how to manage corrosion under insulation (cui) problem?twn-technology.com/download/eddyfi/how to...

How to Manage Corrosion Under Insulation (CUI) Problem?

APCCC18November 7, 2018Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.

What is CUI?

Its Effects

Shared Practice:

CUI Inspection Methodology

Quick Win for CUI

Topics

2Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.

What is CUI?


Insulated Piping

API 570, Piping Inspection Code, Third Edition.Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary. 4

Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.

Insulated Equipment

5

Insulation System

Goh Gim Choon, Materials & Corrosion Overview, Shell Global Solutions. 6

Corrosion Under Insulation (CUI)

Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary. 7

CUI Corrosion Rates

NACE Standard RP0198, The Control of Corrosion Under Thermal Insulation and Fireproofing – A Systems Approach, NACE International.

CUI corrosion rates are higher than expected.

8

API RP 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry, Second Edition.

External Chloride Stress Corrosion Cracking (ECSCC)

9

API TR 938-C, Use of Duplex Stainless Steels in the Oil Refining Industry.

SCC Tendency of Austenitic & Duplex SS

10

Its Effects


Effects of CUI/CUF

https://www.eddyfi.com.API RP 583, Corrosion Under Insulation and Fireproofing, Second Edition. 12

B.J.Fitzgerald et al., CUI Conference in London, 14-1-2004.

CUI of Piping

13

K. Yamamoto, Safety & Reliability of Aged Plants in Chemical Process Industries, Japan, 2017.

A Story of Piping CUI in Japan

14

A Story of Piping CUI in Map Ta Phut


68% is CUI32% is ECSCC

15




17

18

Shared Practice:CUI Inspection Methodology


Purpose:

1. Effectively identify where to damage as a result of CUI.2. Recommend the optimum inspection and/or monitoring methods.

Simplified Methodology Flowchart


Designed Check Sheet (Carbon & Low Alloy Steels)


PARAMETER 0 1 3 5

Operating

Temperature

<-4 °C

or

>177 °C

-4 to 38 °C

or

133 to 177 °C

39 to 77 °C

or

111 to 132 °C

78 to 110 °C

or Cycling Service from

>177 °C to <110 °C

Coating/Age

Quality coating

within 8 years

or system age

<15 years

Quality coating

within 15 years,

or system age

<30 years

General coating

8-15 years

General coating age >15

years,

system age >30 years, or

unknown

Jacketing/

Insulation Condition

System age

<5 years without

deficiencies

Average condition with good

maintenance (such as

sealed, no gaps, CML ports

with plugs)

Average condition with

some deficiencies

Damaged condition

with several deficiencies

Heat Tracing None

High integrity steam system

or

electric tracing

Steam system with medium

integrity

Steam system with visible

leaks

External

EnvironmentNo sweating Arid and inland All other locations

Coastal/marine, cooling

tower overspray, or local

external water source

exposure (deluge system,

dripping steam condensate)

Insulation

TypeInsulating coating

Expanded perlite, foam

glass,

closed cell foam

Fiberglass, perlite, mineral

fiber

(Insulation has <10 ppm Cl)

Calcium silicate, mineral

fiber with >10 ppm Cl, or

unknown

Line Size or

Nozzle SizeEquipment >6 in. >2 in. to 6 in. ≤2 in.

CUI Assessment (Carbon & Low Alloy Steels)

PARAMETER

RATING TOTAL<7 7 to <14 14 to 20 >20 to 27 >27

LIKELIHOOD

RATINGNegligible Low Medium High Extreme

Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.API RP 583, Corrosion Under Insulation and Fireproofing, Second Edition. 21

Designed Check Sheet (Austenitic and Duplex SS)


CUI Assessment (Austenitic and Duplex SS)

PARAMETER


LIKELIHOOD


Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.API RP 583, Corrosion Under Insulation and Fireproofing, Second Edition.

PARAMETER 0 1 3 5

Operating

Temperature

<47 °C

or

>204 °C

47 to 60 °C 122 to 204 °C 61 to 121 °C

Coating/Age

Quality

coating

within 8 years

Quality coating

within 15 years

General coating

8-15 years

General coating >15 years,

or unknown

Jacketing/

Insulation ConditionNo deficiencies




with plugs)


some deficiencies

Damaged condition


Heat Tracing None


or electric tracing (Cl free

covering)


integrity


leaks, or electrical with PVC

covering

External



tower overspray, or external

water source exposure

(deluge system, dripping

steam condensate)

Insulation



glass,

closed cell foam


fiber




unknown

Line Size or


23


Data Collection

24

Prelim Summary

Damage Mechanism Likely Location SusceptibilityP&IDPage

Corrosion Under Insulation (CUI) 4” PG 101. 01 D24 4C Negligible 1

Corrosion Under Insulation (CUI) 3” BF 102. 05 D24 4A Low 2

Corrosion Under Insulation (CUI) 3”-HG23129-A071H Medium 3

Corrosion Under Insulation (CUI) 2”-MD25020-S2A02 High 4


Site Survey

Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.API RP 583, Corrosion Under Insulation and Fireproofing, Second Edition.API RP 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry, Second Edition.

