Anders Rosborg Black

Specialist, FROSIO Level III Inspector

FORCE Technology, Denmark



CUI: Corrosion under insulation - how to
avoid it



CUI Corrosion under insulation


The corrosion under insulation war has been fought for many years
in the petrochemical industry

The corrosion processes are well understood but yet CUI often goes
undetected until the damage is significant

May lead to catastrophic failures, e.g. on equipment operating under
high pressure

May occur on:

Carbon steel (general/localised corrosion)
Stainless steel (localised corrosion/stress corrosion cracking)


Introduction

CUI cost studies have shown that:

40 to 60 % of pipe maintenance costs are caused by CUI

NDE/inspection costs with a high confidence level for detecting
CUI are equal to or exceed field painting costs

Approximately 10 % of the total maintenance budget is spent
repairing damage from CUl

CUI risk
General temperature ranges in which risk of CUI is present:

Carbon steel:
-4 C to + 175 C: Risk of CUI
(highest risk area: +60 C to +120 C)


Stainless steel:
+50 C to +175 C

Insulation of process equipment is normally implemented
when the outer steel temperature exceeds 50 C (due to the
risk of work-related injuries as well as heat loss).





Carbon steel

Insulated carbon steel corrodes due to:

Infiltration of water under insulation (rain, process liquids, fire
water, etc.)
Condensation water
(Ingress of external contaminants)

The insulation material may also contribute to CUI:

Creates a crevice for water retention
May absorb water
May leach contaminants that increase corrosion rate


Temperature and oxygen - corrosion rate
50 100 Temp. C
Closed:
Temperature
controls reaction
Open:
?
Oxygen diffusion
Open
system
Closed
system
Corrosion rate of steel
CUI of carbon steel

Source: NACE SP0198-2010

- Corrosion rates unpredictable

- Simulates closed system

- CUI rates of 1.5 to 3.0 mm
per year may occur (~20 times
greater than atmospherc
corrosion rates)
CASE STORY Corrosion of carbon steel
under insulation
Dripleg from a carbon steel
gas pipe.

Attack
Limit of insulation
Due to significant wall thinning
caused by corrosion, a fracture and a
gas leak occurred.
CASE STORY Corrosion of carbon steel
under insulation
Insulated drain pipe from
offshore installation.
Corrosion attacks were
observed.


One of the corrosion attacks
has caused a leak.
CASE STORY Corrosion of carbon steel
under insulation
Cross sections through corroded
pipes.
Corrosion attacks have
propagated from the outside
surface.

Inside surface of pipe.
CASE STORY Corrosion of carbon steel
under insulation
Corrosion mechanism:


Water (sea water from deluge test) will penetrate the insulation
cover.
The water will evaporate and the chloride concentration will increase.
High chloride concentrations combined with relatively high
temperature from media in the pipe or from heat tracing cause a
very corrosive environment and thus high corrosion rates.
USE THE CORRECT TYPE OF INSULATION AVOID DAMAGES TO
THE INSULATION COVER
Stainless steel

Stainless steel (austenitic or duplex) corrodes due to:

1. Chlorides (or other halides) in presence of water are
transported to the hot surface
2. The chlorides are concentrated by evaporation of the water
3. The chloride concentration reaches a critical level causing
stress corrosion cracking (SCC)
4. (The critical chloride concentration depends on: Temperature
and alloy type)


The insulation material may also contribute to CUI:
Creates a crevice for water retention
May absorb water
May leach contaminants (e.g. chlorides) that cause ESCC


Stainless steel

ESCC:
- Buried AISI 304 pipe in chloride-
contaminated soil
- Surface temp.: ~ 80-90 C
- No insulation => concentration
of chlorides on external surface

Stainless steel

Source: J . Houben, NACE 2012 (ISO 21457).

How is CUI avoided?


1. Avoid that moisture enters the insulation material and the steel
surface:

Correct selection and design of the insulation material

Good design of the item to be insulated e.g. it is difficult to
insulate around flanges, taps, flowmeters, supports, etc.

