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    ROOKWOOL (Non Contact Insulation)

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    devangmajithia
    This document discusses corrosion under insulation (CUI) and how to prevent it. CUI occurs when steel is exposed to water and oxygen under insulation. While insulation keeps steel dry in ideal conditions, it is difficult to ensure insulation remains perfectly dry. CUI risk depends on factors like insulation material properties, installation quality, and maintenance. Proper coating, cladding, and using insulation materials that limit water absorption and retention can help prevent CUI. Testing evaluates insulation impact on corrosion to inform material selection. Non-contact insulation designs may also help by creating an air gap to limit wetness exposure.

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    ROOKWOOL (Non Contact Insulation)

    Uploaded by

    devangmajithia
    200 views28 pages
    This document discusses corrosion under insulation (CUI) and how to prevent it. CUI occurs when steel is exposed to water and oxygen under insulation. While insulation keeps steel dry in ideal conditions, it is difficult to ensure insulation remains perfectly dry. CUI risk depends on factors like insulation material properties, installation quality, and maintenance. Proper coating, cladding, and using insulation materials that limit water absorption and retention can help prevent CUI. Testing evaluates insulation impact on corrosion to inform material selection. Non-contact insulation designs may also help by creating an air gap to limit wetness exposure.

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    ROOKWOOL (Non Contact Insulation)

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    This document discusses corrosion under insulation (CUI) and how to prevent it. CUI occurs when steel is exposed to water and oxygen under insulation. While insulation keeps steel dry in ideal conditions, it is difficult to ensure insulation remains perfectly dry. CUI risk depends on factors like insulation material properties, installation quality, and maintenance. Proper coating, cladding, and using insulation materials that limit water absorption and retention can help prevent CUI. Testing evaluates insulation impact on corrosion to inform material selection. Non-contact insulation designs may also help by creating an air gap to limit wetness exposure.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    200 views28 pages

    ROOKWOOL (Non Contact Insulation)

    Uploaded by

    devangmajithia
    This document discusses corrosion under insulation (CUI) and how to prevent it. CUI occurs when steel is exposed to water and oxygen under insulation. While insulation keeps steel dry in ideal conditions, it is difficult to ensure insulation remains perfectly dry. CUI risk depends on factors like insulation material properties, installation quality, and maintenance. Proper coating, cladding, and using insulation materials that limit water absorption and retention can help prevent CUI. Testing evaluates insulation impact on corrosion to inform material selection. Non-contact insulation designs may also help by creating an air gap to limit wetness exposure.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 28

    Corrosion Under Insulation (CUI)

    and the Insulation System


    By Soeren Nyborg Rasmussen
    ROCKWOOL Technical Insulation, Jubail, 10 December 2015
    The issue

    Corrosion of steel occurs in the


    presence of water and oxygen
    ■ So, obviously, if the steelwork
    under insulation remains dry there
    is no corrosion problem
    ■ But, keeping the insulation dry
    can be difficult which can lead to
    steel work corrosion
    ■ Commonly referred to as corrosion
    under insulation (CUI)
    ■ CUI is found under all types of
    insulation when you have
    installation issues or damages

    Insulation does NOT protect against corrosion.


    Corrosion prevention requires a suitable coating,
    insulation, cladding and installation under
    dry conditions.
    General corrosion process
     Metal + Water + Oxygen => Corrosion

    Accelerating factors:
    • Time of wetness (access to water)
    • Temperature (until the water has evaporated)
    • Soluble salts (expecially chloride)
    • Acidic impurities
    Types of corrosion
     Steel is in general susceptible to CUI in the
    temperature range of 0oC to 175oC. The most General corrosion
    frequently occuring types of CUI are:
    ■ General and pitting corrosion of carbon
    steel, which may occur if wet insulation comes
    in contact with carbon steel
    ■ External Stress Corrosion Cracking (ESCC)
    of austenitic stainless steel, which is a
    specific type of corrosion mainly caused by the
    action of water-soluble chloride from External stress corrosion cracking
    rainwater or if the insulation is not meeting the
    appropiate requirements

    The corroded surface is mostly hidden by the


    insulation system and will not be observed until the
    insulation is removed for inspection or in the event of
    metal failure leading to incidents.
    Typical example corrosion under
    insulation
    Risk of CUI

