Corrosion protection by Metal Cladding Technology ... - Fleming gulf
Corrosion protection by Metal Cladding Technology ... - Fleming gulf
Corrosion protection by Metal Cladding Technology ... - Fleming gulf
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<strong>Corrosion</strong> <strong>protection</strong> <strong>by</strong> <strong>Metal</strong> <strong>Cladding</strong><br />
<strong>Technology</strong>, Case Studies<br />
and Turnaround Incorporation<br />
Iain Hall, Chief <strong>Technology</strong> Officer<br />
United States<br />
Japan<br />
Kazakhstan<br />
China India<br />
Gulf States<br />
South Africa<br />
0<br />
Strictly Confidential
Presentation Overview<br />
1. Short Company Introduction<br />
2. <strong>Metal</strong> <strong>Cladding</strong> <strong>Technology</strong><br />
3. Case Studies<br />
4. Turnaround Implementation<br />
1<br />
Strictly Confidential
Important IGS Milestones<br />
<strong>Metal</strong>spray is<br />
established,<br />
serving the pulp<br />
and paper industry<br />
with thermal spray<br />
protective coatings<br />
The Company<br />
acquires Department<br />
of Energy high<br />
temperature erosion<br />
testing facility<br />
Adds mechanical<br />
service capabilities<br />
IGS acquires<br />
UTT on-site<br />
experience<br />
O&G - Sasol<br />
1980 1991 1994 1995 2000 2003 2007 2007 2011<br />
2<br />
Begins service<br />
agreement<br />
with Tengiz<br />
Chevroil in KZ<br />
The<br />
Company<br />
adds weld<br />
overlay<br />
capabilities<br />
IGS is the most experienced, longest tenured integrated provider of in situ surface <strong>protection</strong><br />
in international critical process markets.<br />
Strictly Confidential<br />
IGS continues engagement<br />
with TengizChevroil in a 7<br />
year maintenance contract.<br />
Is actively engaged in<br />
Equipment Maintenance with<br />
Qatar Petroleum, Total (Off-<br />
Shore), Oryx, Dolphin Energy,<br />
ADGAS (2012/3)<br />
2013
IGS Global Presence – Qatar / UAE and soon KSR Base<br />
Projects Completed <strong>by</strong> IGS to Date<br />
Near-Term Expansion Opportunities<br />
3<br />
QP<br />
ORYX<br />
DOLPHIN<br />
TOTAL<br />
ADGAS<br />
Strictly Confidential
2. What is <strong>Metal</strong> <strong>Cladding</strong>/Coating ?<br />
4<br />
Strictly Confidential
What it is not !<br />
5<br />
Strictly Confidential
<strong>Metal</strong> <strong>Cladding</strong> Protection<br />
6<br />
Strictly Confidential
Thermal Spray Process<br />
7<br />
Strictly Confidential
Reliable <strong>Corrosion</strong> Resistance<br />
with High Velocity Thermal Spray<br />
8<br />
Strictly Confidential
Coating Application – Wire Feedstock<br />
Low Velocity Arc Spray<br />
(TWAS)<br />
• High Oxide content<br />
• Interconnected oxides<br />
and porosity<br />
(Only good for Al,Zn)<br />
9<br />
High Velocity Arc Spray<br />
(HVAS)<br />
• Higher Density<br />
• Higher Bond strength<br />
• More Homogenous<br />
Microstructure<br />
Strictly Confidential
Coating Application – Powder Feedstock<br />
High Velocity Oxy Fuel (HVOF)<br />
compressed<br />
airoxy/propa compressed ne<br />
air high alloy<br />
compressed<br />
powder<br />
airoxy/propa<br />
compressed ne<br />
air<br />
10<br />
air<br />
envelope<br />
substr<br />
ate<br />
Strictly Confidential
Coating Base <strong>Metal</strong> Interface<br />
<strong>Metal</strong> <strong>Cladding</strong><br />
11<br />
Strictly Confidential<br />
Base <strong>Metal</strong> – Acid Etched
Surface Profile<br />
Interface – 50MPa Bond Strength<br />
No Heat Affected Zone (HAZ)<br />
12<br />
Strictly Confidential
<strong>Corrosion</strong> Mechanism<br />
Coating<br />
Particles<br />
Substrate<br />
Permeation <strong>by</strong><br />