Pipe Shoe Small Branch Connection (Tee)

Damaged Jacketing Termination of Insulation on Vertical Pipe

26

Summary


RepresentativeLocation

Inspection and Monitoring Methods

VT

(V

isu

al

Insp

ecti

on

)

PE

C (

Pu

lse

d E

dd

y C

urr

en

t)

UT

M (

Ult

raso

nic

Th

ick

ne

ss M

ea

su

rem

en

t)

LR

UT

(Lo

ng

Ra

ng

e U

ltra

so

nic

Te

sti

ng

)

RT

(R

ad

iog

rap

hic

Te

sti

ng

)

EC

(E

dd

y C

urr

en

t)

PT

(Liq

uid

Pe

ne

tra

nt

Te

sti

ng

)

IR (

Infr

are

d T

he

rmo

gra

ph

y)

Ne

utr

on

Ba

ck

sca

tte

r

On

-lin

e M

on

ito

rin

g(e

.g.,

Wir

ele

ss U

T S

en

so

r, A

E S

en

so

r)

Pro

ce

ss M

on

ito

rin

g

OSI (Onstream Inspection)


4” PG 101. 01 D24 4C Negligible 1 Pipe Shoe OSI OSI OSI OSI


3” BF 102. 05 D24 4A Low 2Small Branch Connection

(Tee)OSI OSI OSI


3”-HG23129-A071H Medium 3 Damaged Jacketing OSI OSI OSI OSI


2”-MD25020-S2A02 High 4Termination of Insulation

on Vertical PipeOSI OSI OSI OSI OSI



Example (1.25Cr-0.5Mo Steel (T >177°C))

28

PARAMETER 0 1 3 5

Operating

Temperature

<-4 °C

or

>177 °C

-4 to 38 °C

or

133 to 177 °C

39 to 77 °C

or

111 to 132 °C

78 to 110 °C


>177 °C to <110 °C

Coating/Age

Quality coating

within 8 years

or system age

<15 years

Quality coating

within 15 years,

or system age

<30 years

General coating

8-15 years


years,


unknown

Jacketing/


System age

<5 years without

deficiencies




with plugs)


some deficiencies

Damaged condition


Heat Tracing None


or

electric tracing


integrity


leaks

External







Insulation



glass,

closed cell foam


fiber




unknown

Line Size or


PARAMETER


LIKELIHOOD



19

CUI Assessment

29

Summary


RepresentativeLocation

Inspection and Monitoring Methods

VT

(V

isu

al

Insp

ecti

on

)

PE

C (

Pu

lse

d E

dd

y C

urr

en

t)

UT

M (

Ult

raso

nic

Th

ick

ne

ss M

ea

su

rem

en

t)

LR

UT

(Lo

ng

Ra

ng

e U

ltra

so

nic

Te

sti

ng

)

RT

(R

ad

iog

rap

hic

Te

sti

ng

)

EC

(E

dd

y C

urr

en

t)

PT

(Liq

uid

Pe

ne

tra

nt

Te

sti

ng

)

IR (

Infr

are

d T

he

rmo

gra

ph

y)

Ne

utr

on

Ba

ck

sca

tte

r

On

-lin

e M

on

ito

rin

g(e

.g.,

Wir

ele

ss U

T S

en

so

r, A

E S

en

so

r)

Pro

ce

ss M

on

ito

rin

g

OSI (Onstream Inspection)


4” PG 105. 01 D34 4C Medium 5 Pipe Supports OSI OSI OSI


Result


Quick Win for CUI


PARAMETER 0 1 3 5

Operating

Temperature

<-4 °C

or

>177 °C

-4 to 38 °C

or

133 to 177 °C

39 to 77 °C

or

111 to 132 °C

78 to 110 °C


>177 °C to <110 °C

Coating/Age

Quality coating

within 8 years

or system age

<15 years

Quality coating

within 15 years,

or system age

<30 years

General coating

8-15 years


years,


unknown

Jacketing/


System age

<5 years without

deficiencies




with plugs)


some deficiencies

Damaged condition


Heat Tracing None


or

electric tracing


integrity


leaks

External







Insulation



glass,

closed cell foam


fiber




unknown

Line Size or


PARAMETER


LIKELIHOOD



Quick Win for Piping

33

Equipment Type Potential Locations Photos

Piping

(≤2 in.)

Deadlegs (Vents and Drains)

Instrument Connections

Vibrating Piping Systems

Examples of Susceptible Areas (Piping)

34


PARAMETER 0 1 3 5

Operating

Temperature

<-4 °C

or

>177 °C

-4 to 38 °C

or

133 to 177 °C

39 to 77 °C

or

111 to 132 °C

78 to 110 °C


>177 °C to <110 °C

Coating/Age

Quality coating

within 8 years

or system age

<15 years

Quality coating

within 15 years,

or system age

<30 years

General coating

8-15 years


years,


unknown

Jacketing/


System age

<5 years without

deficiencies




with plugs)


some deficiencies

Damaged condition


Heat Tracing None


or

electric tracing


integrity


leaks

External







Insulation



glass,

closed cell foam


fiber




unknown

Line Size or


PARAMETER


LIKELIHOOD



Quick Win for Pressure Vessels

35

Equipment Type Potential Locations Photos

Pressure Vessels

(Water Collection Points)

Bottom of Horizontal Vessels

Termination of Insulation at

Saddles

Insulation Support Rings

Examples of Susceptible Areas (Pressure Vessels)

36


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