KIC
Prevention of
Corrosion Under Insulation
150 years
Vanmarsenille Chris
Oktober 15, 2015
150 years
Corrosion Under Insulation
Damage Mechanism
Chlorides, Air Pollutants
Water
Paint / Coating
Jacketing
CS / SS pipe
Insulation
Scale Formation/Corrosion
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
2
150 years
Corrosion Under Insulation
Effect of Preventive Measures
Extent of Preventive Measures / Decreasing Failure Probability / Lower Life-Cycle-Costs
150 years
Corrosion Under Insulation
Examples
Damaged Jacketing
Openings
Carbon Steel
Stainless Steel
Increase plant efficiency
OPTIMIZED
Reliable operation
C
U
I
STABILIZED
LICENSE TO OPERATE
Ensure Safety &
Compliance
4
150 years
Corrosion Under Insulation
Impact in the Industry
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
CUI MI Fora, 2015
150 years
Corrosion Under Insulation
CUI Life Cycle
DESIGN
Ergonomics
Avoid cladding perforations
Selection coating
CONSTRUCTION
Good surface preparation
Special attention piping supports
Protect insulation against moisture
MAINTENANCE
Avoid damaging
of cladding
Repair damaged
insulation
INSPECTION
Adequate visual inspection
Supporting NDT techniques
Remove insulation at
suspicious/damaged
locations
150 years
BASF Path Forward: Global CUI Task Force
Organizational Set-Up
Global Site Committee
Task Force CUI Antwerp Site
Lead: C. Vanmarsenille, (ESP/P)
WG Design & Construction:
Lead: (ESP/PM)
WG Inspection & Maintenance:
Lead: (ESP/B)
Task Force CUI NA
Mat. Eng. (NCE/T)
Mech. (NCE/F)
Mech. (NCE/G)
Next Task Force CUI ?
ESP / GTG
Sponsor
(Tech. support)
on demand (expanded)
CMT / CPT
Global Leadership team
Techn. Expertise
Steering Committee
Implementation
Support Team AP
Core Task Force
Expertise & Concept
Lead: N.N
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)
on demand:
N.N. (GUS) , N.N. (ZOT)
Alignment by topic
Sponsor
(Management support)
Operation
Implementation
Maintenance
Support
Team EU
Engineering
Lead: N.N.
Operation
Implementation
Maintenance
Support
Team NA
Engineering
Lead: S. Brandenburg
Operation
Implementation
Maintenance
Support Team SA
Engineering
Lead: N.N.
Operation
Maintenance
Engineering
150 years
Corrosion Under Insulation
CUI Life Cycle approach
I New plants
and revamp
II Existing
plants
III Awareness
Main Topic
Steps
Examples
Prevention
(design &
construction)
Design
- Evaluation of need of
insulation
- Personell protection
Construction (contractors)
- Importance of QA/QC
Process (sites and
projects)
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
Awareness and Training
- Address CUI as part of
design and preventive
maintenance
Detection,
Mitigation,
Prevention
(maintenance)
Awareness
Staffs & Contractors Training on CUI
150 years
From Creating Awareness to Personal Involvement
Foto : lekkende pijp
Hole as result of
corrosion under
insulation.
Potential for a
severe incident.
We want good prevention, do not count on your luck!
9
150 years
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 inspect
10
150 years
CUI Critical Factors
Water ingression in insulation is a CUI driver
Condition of insulation
Condition of jacketing
Condition of silicon sealing
Condition of painting
Damaged painting exposes the metal
Paint degrades after 10 years
Operating temperature range contributing to CUI
Carbon steel :
-15C to 175C (API571: 10 F to 350F)
Stainless steel :
50C to 150C (API571: 140F to 400F)
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
150 years
CUI Suspected Locations
Areas
exposed to
Water
ingress
Acid
Vapours
Process
Spills
Plume of
cooling
towers
Sprinkler
& steam
vents
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
150 years
CUI What do I need to do?
Preventing CUI is everyones 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
Hang support and damaged jacketing
Personnel
Protection mesh : wire cages
13
150 years
CUI What do I need to do?
Construction & Maintenance
Prevent water ingress
=> good design & maintenance practices
Good surface preparation & coating,
including all field welds!
Strong Quality Control of painting, insulation and cladding
Cover open ends when insulation is removed
INTERNAL
CUI MI Fora, 2015
14
150 years
CUI What do I need to do?
Operators
Look for and report damaged insulation or cladding
Report leaks: product, steam tracing,
All
Do NOT walk on insulation, do NOT damage the cladding
Walking on insulation Cladding
damage Water ingress CUI
INTERNAL Look
CUI MI Fora, 2015
for and report
15
150 years
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
16
Thank You!
150 years