corrosive media<br />
Low Velocity<br />
High Velocity<br />
13<br />
Strictly Confidential
Base Alloy Selection<br />
14<br />
Strictly Confidential
Process and Material <strong>Technology</strong><br />
Material Development<br />
We customize solutions to meet<br />
applications across end markets.<br />
Process Design and<br />
Optimization<br />
15<br />
Strictly Confidential<br />
UTEx 5-420 + 5-620(Chevron Spec)<br />
Specified for corrosion <strong>protection</strong><br />
H2S and Cl service<br />
•High Velocity Application<br />
•Low stress, low permeability<br />
•High Bond Strength<br />
•Independent qualification through:<br />
Chevron, Total, TWI
Material performance testing<br />
16<br />
Strictly Confidential
Coating Resistance - Permeability<br />
<strong>Corrosion</strong> Rate (mpy)<br />
1200<br />
1000<br />
800<br />
600<br />
400<br />
200<br />
High Velocity Coating<br />
<strong>Corrosion</strong> Rate of High and Low Velocity<br />
Alloy 625 Coatings v s Thickne ss<br />
Low Velocity Coating<br />
0<br />
0 20 40 60 80 100<br />
Coating Thickness (mils)<br />
High Velocity Low Velocity<br />
Low Velocity Trend High Velocity Trend<br />
17<br />
Strictly Confidential
UTEx 5-420 Low Stress – Low Oxide HVAS Coating<br />
Characteristics<br />
Porosity < 1 %<br />
Total Oxides < 5 %<br />
Bond Strength 46 MPa<br />
Nominal Material Composition<br />
18<br />
Strictly Confidential
Strictly Confidential<br />
UTEx 5-620(Chevron) Low Stress – Low Oxide HVAS Coating<br />
Characteristics<br />
Porosity < 1 %<br />
Total Oxides < 5 %<br />
Bond Strength 47 MPa<br />
Nominal Composition<br />
19
Automated Weld Overlay - CRO<br />
20<br />
Strictly Confidential
Weld Overlay <strong>Technology</strong><br />
21<br />
IGS - Pulsed MIG<br />
Spray Transfer<br />
Strictly Confidential<br />
• Strong magnetic field from rapid high current<br />
pulsing initiates rotary spray transfer<br />
• Droplet size much less than electrode<br />
diameter<br />
• Higher current results in less heat, less<br />
distortion, less dilution<br />
• Reduced heat affected zone<br />
• Better weld chemistry
Weld Overlay <strong>Technology</strong><br />
22<br />
• NBIC R-Stamp<br />
• ASME Sec IX<br />
PQR/WPS<br />
Strictly Confidential<br />
Flexible on-site, in-situ field<br />
application – shell and nozzles
3. Case Studies<br />
23<br />
Strictly Confidential
Alloy Selection for Slug Catcher Application<br />
Total ABK – Slug Catcher (2 units):<br />
Substrate /Base:<br />
Carbon Steel – 316 strip clad WO<br />
<strong>Corrosion</strong> Mechanism :<br />
Pitting in 316L initiating due to Chlorides<br />
Shell and Nozzles :<br />
Thermal Spray / Weld Overlay<br />
24<br />
Strictly Confidential
Alloy Selection for Slug Catcher Application<br />
25<br />
Strictly Confidential
Alloy Selection for Slug Catcher Application<br />
Ideal Alloys<br />
Ni,Cr, high Mo – C276<br />
High Pitting <strong>Corrosion</strong><br />
Resistance<br />
Shell Internals<br />
Thermal Spray<br />
Nozzles:<br />
Thermal Spray and<br />
Weld Overlay<br />
26<br />
Strictly Confidential
Alloy Selection for Slug Catcher Application<br />
Nozzles:<br />
Weld Overlay qualified per<br />
ISO 15156 ASME IX<br />
27<br />
Strictly Confidential
Alloy Selection for Slug Catcher Application<br />
28<br />
Strictly Confidential
Amine Regeneration Column<br />
Substrate /Base:<br />
Carbon Steel<br />
<strong>Corrosion</strong> Mechanism :<br />
Large scale pitting and washing out<br />
Coating Used:<br />
UTEx 5-420 – UTEx 6-210 Sealant<br />
Desired Outcome:<br />
Protect shell for four years until<br />
replacement<br />
2 yr Inspection Outcome:<br />
Extend coating, cancel immediate<br />
vessel replacement<br />
