eliminate corrosion damage prior to HVTS application. This ensured appropriate substrate condi- tions for long-term adhesion and performance. Fractionator tower • Operating conditions: 0.34 MPa/370°C. • Process fluid: Crude oil. • Cladded area: 32.8 m². Extensive pitting corrosion was identified prior to repair. Surface grinding and prepa-

ration were conducted to remove all corrosion features, followed by verification of substrate condition before appli - cation. This step was critical to ensuring cladding integrity, particularly under high-temperature service conditions. Recovery column tower (preventive application) • Operating conditions: 0.34 MPa/194°C. • Process fluid: Benzene, toluene. • Cladded area: 11 m². In contrast to other assets, only mild corrosion was observed. The alloy cladding technology was applied as a preventive measure, demonstrating its applicability not only for repair but also for proactive corrosion management. The horizontally oriented heat exchanger presented significant access limitations, with an internal diameter of approximately 850 mm. Application was required over approximately two-thirds of the internal surface. Despite these constraints, the higher bond strength alloy cladding was successfully applied, demonstrating suitabil- ity for confined and geometrically complex environments (see Figure 6 ). Heat exchanger (restricted geometry) • Operating conditions: 8.73 MPa/350°C. • Process fluid: Hydrocarbons. • Cladded area: 5.3 m².

Figure 6 Equipment after HVTS application

• Extent and morphology of corrosion damage (for example, generalised thinning versus localised pitting). • Remaining wall thickness relative to allowable limits (Fitness-for-Service [FFS]considerations). • Accessibility and geometric constraints. • Process conditions and expected degradation mechanisms. Where structural restoration was not required and sub- strate integrity remained acceptable, the alloy cladding with its dense microstructure and higher bond strength coating was selected as a corrosion-resistant barrier. In all cases, surface preparation was treated as a critical step, with complete removal of degraded coatings and pitting damage prior to application. Representative applications To illustrate the range of applications, several representa- tive assets are summarised for:

Gas drain separation tank • Operating conditions: 10 MPa/150°C. • Process fluid: Hydrocarbons, water, H2 S. • Cladded area: 5.3 m².

Application was required on the lower dome section of the vessel, necessitating work in a face-down orientation. Enhanced quality control procedures were implemented to ensure complete coverage and adhesion under these chal- lenging conditions.

Sulpholane stripper • Operating conditions: 0.34 MPa/195°C. • Process fluid: Hydrocarbons. • Cladded area: 26 m2.

Solvent regenerator • Operating conditions: 0.34 MPa/232°C. • Cladded area: 1.5 m².

The sulpholane stripper exhibited significant hydrocar - bon-induced corrosion, with previous coating systems showing inadequate performance. Inspection revealed widespread pitting corrosion beneath the existing coating. All previous coatings were removed, and surface

Severe corrosion and pitting were identified. Complete removal of corrosion damage prior to appli- cation was emphasised to ensure long-term cladding performance.

Revamps 2026