Corrosion

Under
Insulation
Loop steam drum

Present by : Patiphon Suksawat

Contents
 Leader
Patiphon Suksawat

Consultant

Wasan Cheeppensuk Atip Nualnet

CUI team

Komsan Bangkrut Nawa Bunsayang Narong Sakulprasitsiri

What is CUI (Corrosion Under Insulation) ?
- CUI is a particularly severe form of localized corrosion
that has been plaguing chemical process industries since the
energy crisis of the s forced plant designers to include much
more insulation in their designs
- Intruding water is the key problem in CUI Special care
must be taken during design not to promote corrosion by
permitting water to enter a system either directly or indirectly by
capillary action
What is CUI (Corrosion Under Insulation) ?

External damage

Carbon steels or Stainless

low alloy steels steels

Subject to stress
Subject to thinning
corrosion cracking
• CUI is the mainly problem in petrochemical
plant.
• Current Inspection Program is not consider
corrosion under insulation problem.
• Increase Reliability of Plant.

Reference TPE
 Conclusion and Future action Plan

Inspection ( Visual and Ultrasonic Testing)

Risk Evaluation and Identification

List up EQ and Collection Data

Make Inspection Guide Line (Check Sheet)

Select Loop To Implement CUI

Study CUI Theory From API 581, 570

Schedule
 Insulated Piping Systems
Susceptible to CUI

1. Carbon steel piping systems, including those insulated

operating between (– C to C).
2. Austenitic stainless steel piping systems operating
between ( C– C).
Common Locations on Piping Systems
Susceptible to CUI

Flange Tee

Valve
Common Locations on Piping Systems
Susceptible to CUI

Ve
nt

Insulation has Support point

Guide Line for CUI inspection

No

Yes

No

Yes

- 12 -
Check Sheet

- 13 -
Loop steam drum

TE-201

PM-500 A,B

PE-302
TD-1203

TD-1201

TD-1210
TA-203A

PE-502

PD-1205
List up Equipment
No. Line No.
10BW-0201-4B-3P2-H3-17K
10BW-0202-4B-3P2-H3-17K
10BW-0203-2B-1P2-H3-13.5K
10BW-0205-3B-P2(1S1(V))-H2-5K
10BW-0208-6B-1P2-H3-13.5K
10BW-0209-6B-1P2-H3-13.5K
10S-0006-4B-1P2-H3-13.5K
10SC-0001-6B-1S1(V)-H3-13.5K
10SC-0002-4B-1P2-H3-13.5K
1BW-0201-6B-P2-H-9.5K
1BW-0202-6B-P2-H-9.5K
1BW-0203-1.5B-1S1(V)-H-5K
1BW-0205-2B-P2-H-9.5K
1BW-0206-3B-P2-H-9.5K
1BW-0210-6B-P2-H-5K
1BW-0211-8B-P2-H-5K
1BW-0212-8B-P2-H-5K
1BW-2202-4B-P2-H-5K
1S-0001-4B-P2-H-5K
1S-0005-6B-P2-H-5K
- 15 -
No. Line No.
1S-0201-2B-P2
1S-0202-1.5B-P2
1S-0203-2B-P2
1S-0205-3B-P2
25SC-0001-6B-3P2-H3-28.5K
25SC-0001-6B-3S1-H3-28.5K
25SC-0004-6B-3S1-H3-28.5K
3BW-0201-3B-1P2-H2-13.5K
3BW-0202-3B-1P2-H2-13.5K
3BW-0203-1B-1S1(V)-H2-5K
3BW-0203-1B-P2-H2-5K
3BW-0204-3B-P2-H2-5K
3BW-0204-4B-PS(1S1(V))-H2-5K
3BW-0205-3B-P2-H2-5K
3S-0001-12B-P2-H2-5K
3S-0009-4B-P2-H2-5K
3SC-0008-8B-1S1(V)-H2-5K
3SC-0202-3B-P2(1S1(V))-H2-5K
3SC-5502-4B-P2-H2-5K
LPW-0001-3B-1S1(J)-H-13.5K
List up Equipment
No. Line No. No. Line No.

10BW-0205-3B-P2(1S1(V))-H2-5K

25SC-0001-6B-3S1-H3-28.5K
25SC-0004-6B-3S1-H3-28.5K
10SC-0001-6B-1S1(V)-H3-13.5K

1BW-0201-6B-P2-H-9.5K 3BW-0203-1B-1S1(V)-H2-5K
1BW-0202-6B-P2-H-9.5K
1BW-0203-1.5B-1S1(V)-H-5K
1BW-0205-2B-P2-H-9.5K 3BW-0204-4B-PS(1S1(V))-H2-5K
1BW-0206-3B-P2-H-9.5K
1BW-0210-6B-P2-H-5K
1BW-0211-8B-P2-H-5K
1BW-0212-8B-P2-H-5K 3SC-0008-8B-1S1(V)-H2-5K
1BW-2202-4B-P2-H-5K 3SC-0202-3B-P2(1S1(V))-H2-5K
1S-0001-4B-P2-H-5K
1S-0005-6B-P2-H-5K LPW-0001-3B-1S1(J)-H-13.5K

