Inspection of insulated piping

& equipment

By
• Inspection
 Sources

• API 570: for in service piping inspection

• API571: for in service damage mechanisms
• API 572: for in service equipment inspection
• UOP- TYRI / HP BASIC PRACTICE
• OISD
• Various book on CUI on net.
 Insulated vessels and piping which are
potentially more susceptible to CUI:

1 Exposed to CT mists and coastal salinity.

2 Process spills or ingress of moisture.

3 Operating temp: CS:-12 Deg C to 180 deg C

3 Intermittent service.

4 Austenitic stainless steel: 66 Deg C to 204 Deg C

5 Vessels/piping with damaged/deteriorated
insulation.

6 Termination of insulation.

7 “Sealing” which has hardened separated or is

missing.( Avg age of sealant: 3-5 yrs)

8 Equipment/piping more than 5 yrs old, Unpainted

equipment.

9 Horizontal piping (check for corrosion at joints or

piping branches at the bottom of the pipe).
10 Equipment/piping that has been out of
service due to extended shutdowns or
mothballing.
11 The lip or rim on bucket-type
insulation support rings on vessels may
act as a moisture dam.
12 Stiffening rings extending beyond the
insulation may allow moisture intrusion.
13 Rod hangers or clamps supporting
piping by direct contact protrude
through the jacketing.
 INSPECTION METHODOLOGY for
UTM
1. No specific numeric guidelines for number of
thickness measurement locations (TML’s) provided
in API 570
2. More TML’s should be provided when there is:
1. Higher potential for creating a safety or environmental
emergency in the event of leak
2. High expected or experienced corrosion rate
3. Higher potential for localized corrosion
4. More complexity in terms of fittings, branches, dead legs,
injection points and other similar items
5. Higher potential for CUI.
 INSPECTION METHODOLOGY for
VISUAL INSPECTION
API 571/NACE RP0198,UOP-TYRI:
• Partial and/or full stripping recommended where CUI
conditions are prevalent.
• Spot (thickness) and new techniques can be misleading
due to lack of expertise and technique limitations. (Ref:
“Take a systems approach to corrosion under insulation” BY Goldberg, Linda)
API 570 recommendations with respect to % of area
to be inspected.
Piping Class Areas with damaged Suspected Areas with
Insulation Suspected Temp. Range
Class I 75% 50%
Class II 50% 33%

Class III 25% 10%

 Practices being followed at BPCL,
MRPL and HPMR for UTM and visual
inspection
• Piping: Inspection pockets at every 6 / 10
meters on horizontal section, bends and T-
joints.
• Equipment: Four location at NEWS all around
the circumference, nozzles and at saddle
supports
• Removal of insulation at damaged insulation
locations
 Our System
• Inspection program:
– Identified equipment and piping loops prone to CUI
– Periodicity of inspection finalized. (Once in two
years)
– OSI reports included isometrics with location of
pockets and damaged insulations.
– Inspection Checklist in place.

• Insulation specs bench marking: in line with

Indian Industries. (Ref. Presentation in PRM
dated 28/3/2008)
Link:http://mr.hpcl.co.in/analysis/Insulation%20rev%204.pdf
Inspection report
Insp. Report Attachment
 Conclusion
• Our system / practices for inspection
by removing insulation at designated
places is in line with practices being
followed in other Indian coastal
refineries.
• To enhance further reliability, visual
inspection by removal of insulation at
suspected areas as per API 570 (10%-
50%) to be considered.
 Way forward…
• Constraints:
– Absence of insulation pockets.
– Approach at higher elevations.
• Removable Inspection pockets to be
made mandatory at all CML on
equipment and piping. (Status: approx
40% in DHDS and 5% in other units at
FR & LR: done).
• Damaged insulation shall be repaired
urgently.
Sample photographs on field
survey at LR
Mechanical Damage
to Insulation cladding
Mechanical Damage to Insulation
cladding
Water/ moisture ingress
iced under cold insulation
& opened cladding
 Cladding is corroded &
insulation is exposed

Wax deposits on insulation

cladding
Insulation cladding
is damaged / missing
Insulation end cap is
damaged
Insulation is missing
Old insulation & end
caps are missing
Bad condition of insulation in
pipe alley
Bad condition of insulation in
pipe alley
Insulation/cladding is
open at all locations in
pipe alley lines
Ingress of water vapors in
insulation at open T- section,
steam jetting
Insulation cladding at T-
joint opened, & water/
vapor dripping
Water spray on
insulated pipeline
Insulation cladding
perforated due corrosion
under cladding.
Bitumen paper has become
loose and broken
Weather proofing is
cracked/ eroded
over the period.
Weather proofing is
cracked/ eroded
over the period