i-Neema Ghana Ltd

Corrosion Under Insulation – Root Causes and Effects, we have the Cure
 i-Neema Ghana Ltd
Corrosion Under Insulation – Root Causes and Effects, we have the cure
Lobster backs

Joints in saddles Vertical risers act

As watersheds

Low elevation

Saddles trap water

Heat sink attracts vapour
Mid joints

Water penetration into Insulation is the primary cause of CUI – if the water
can be prevented from entering the Insulation – CUI can be negated.
 i-Neema Ghana Ltd
Corrosion Under Insulation – Root Causes
Corrosion Implications of Insulation Types
Type Water Extract Chloride
Calcium silicate alkaline (pH 7-10) possibly high
Fibre glass
Cellular glass
Ceramic fibre
Mineral wool neutral (pH 6-7) low (~2 mg/l)
Organic foams acid (pH 2-3) possibly high

Chemical extraction from Insulation can accelerate CUI

 i-Neema Ghana Ltd
 CUI exists in every Hydrocarbon Processing Plant Worldwide

 How can CUI problems be Repaired and then Negated – On-stream ?

 i-Neema Ghana Ltd
Corrosion Under Insulation – i-Neema Solutions
Compliant Repair Not always Required
Where the corrosion is less than the corrosion
allowance or the calculated Tmin.
These are more cosmetic repairs to arrest the
corrosion however it is important to select the
correct protective coatings. Belzona products
are Heat and Chemical resistant and also fully
submersible minimizing the chances that the
corrosion can return.
Compliant Repairs
There are accepted International Standard for
the use of composite materials for repair of
pipework and tanks and where the client
requires certification:

- ASME PCC-2-2008
- ISO / TS 24817
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i-Neema Ghana Ltd
Corrosion Under Insulation – Case Studies
Client : Exxon , Singapore

Date : Year 2001

Equipment :
Fractionator Tower T102 operating at
120C

Problem :
Loss of wall thickness and unable to shut down the
process

Solution:
Manual preparation followed by repair and protective
coating with single component heat activated system
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i-Neema Ghana Ltd
Corrosion Under Insulation – Case Studies

Client : Offshore Gas Company , UK

Date : Year 2005

Equipment :
Gas Process pipe work operating at 90 – 115C

Problem :
Pitting corrosion and
unable to shut down the process

Solution:
Water Jetting preparation followed by repairs to
pitting and protective coating with and single
component heat activated system
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i-Neema Ghana Ltd

Corrosion Under Insulation – i-Neema Solutions

“ Code Compliant Solutions “

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i-Neema Ghana Ltd
Corrosion Under Insulation – i-Neema Solutions
ASME PCC-2-2008

ISO / TS 24817
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i-Neema Ghana Ltd
Corrosion Under Insulation – i-Neema Solutions
ASME PCC-2 and ISO/TS 24817 allow for the repair of the
following: -

• Thinned wall defects

• Through wall defects

• Straight Pipe
• Complex Geometries, inc. bends, tees, reducers etc.
• Bulk Storage Tanks and Pressure Vessels
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i-Neema Ghana Ltd

Corrosion Under Insulation – i-Neema Solutions

• ASME PCC-2 only allows for the repair of

tanks and vessels through the application
of a full circumferential repair

• ISO 24817 allows for the same tank or

vessel to be repaired by a patch repair

• Further developments to ASME PCC-2 will

include specific sections dealing with tanks,
vessels and patch repair
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i-Neema Ghana Ltd

Corrosion Under Insulation – i-Neema Solutions

Repair Life

Code Compliant
repairs are designed
and calculated for
design lives of up to 20
years using standard
safety factors
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i-Neema Ghana Ltd
Corrosion Under Insulation – Case Studies
Client : Statoil , Norway
Date : Year 2009

Equipment :
Production pipe work on Offshore
Platform

Problem :
Corrosion Under Insulation
Pitting and loss of wall thickness

Solution:
Preparation by Grit Blasting and compliant
Composite repair installed.
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i-Neema Ghana Ltd
Corrosion Under Insulation – Case Studies
Client : Exxon , Norway
Date : Year 2009

Equipment :
Produced water process piping

Problem :
CUI resulting in perforations of
piping system

Solution:
Preparation by Grit Blasting and compliant
Composite repair installed.