    Carbon/mild steel – risk


    of corrosion

    Stainless steel – risk of


    ESCC

    Reference: Shell DEP 30.46.00.31-


    Gen. September 2011
    Preventing corrosion
    (Risk mitigation)
    Critical factors
    Numerous factors are involved in causing or
    preventing corrosion under insulation Design?
    ■ Surrounding environment
     Indoor/outdoor
     Land / oceanic climate
     Acidic environment
    ■ Operation of the plant
     Cyclic or continous operation
     Temperatures
    ■ Choise and installation of coating system
    Maintenance
    ■ Design, choice and installation of the
    insulation system
    ■ Actual operation
     Prompt, promptly maintenance
     Foot traffic
     Risk based inspection procedures

    Foot traffic
    Design phase:

    Design pipes, vessels etc. with corrosion protection in mind:

    Consider:

     Avoidance of water traps, unintended bimetallic corrosion etc.

     Smooth surfaces, access for surface preparation and coating application

     Prevention of water ingress

    Ref.: ISO 12944-3


    Choice and installation of
    coating system
     Coating system should be suitable for the
    operational temperatures (also when wet) Blasting

     Surface preparation and application is critical for


    performance and suppliers guidelines must be
    followed.
     Avoid damage of coating system after
    application.
    Coating / painting
    System Temperature range Surface Surface First coat Finishing coat
    no preparation(1) profile µm µm (mil) µm (mil)
    (mil)
    CS-1 -45°C/50°F to 60°C/140°F ISO 8501-2: Sa 2½/ 50-75 High build epoxy High build epoxy
    SSPC SP 10 (2-3) 125 – 175 (5-7) 125 – 175 (5-7)
    CS-2 -45°C/50°F to 150°C/300°F ISO 8501-2: Sa 2½/ 50-75 Epoxy phenolic/ Epoxy phenolic/
    SSPC SP 10 (2-3) novolac novolac
    100-200 (4-8) 100-200 (4-8)
    CS-3 -45°C/50°F to 595°C/1100°F ISO 8501-2: Sa 3/ 50-75 Thermal sprayed Optional: Sealer:
    SSPC SP 5 (0.5-1) Aluminium Type acc. to
    250-375 (10-15) service temp. 40
    CS-4(2) -45°C/50°F to 650°C/1200°F ISO 8501-2: Sa 2½/ 40-65 Inorganic Inorganic Thermal spray of aluminium
    SSPC SP 10 (1.5 – 2.5) copolymer(3) copolymer(3)
    100-150 (4-8) 100-150 (4-8)
    Thermal sprayed aluminum
    Watertight insulation protection /cladding is
    the first line of defence against CUI

     The cladding should shed water

     Sealing of joints

     Inspection points
    Quality control in all phases:

     Steel quality, Steel work, Surface preparation, Coating application, Insulation


    installation, Cladding installation ....
    Actual operation

     Prompt, promptly maintenance

     Avoid foot traffic, and other unnecessary activities that may damage the
    system

     Risk based inspection procedures


    Where is CUI a risk factor – where should the
    inspection be more frequent?

     RISK = Probability X Consequence

    Probability of CUI is affected by: Age, condition of cladding, location


    (corrosivity of environment), operational temperatures, insulation material,
    quality/age of primary corrosion protection etc. (where does the water go?)

    Consequence of CUI is: Cost of shut-down for replacement, Environmental and


    safety hazards in case of leak etc.

    Probability/ High Medium Low


    Consequence
    High
    Medium
    Low
    How does the insulation
    material affect corrosion?
    Insulation selection
    NACE SP0198-2010 (2.1.2):
    CUI of carbon steel is possible under all types of insulation. The insulation type
    may only be a contributing factor. The insulation characteristics with the most
    influence on CUI are:
    ■ Water-leachable salt content in insulation, such as chloride, sulphate and acidic
    materials that may contribute to corrosion;
    ■ Water retention, permeability, and wettability of the insulation; and
    ■ Foams containing residual compounds that react with water to form
    hydrochloric or other acids.
    Because CUI is a product of wet metal exposure duration, the insulation system
    that holds the least amount of water and dries most quickly should result in the
    least amount of corrosion damage to equipment.
    Corrosion can be reduced by careful selection of insulation materials.
    Corrosion happen under all types of insulation but there
    are differences

    ■ Go beyond the obvious (, MST, …): To minimize the risk of CUI, it is also
    important that the insulation does not affect the steel, does not absorb
    water and is open to vapour so that moisture can easily egress the insulation
    ■ Essential properties and test methods
    Water absorption should be less than 1kg/m2 EN1609

    Water vapour resistance () is close to 1,0 EN12086

    pH is neutral to slightly alkaline

    Conforms to the stainless steel corrosion specification as ASTM C795


    per ASTM test methods C692 and C871
    Water leachable chloride content < 10mg/kg [AS-Quality] EN13468

    Mass Loss Corrosion Rate < reference test ASTM C1617


    The amount of corrosion testing related to insulation
    products is limited
    Results from natural weathering testing:
    Massachusetts, US in 2009, 12 weeks outdoor
    testing. Insulation installed over bare mild steel
    with no cladding.