Cover above the insulated item (against rainfall, etc).



2. Application of corrosion protection

On average, 60 % of all insulation in service for more than
10 years will contain corrosion-inducing moisture!




It is difficult to isolate around flanges, taps,
flowmeters, supports, etc.

CUI in inorganic zinc-coated heater after 8 years caused by water ingress around steam
inlet nozzle (J . Houben, NACE 2012).



Corrosion protection

Carbon steel:

Organic coatings
Thermal-sprayed aluminum (TSA)
(Personnel protecting cages)

Stainless steel (austenitic or duplex):

Organic coatings
Thermal-sprayed aluminum (TSA)
Al-foil wrapping (prevents ESCC and pitting)
(Personnel protecting cages)


Organic coatings on carbon steel

Experience shows that organic protective coatings on piping in CUI
service ranges from 5-13 years (Exxon Mobil, J PCL April 2005)

Once the protective life is reached, field re-painting is necessary (or
periodic NDE in order to monitor CUI).

Coatings may be damaged during handling and installation - leaving
unprotected areas.

Important parameters for coatings used for CUI prevention:
- High permeability resistance (barrier protection)
- High flexibility (for cyclic temperature service)


Methods of protection
Galvanic protection
Inhibitive protection
Barrier protection
Carbon steel, corrosion protection

Protective coatings, NACE SP0198-2010:
Similar suggested systems for stainless steel given in NACE SP0198-2010
Carbon steel, corrosion protection
Recommended systems, FORCE Technology:
Temperature range Recommended systems*
-30 C to +120 C Epoxy, modified (e.g. phenolic).
Pigmented with aluminium, glass
flakes or MIO.

2-3 coats, total DFT 300 m
TSA (200 m) with 1x epoxy
sealer**
+120 C to +540 C TSA (200 m) with 2x silicon-
aluminum sealer**
* The specifications are guiding only. Coating manufacturer should be contacted for final
assessment.
** Sealer is used to fill in the porosity of the TSA (5-30 %).



TSA
TSA may provide long-term corrosion protection at significant life
cycle cost savings, however at higher initial costs.

TSA provides atmospheric corrosion protection for more than
40 years.

Has been recorded to provide 25-30 years of maintenance and
inspection-free CUI service.

Application by electric arc or flame spray.

Requires high quality surface preparation and strict application
control.
TSA / metallisation
Advantages
The coating is robust
Minor pores/damages are protected by the surrounding coating
No under-rusting
Unlimited construction sizes
No risk of deformations (cold process)

Disadvantages
No treatment in hollow spaces, inside pipes, etc.
The treatment prescribes a certain structural design
Sharp edges must be chamfered/rounded
Often large variations in layer thickness
Quality control
Price

TSA
J . Houben (ExxonMobil), NACE 2012.

Important that TSA is included already in the design phase! It may be very
expensive to change the design later on / apply additional TSA on-site.

Key points for TSA application for CUI prevention:

CUI Prevention Strategy

Data from operating facilities shows that water-free insulation is not
practical in ageing facilities. Thus a CUI prevention strategy is
necessary in order to provide long-term and reliable prevention of CUI:

Choice between strategies:

1. Organic coatings on carbon steel;
- Ongoing re-painting
- NDE (does not prevent CUI but predicts remaining life).

2. TSA on Carbon Steel

3. Stainless steel (+ TSA or Al foil wrapping)


Initial, maintenance and inspection costs need to be assessed for each
choice in order to give lowest total lifetime cost.
CUI Prevention Strategy

At last the easy initiatives may give significant results:

Do not walk on metallic insulation covers!






CUI Prevention Strategy

At last the easy initiatives may give significant results:

Do not walk on metallic insulation covers!

Make sure that access roads are created during repair work in
order to minimise risk of damage to the insulation.

If insulation cover is damaged, repair immediately. Do not wait
until next year.

Make sure that on-site coating repair complies with international
(and internal company) standards.








Thank you for your attention!