CUI: Corrosion under insulation - how to avoid it

Anders Rosborg Black Specialist, FROSIO Level III Inspector FORCE Technology, Denmark

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

Corrosion rate of steel Closed: Closed system Temperature controls reaction Open: ? Open system 50 100 Oxygen diffusion

Temp. C

CUI of carbon steel

- 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)

Source: NACE SP0198-2010

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 chloridecontaminated 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, JPCL 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 -30 C to +120 C Recommended systems* 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 siliconaluminum 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
Key points for TSA application for CUI prevention:

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.

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!