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98512 RESULTS OF HELD APPLICATION AND LABORATORY TESTING OF THERMAL SPRAY UNS N10276 COATING FOR SOUR MNE VESSELS

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Product Number: 51300-98512-SG
ISBN: 98512 1998 CP
Author: J. J. Baron, M. G. Hay, K. G. Goerz, R. W. Schubert, F. B. Easterly
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The Caroline sour gas processing plant pressure vessels were constructed of bare carbon-manganese steel. Early detection of internal surface corrosion and hydrogen blistering led to a decision to field-apply a UNS N10276 coating. The dual-wire arc-spray technique waa chosen fnllowing a careful review of the technical merits and costs of the alternatives, It was used to coat portions of eight vessels during a planned plant turnaround in 1995. A laboratory program was subsequently initiated in order to define the coating’s corrosion resistance and its effectiveness in preventing corrosion of, and hydrogen damage to, the steel substrate. This program examined the effect of variations in coating thickness and coverage, and steel substrate surface topography on coating performance in simulated rich amine (plant) and standard NACE International sour environments. In addition, an effective field repair procedure was qualified. The results of the inspection of the coating in three vessels after eighteen months’ service justified the selection of the coating material and application technique. Only minor repairs to the coating in one vessel were required. This paper gives the results of the laboratory program and plant inspections, and provides guidelines for the application of thermal spray coatings in the field. Keywords: sour gas, corrosion, hydrogen damage, pressure vessels, steel, amine, thermal spray coatings, laboratoy testing, field application, experience.
The Caroline sour gas processing plant pressure vessels were constructed of bare carbon-manganese steel. Early detection of internal surface corrosion and hydrogen blistering led to a decision to field-apply a UNS N10276 coating. The dual-wire arc-spray technique waa chosen fnllowing a careful review of the technical merits and costs of the alternatives, It was used to coat portions of eight vessels during a planned plant turnaround in 1995. A laboratory program was subsequently initiated in order to define the coating’s corrosion resistance and its effectiveness in preventing corrosion of, and hydrogen damage to, the steel substrate. This program examined the effect of variations in coating thickness and coverage, and steel substrate surface topography on coating performance in simulated rich amine (plant) and standard NACE International sour environments. In addition, an effective field repair procedure was qualified. The results of the inspection of the coating in three vessels after eighteen months’ service justified the selection of the coating material and application technique. Only minor repairs to the coating in one vessel were required. This paper gives the results of the laboratory program and plant inspections, and provides guidelines for the application of thermal spray coatings in the field. Keywords: sour gas, corrosion, hydrogen damage, pressure vessels, steel, amine, thermal spray coatings, laboratoy testing, field application, experience.
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