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Process Safety Beacon

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Messages for Manufacturing Personnel

Insulation Does NOT Prevent Corrosion

Corrosion Attacks Piping

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February 2005

Corrosion Attacks Structural Supports

Heres What Happened

Under insulation corrosion does not discriminate. It
attacks process piping, vessels, and structural supports.
The photograph on the left shows major
external corrosion of a pipe transferring
Phenol. The pipe was insulated and failed
before the corrosion was discovered.
Although no one was injured, it was very
expensive to correct the environmental
damage and make piping system repairs.
Why This Happened
Thermal insulation and fire proofing
provide the cover for corrosion to hide
under and the right environment for it to
start and grow in. This cover may trap
moisture or spilled chemicals, that under
certain circumstances, form corrosive
conditions that attack the underlying
steel. Because it is hidden from sight, the
corrosion often progresses undetected for
many years and may result in failure.

The sphere in the photograph on the right

collapsed during hydro testing. The legs
were fire proofed, hiding corrosion of the
structural steel.
When the sphere was
partially filled with water, it collapsed. One
person was killed and one was seriously
injured.

PSID members see: Free Search--Corrosion

What You Can Do to Detect or Prevent Hidden Corrosion

Know what structures and equipment in your process have the
potential for under insulation corrosion.
Check low points where moisture might accumulate
Be aware of and look for the signs of hidden corrosion:
Rust stains or discoloring
Bulges, blisters or bubbles
Small leaks, drips or wisps of vapor or odors
Inspectlook, but dont touch.
If you disturb a severely corroded area, a leak may
occur. Plan inspections and, when necessary, shut down
systems before removing corrosion.

Be alert for the signs of hidden corrosion !

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