Revamps 2026 Issue

Hot separator • Operating conditions: 3.04 MPa/121°C. • Process fluid: Hydrogen, naphtha. • Cladded area: 5.3 m².

Rather than representing competing technologies, WOL and alloy cladding can be considered part of a broader set of engineered solutions. Selection should be based on tech - nical requirements, operational constraints, and lifecycle considerations. Conclusions This study has evaluated the application of high-velocity thermal spray alloy cladding for corrosion mitigation in refinery process equipment, in comparison with conven - tional repair methods. The following conclusions can be drawn: • WOL remains a well-established and effective method for corrosion protection and structural restoration, par - ticularly where wall thickness has fallen below allowable limits. A combined approach, utilising both welding-based and thermal spray technologies as appropriate, enables optimised asset integrity management • Alloy cladding provides a dense, low-permeability corro - sion barrier with high adhesion strength and minimal ther - mal impact on the substrate. • HVTS is particularly suitable for applications requiring rapid execution, minimal heat input, and adaptability to complex geometries. • The selection of repair methodology should be based on an engineering assessment of equipment condition, oper - ating environment, and maintenance constraints. • A combined approach, utilising both welding-based and thermal spray technologies as appropriate, enables opti - mised asset integrity management.

Pitting corrosion was concentrated in the lower shell region. Surface preparation was conducted in coordination with the site contractor to achieve the required substrate condition, highlighting the importance of collaborative execution. Key observations Across all applications using the proprietary alloy cladding discussed throughout, several consistent observations were noted using this dense corrosion resistant barrier: • Surface preparation was critical : Complete removal of pitting corrosion and degraded coatings was essential to ensure cladding performance. • Applicability across diverse conditions : The alloy clad - ding was successfully applied across a wide range of tem - peratures, pressures, and process environments. • Adaptability to complex geometries : The technology was effectively implemented in confined spaces, irregular geometries, and difficult orientations. • Preventive and corrective use cases: HVTS alloy clad - ding with its dense corrosion barrier was applied both as a repair solution and as a preventive corrosion barrier. The multi-asset implementation demonstrates the importance of selecting repair strategies based on asset condition and operational constraints. While WOL remains appropriate in cases requiring structural restoration, alloy cladding provides an effective solution where: • Corrosion protection is required without significant wall loss. • Application time is limited. • Thermal input must be minimised. • The results indicate that a combination of technologies, applied based on engineering evaluation, can provide opti - mised outcomes for asset integrity management. Performance The case studies presented demonstrate that both weld overlay and HVTS alloy cladding can provide effective corrosion mitigation when applied under appropriate conditions. Weld overlay remains a robust and proven solution, particularly in applications requiring restoration of wall thickness or where extended shutdowns allow controlled welding procedures and post-treatment. Higher bond strength alloy cladding, by contrast, offers advantages in applications where: • Rapid execution is required within limited turnaround windows. • Thermal input must be minimised to avoid distortion or additional processing. • Complex internal geometries limit the feasibility of weld - ing-based approaches. The performance of advanced alloy cladding technology in long-term service, as demonstrated in the bespoke case studies, indicates that it can provide durable corrosion pro - tection when applied under suitable conditions.

HVTS is a mark of Integrated Global Services (IGS).

Recommended reading 1 API 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry, American Petroleum Institute, 2020. 2 API 579-1 / ASME FFS-1, Fitness-For-Service, American Petroleum Institute / ASME, 2021. 3 ISO 14923, Thermal spraying – Characterization and testing of thermal spray coatings, International Organization for Standardization, 2005. 4 JIS H 8300 (series), Thermal spraying – General principles, Japanese Industrial Standards Committee. 5 Integrated Global Services, HVTS Application Case Studies in Japanese Refinery Equipment, Technical Report, 2023. Shinji Masuzaki is a Sales Representative at IGS Japan, specialising in business development and project execution for corrosion mitiga - tion and asset integrity solutions for the refining and petrochemical sectors. With more than 20 years of experience in heavy industry, he has played a key role in delivering HVTS life-extension projects across Japan since joining IGS in 2021. Email: shinji.masuzaki@igsjapan.com

Revamps 2026