- 16 -
Collection Data
Collection Data
Collection Data
 Consequence of failure rating
Consequence
1 2 3 4 5
class
No / Slight Minor Local Major Extensive
Economics Damage Damage Damage Damage Damage
< 0.4 M 0.4 – 4 M 4 – 40 M 40 – 400 M > 400 M
No / Slight Multiple
Health & Safe Minor Injury Major Injury Single Injury
Injury Injury
No / Slight Minor Localized Major Massive
Environment
effect effect effect effect effect

Select 3

Example
- 20 -
Probability Score Table of Carbon Steel
Initial
Operating Wall thickness Internal corrosion External coil / External
Point Coating Insulation Type
Temperature surface feature / erosion rate Steam tracing environment
Status

> 175 0C
Full QA paint
0 Or Negligible Not present Inside Building
protection
< -5 0C

Perlite
Foamglass Rarely wetted
Low High Integrity
1 150 – 175 0C Closed cell >7.1 mm (<10% of the
( < 0.1 mm/y) design
Foam (right time)
type)

Normal QA Fiberglass 4 – 7.1 mm or

-5 – 500C paint Cal Sil, surface location Intermittently
Medium Medium Integrity
3 or protection Asbestos of penetrations wetted (~40% of
(0.1-0.4 mm/y) design
120 – 150 0C field weld at Mineral Rock through the time)
construction wool insulation

< 4 mm or
Permanently
surface at
wetted (e.g.
Unpainted or location of High Low Integrity
5 50 – 120 0C condensation,
Unknown reinforcement ( >0.4 mm/y) design
cooling tower
ring & other
dripping water
5+5+1+1+1+0+1 = 14 water traps

score Example
Probability Score Table of Stainless Steel

Operating Initial Coating External coil / External

Points Insulation Type
Temperature Status Steam tracing environment

Constantly > 150 Low chloride

0C or Constantly Full QA paint
0 insulation material Not present Inside Building
protection
< 50 0C (<10 ppm Cl-)

Rarely wetted
High Integrity
2 (<10% of the
design
time)

Permanently
Normal QA paint
protection field
wetted (e.g.
Medium Integrity
4 120 – 150 0C weld at condensation,
design
construction cooling tower
dripping water

Higher chloride Intermittently

Unpainted or Low Integrity
7 50 – 120 0C insulation material wetted (~40% of
Unknown design
(>10 ppm Cl-) the time)

score
- 22 -
CUI Criticality ranking

Example
- 23 -
CUI Confidence rating
CUI Confidence Questions Yes Interm NO
Cladding and Insulation conditions
-Cladding/Insulation fully maintained : Yes
+1 0 -1
0 -1 + 0 = - 1
-Cladding/Insulation normal : Interm
-Cladding/Insulation in poor condition : NO
Multiple reliable inspections for CUI have been carried been
carried out
-Frequent inspection and selective delagly fallowed by
+1 0 -1
appropriate remedial action : Yes
-Inspection irregular / not standard : Interm
- No proper inspections : No
Monitoring CUI promoting condition
- The pressure of all possible CUI promoting condition
(see susceptibility categories) has been established and
quantified : Yes
- The operating temperature is monitored and constantly +1 0 -1
in identified rouge and coating condition is know /
established : Interm
- The operating temperature is not established or the
coating condition is not know : No

score Example

- 24 -
Strategy Matrix for Carbon Steel

Strategy 3

Example
- 25 -
Strategy Matrix for Stainless Steel

- 26 -
Strategies for Carbon steel
Strategies for Carbon steel
Strategies for Stainless Steel
Strategy flowchart
Strategy 3

Yes No
Piping > 8 in

100 % NDE and delegging of all Delegging of

susceptible area within 6 years susceptible within 6
years

Yes No
Significant
CUI found

Every Delag 100% Delag more selective area

6 years within 1 year Within 1 year Every
6 years

Significant
CUI found No
Repair and Paint Yes

100 % delegging , repair and paint Adjust confidence

within 1 year with +1
Risk Evaluation and Identification
CUI Criticality ranking

Medium High
Medium
Noinspection
Strategy Matrix

Strategy
Strategy
No inspection
Inspection
Inspection
Inspection
Inspection
Inspection
Inspection
Inspection
Inspection
Strategy flowchart
Strategy 3

Yes No
Piping > 8 in

100 % NDE and delegging of all Delegging of

susceptible area within 6 years susceptible within 6
years

Yes No
Significant
CUI found

Every Delag 100% Delag more selective area

6 years within 1 year Within 1 year Every
6 years

Significant
CUI found No
Repair and Paint Yes

100 % delegging , repair and paint Adjust confidence

within 1 year with +1
Inspection
Risk management

Corrosion

Think of module

Friendship
Thank You
 N/A = not available

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