    Ref.: Williams, J. Evans, O., “THE INFLUENCE OF INSULATION MATERIALS ON CORROSION UNDER
    INSULATION,” NACE, Calgary Canada, February 2010.
    CUI Simulation Measurements – ASTM G189-07
    The test apparatus is constructed such that it contains six separate test
    samples in one test. Test samples are carbon steel.
    The insulation is wetted and dried in set cycles of cold (60°) and hot (150°C).
    The liquid used is recycled so that leaching products of the specific insulation
    influence the corrosion.
    Cyclic test One cycle No of cycles
    Duration 20 hours 4 hours 21 (21 days)
    Temperature 60°C 150°C
    Wet/dry Wet Dry
    CUI Simulation Measurements – ASTM G189-07

    CUI Test set-up


    “Water on the pipe”

    Stone wool PS (ASTM C547)

    Aerogel (ASTM C 1728)

    Cellular glass (ASTM C 552)


    New tools in the CUI battle
    Non contact insulation

     Spacers ensure an air gap between the steel pipe and the insulation.

     Reduced time of ”Wetness” = lower corrosion rates


     Hot water immersion like situations are avoided/limited = extended
    lifetime of the protective coating system

    Combining a spacer with an insulation material with a high water


    vapour permeability allow the water to move to the cladding where it
    can condense, run to a lower point and be tapped out.
    Results of corrosion testing with spacers Norway 1:
    Results from accelerated testing in Norway,
    2005: Comparing mineral wool and spacer with
    cellular glass directly on the pipe.

    Operational temperature: 105°C, with


    biweekly 30 minutes immersion in
    Seawater. Test duration 3 months.

    Mineral wool and spacer: Limited


    corrosion and coating intact. Cellular glass: Severe corrosion and
    coating damage.
    ASTM G189-07 testing of non-contact insulation
    CUI simulation tests carried out by METALogic on behalf of ROCKWOOL Technical
    Insulation in accordance with ASTM G189-07.

    Comparing ASTM C547 pipe sections direct on pipe and via use of spacer rings

    • Up to 21 cycles of 24 hours (20 hrs. 60oC wet – 4 hrs 150oC dry)


    • Use of demineralized water

    Direct to metal

    Non-Contact Insulation
    Results of corrosion/coating testing with spacers
    Norway 2:
    Results from accelerated testing in Norway (Statoil) 2009:
    Comparing mineral wool with and without spacers.

    Operational temperature: 140°C, with 20


    minutes immersion in Seawater 3 times a
    week. Test duration 2 months.

    Significant difference in coating performance – even for TSA


    Ref.: NACE paper 10022, K. Haraldsen
    Spacers – what is on the market?

     Metal solutions – available from main Insulation installers

     Polymer based solutions are becoming available offering added


    advantages.

    Main advantage of metal solutions is higher temperature resistance

    Main advantages of polymer based solutions are :


     No damage to heat tracing and coating
     No damage to coating
     Lower risk of injuries/damage due to sharp edges.
     More efficient installation
    Seamless cladding

     Seamless cladding based on UV cured GRP is an alternative tool in


     the CUI fight.

     Eliminate/minimize water ingress


     Cladding with higher mechanical and chemical resistance
    Wrap up

     CUI is a system challenge and must be addressed and planned from design
    phase to service. Including steps as:

     steelwork quality and design (smooth surfaces, water shedding)

     coating selection and application,

     insulation selection and installation,

     cladding selection and installation

     Inspection and maintenance plans in service – possibly risk based

     Quality control important in all phases.

     The choice of insulation material do influence corrosion rates. Care should


    be given to the selection. Old assumptions may not hold-up.

     New tools in the CUI fight are becoming available – some are available and
    some being finalised in the laboratories.
    Thank you for your attention

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