29<br />
Strictly Confidential
Amine Regeneration Column<br />
30<br />
Strictly Confidential
Amine Regeneration Column<br />
31<br />
Strictly Confidential
Amine Regeneration Column<br />
32<br />
Strictly Confidential
Amine Regeneration Column<br />
Original Condition Condition after 2 yrs<br />
33<br />
Strictly Confidential
Other <strong>Corrosion</strong> Applications and<br />
Case History<br />
• General broad area metal loss<br />
• Aggressive pitting<br />
• Stress <strong>Corrosion</strong> Cracking<br />
• <strong>Metal</strong> Dusting<br />
• Fe Contamination<br />
• Belzona/Epoxy Permanent Replacement<br />
• Atmospheric / Marine <strong>Corrosion</strong><br />
34<br />
Strictly Confidential
Upstream, Downstream and other Petrochem applications<br />
Total<br />
Belgium<br />
Sasol Synthetic Fuels<br />
South Africa<br />
Tengizchevroil<br />
Kazahkstan<br />
Shell<br />
Canada<br />
BP<br />
Lima USA<br />
Caltex<br />
South Africa<br />
Chevron<br />
Canada<br />
Eneos<br />
Japan<br />
Oryx +<br />
QP<br />
Qatar<br />
35<br />
Amine<br />
Regenerator<br />
Flare KO Pot<br />
H2S Absorber<br />
Sulfinol Contactor<br />
Incinerator<br />
Oxygenate Removal<br />
Column<br />
Process Cooling Water<br />
Heat Exchanger<br />
Waste Heat Boiler<br />
Synthol Reactor<br />
Strictly Confidential<br />
Catalyst loading<br />
valves and piping<br />
Overhead Condenser<br />
Acid Gas<br />
Scrubber Column<br />
Buffer Drum Oxygen Intercooler<br />
Hot Quench Tower Storage Tanks<br />
Distillation Columns<br />
Amine Contactor
4. Turnaround Incorporation<br />
36<br />
Strictly Confidential
What is required from a First Class Contractor ?<br />
Surface<br />
Protection Broad Service<br />
Technologies:<br />
HVAS / HVOF<br />
WeldOverlay<br />
TWAS(Al)<br />
Monitoring<br />
Simulation<br />
Failure Analysis<br />
Testing<br />
0 LTI’s<br />
In last 3 years<br />
Proven<br />
Experience and<br />
Good Track<br />
Record<br />
37<br />
Ownership<br />
Of <strong>Technology</strong><br />
External<br />
Partnerships<br />
Project<br />
Management,<br />
Equipment,<br />
Labour, Materials<br />
and Deployability<br />
Strictly Confidential
Continuous Improvement Process Approach<br />
38<br />
Strictly Confidential
What is required from a First Class Customer ?<br />
• Pre - ”Request For Quotation” Collaboration<br />
• Primary Scope of Work<br />
• Battery Limits – (Supplemental in/out of scope)<br />
• Pricing Structure ( Fixed + Discovery Scope)<br />
( lump sum + unit priced scope)<br />
• Request for Quotation<br />
• Fixed and Flexible submission format<br />
• Post Bid Review<br />
• <strong>Technology</strong> / Efficiency gains / Pricing structure<br />
• Post Award Scope, Time and Resource Optimization<br />
• Inclusivity in Turnaround Planning<br />
39<br />
Strictly Confidential<br />
or $/m2 ?
What is required from a First Class Customer ?<br />
• Fast Efficient Communication Channels<br />
• Safety<br />
• Quality<br />
• Scope Completion / Change<br />
• Permit<br />
• Resource provision ( scaffold etc)<br />
• Contractual liason<br />
• Post Turn Around<br />
• Best Practices<br />
• Lessons Learned<br />
• Initiate Planning for Next Outage<br />
40<br />
Strictly Confidential
IGS Contact Details :<br />
Iain Hall, Chief <strong>Technology</strong> Officer<br />
iainhall@integratedglobal.com<br />
+1 804 314 5603<br />
Local Representation - Petro<strong>gulf</strong> :<br />
S.Y. Satish – Sr Sales and Marketing Manager<br />
satish@petro<strong>gulf</strong>.org<br />
+97455882314<br />
United States Japan<br />
Kazakhstan<br />
China India<br />
Gulf States<br />
South Africa<br />
41<br />
Strictly Confidential
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