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KIC

Prevention of

Corrosion Under Insulation

Vanmarsenille Chris

Oktober 15, 2015

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Damage Mechanism

2

Jacketing

Insulation

Paint / Coating

CS / SS pipe

Scale Formation/Corrosion

Water

Chlorides, Air Pollutants

Water (with impurities) penetrates insulation

Insulation collecting moisture, liquid contacting equipment surface

Water evaporating and condensing in a loop

Concentration of impurities on equipment surface

Diffusion of water underneath paint or coating, coating spalling off

Continuous (hidden) corrosion process

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Effect of Preventive Measures

Extent of Preventive Measures / Decreasing Failure Probability / Lower Life-Cycle-Costs

3

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Examples

4

STABILIZED

Reliable operation

Increase plant efficiency

Ensure Safety &

ComplianceLICENSE TO OPERATE

OPTIMIZED

C

U

I

Damaged Jacketing Openings Carbon Steel

Stainless Steel

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CUI is impacting all industry branches (esp. the chemical and

petrochemical)

CUI is impacting all the sites

OSBL assets such as pipe racks and tanks

ISBL assets at the sites

CUI is leading to major incidents

5

Corrosion Under InsulationImpact in the Industry

CUI – MI Fora, 2015

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DESIGN

CONSTRUCTION

MAINTENANCE INSPECTION

• Ergonomics

• Avoid cladding perforations

• Selection coating

• … • Good surface preparation

• Special attention piping supports

• Protect insulation against moisture

• …

• Avoid damaging

of cladding

• Repair damaged

insulation

• …

• Adequate visual inspection

• Supporting NDT techniques

• Remove insulation at

suspicious/damaged

locations• …

6


CUI – Life Cycle

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BASF Path Forward: Global CUI Task ForceOrganizational Set-Up

Steering CommitteeESP / GTG

on demand (expanded)

CMT / CPT

Sponsor

(Management support)

Global Site Committee

ImplementationSupport Team AP

Lead: N.N

• Operation

• Maintenance

• Engineering

Sponsor

(Tech. support)

Global Leadership team

Techn. Expertise

Task Force CUI Antwerp SiteLead: C. Vanmarsenille, (ESP/P)

WG Design & Construction:

Lead: (ESP/PM)

WG Inspection & Maintenance:

Lead: (ESP/B)

on demand:

N.N. (GUS) , N.N. (ZOT)

Core Task ForceExpertise & Concept

Lead: GTG/M

ESP/B

Mat. Eng. (GTG/MM)

Inspection (GTG/MI)

Mech. Des. (GTG/MD)

Mat.Eng. (NCE/T)

Mat. Eng. (NCE/T)Inspect. (PTQ/P)

Mat. Eng. (ACT/D)

Inspect. (CTE/Q)

Inspect. (SA/TRD)

Corr. Protect. (EST/CS)

Task Force CUI NA

Mat. Eng. (NCE/T)

Mech. (NCE/F)

Mech. (NCE/G)

Next Task Force CUI ?

Implementation

Support Team EU

Lead: N.N.

• Operation

• Maintenance

• Engineering

Implementation

Support Team NA

Lead: S. Brandenburg

• Operation

• Maintenance

• Engineering

Implementation

Support Team SA

Lead: N.N.

• Operation

• Maintenance

• Engineering

A l i g n m e

n t b y t o p i c

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Main Topic Steps Examples

I New plants

and revamp

Prevention

(design &

construction)

Design - Evaluation of need of

insulation

- Personell protectionConstruction (contractors) - Importance of QA/QC

Process (sites and

projects)

II Existing

plantsDetection,

Mitigation,

Prevention

(maintenance)

Risk Assessment - Takes into account

age, condition of

cladding, of paint,

temperature, product, … Inspection & Maintenance Strategies - Visual external insp.

- CUI local inspection

NDT Methods - Some exp. with IR

III Awareness Awareness Awareness and Training - Address CUI as part of

design and preventive

maintenance


CUI – Life Cycle approach

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9

Foto : lekkende pijp

Staff’s & Contractors’ Training on CUI From Creating Awareness to Personal Involvement

Hole as result of

corrosion underinsulation.

Potential for a

severe incident.

We want good prevention, do not count on your luck!

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CUI – what is it ?

Corrosion, Under Insulation of your piping and equipment

It affects

Carbon Steel → Localised areas of corrosion

Stainless Steel → External Chloride Stress Corrosion Cracking

When

1. Water or moisture gets into the insulation and on the metal

2. The coating is damaged / end of life

3. The temperature range favours CUI

Resulting in risks : RELEASE / RISK OF FIRE / …

“CUI => Act before it bites you !

Do not tolerate CUI => eliminate it, be proactive

CUI is hidden => know where to look & to inspect10

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CUI – Critical Factors

Water ingression in insulation is a CUI driver

Condition of insulation

Condition of jacketing

Condition of silicon sealing

Condition of paintingDamaged painting exposes the metal

Paint degrades after 10 years

Operating temperature range contributing to CUI

Carbon steel : -15°C to 175°C (API571: 10° F to 350°F)

Stainless steel : 50°C to 150°C (API571: 140°F to 400°F)

Unfavourable operating conditions

Sweating operation (below dew point) resulting in condensation on metal

Cyclic and intermittent operation: cycles of condensation

Chlorides: coastal / sea climate, plume of nearby cooling towers, … 11

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CUI – Suspected Locations

Steam tracing systems with tracing leaks

Dead legs

Holes or openings in jacketing

Damaged coatings

Hardened, old, or missing silicon sealing

Pipe supports, hangers Protrusions through insulation

Termination of insulation at flanges & piping components

Termination of insulation in a vertical pipe

…

12

Water

ingress

Acid

Vapours

Process

Spills

Plume of

cooling

towers

Sprinkler

& steam

vents

Areas

exposed to

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CUI – What do I need to do?

Preventing CUI is everyone’s responsibility!

Everybody has a role in prevention and detection!

Designers: Use mesh wire for personnel protection

Use insulation only when necessary

Select the right coating system

13Hang support and damaged jacketing Personnel Protection mesh : wire cages

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Construct ion & Maintenance

Prevent water ingress

=> good design & maintenance practices

Good surface preparation & coating,

including all field welds! Strong Quality Control of painting, insulation and cladding

INTERNALCover open ends when insulation is removed

14CUI – MI Fora, 2015


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Operators

Look for and report damaged insulation or cladding

Report leaks: product, steam tracing, …

Al l

Do NOT walk on insulation, do NOT damage the cladding

INTERNAL

Walking on insulation → Cladding

damage → Water ingress → CUI Look for and report

15CUI – MI Fora, 2015


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Challenges

Implementation of awareness

feedback of observed defects

maintenance budget

Information and scoping and scheduling of the inspection programs for equipment

and piping, including the increased CUI focus for the inspections

Supervisors and inspectors

– Sufficient inspectors with CUI focus

– Sufficient qualified supervisors for painting / insulation

– Sufficient scaffolding supervisors

CUI guidelines require upgrade of local standards implementation

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Thank You!

cui @ basf okt 2015 rev 2

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