corrosion under insulation

Internal Use Only – Do not distribute

Corrosion

Insulation

Present by : Patiphon Suksawat

Loop steam drum

Contents

Introduction

Organization

How to Implement CUI ?

My Inspiration

My gain

Patiphon Suksawat

Wasan Cheeppensuk Atip Nualnet

Komsan Bangkrut Nawa Bunsayang Narong Sakulprasitsiri

ORGANIZATION

Leader

Consultant

CUI team

- CUI is a particularly severe form of localized corrosion that has been plaguing chemical process industries since the energy crisis of the 1970s forced plant designers to include much more insulation in their designs.

- Intruding water is the key problem in CUI. Special care must be taken during design not to promote corrosion by permitting water to enter a system either directly or indirectly by capillary action.

What is CUI (Corrosion Under Insulation) ?

External damage

Carbon steels orlow alloy steels

Stainlesssteels

Subject to thinningSubject to stress corrosion cracking

What is CUI (Corrosion Under Insulation) ?

• CUI is the mainly problem in petrochemical plant.

• Current Inspection Program is not consider corrosion under insulation problem.

• Increase Reliability of Plant.

Reference TPE

Study CUI Theory From API 581, 570

Make Inspection Guide Line (Check Sheet)

Select Loop To Implement CUI

List up EQ and Collection Data

Risk Evaluation and Identification

Inspection ( Visual and Ultrasonic Testing)

Conclusion and Future action Plan

Schedule

1. Carbon steel piping systems, including those insulated operating between (–5°C to 175°C).

2. Austenitic stainless steel piping systems operating between (50°C–150°C).

Insulated Piping Systems Susceptible to CUI

Flange Tee

Common Locations on Piping Systems Susceptible to CUI

Internal Use Only – Do not distribute Support pointInsulation has deteriorated

Common Locations on Piping Systems Susceptible to CUI

Internal Use Only – Do not distribute - 12 -

Insulated equipment or line work

Do not consider CUI

Do CUI for Carbon Steel

Do CUI for

Stainless Steel

Constant

-5 C< T < 175 C

Material Carbon or

Low alloy steel

Guide Line for CUI inspection

Check Sheet

PE-302

PE-502

PM-500 A,B

PD-1205

TA-203A

TD-1203

TD-1201

TD-1210

TE-201

Loop steam drum

No. Line No.

1 10BW-0201-4B-3P2-H3-17K

2 10BW-0202-4B-3P2-H3-17K

3 10BW-0203-2B-1P2-H3-13.5K

4 10BW-0205-3B-P2(1S1(V))-H2-5K

5 10BW-0208-6B-1P2-H3-13.5K

6 10BW-0209-6B-1P2-H3-13.5K

7 10S-0006-4B-1P2-H3-13.5K

8 10SC-0001-6B-1S1(V)-H3-13.5K

9 10SC-0002-4B-1P2-H3-13.5K

10 1BW-0201-6B-P2-H-9.5K

11 1BW-0202-6B-P2-H-9.5K

12 1BW-0203-1.5B-1S1(V)-H-5K

13 1BW-0205-2B-P2-H-9.5K

14 1BW-0206-3B-P2-H-9.5K

15 1BW-0210-6B-P2-H-5K

16 1BW-0211-8B-P2-H-5K

17 1BW-0212-8B-P2-H-5K

18 1BW-2202-4B-P2-H-5K

19 1S-0001-4B-P2-H-5K

20 1S-0005-6B-P2-H-5K

No. Line No.

21 1S-0201-2B-P2

22 1S-0202-1.5B-P2

23 1S-0203-2B-P2

24 1S-0205-3B-P2

25 25SC-0001-6B-3P2-H3-28.5K

26 25SC-0001-6B-3S1-H3-28.5K

27 25SC-0004-6B-3S1-H3-28.5K

28 3BW-0201-3B-1P2-H2-13.5K

29 3BW-0202-3B-1P2-H2-13.5K

30 3BW-0203-1B-1S1(V)-H2-5K

31 3BW-0203-1B-P2-H2-5K

32 3BW-0204-3B-P2-H2-5K

33 3BW-0204-4B-PS(1S1(V))-H2-5K

34 3BW-0205-3B-P2-H2-5K

35 3S-0001-12B-P2-H2-5K

36 3S-0009-4B-P2-H2-5K

37 3SC-0008-8B-1S1(V)-H2-5K

38 3SC-0202-3B-P2(1S1(V))-H2-5K

39 3SC-5502-4B-P2-H2-5K

40 LPW-0001-3B-1S1(J)-H-13.5K

List up Equipment

No. Line No.

4 10BW-0205-3B-P2(1S1(V))-H2-5K

8 10SC-0001-6B-1S1(V)-H3-13.5K

10 1BW-0201-6B-P2-H-9.5K

11 1BW-0202-6B-P2-H-9.5K

12 1BW-0203-1.5B-1S1(V)-H-5K

13 1BW-0205-2B-P2-H-9.5K

14 1BW-0206-3B-P2-H-9.5K

15 1BW-0210-6B-P2-H-5K

16 1BW-0211-8B-P2-H-5K

17 1BW-0212-8B-P2-H-5K

18 1BW-2202-4B-P2-H-5K

19 1S-0001-4B-P2-H-5K

20 1S-0005-6B-P2-H-5K

No. Line No.

26 25SC-0001-6B-3S1-H3-28.5K

27 25SC-0004-6B-3S1-H3-28.5K

30 3BW-0203-1B-1S1(V)-H2-5K

33 3BW-0204-4B-PS(1S1(V))-H2-5K

37 3SC-0008-8B-1S1(V)-H2-5K

38 3SC-0202-3B-P2(1S1(V))-H2-5K

40 LPW-0001-3B-1S1(J)-H-13.5K

Collection Data

Consequence class

1 2 3 4 5

Economics

No / SlightDamage

< 0.4 M฿

MinorDamage

0.4 – 4 M฿

LocalDamage

4 – 40 M฿

MajorDamage

40 – 400 M฿

ExtensiveDamage

> 400 M฿Health & Safe

No / SlightInjury

Minor Injury Major Injury Single InjuryMultiple

Injury

EnvironmentNo / Slight

effectMinoreffect

Localizedeffect

Majoreffect

Massiveeffect

Consequence of failure rating

Example

Select 3

1S-0001-4B-P2-H-5K

PointOperating

Temperature

Initial Coating Status

Insulation TypeWall thickness surface feature

Internal corrosion / erosion rate

External coil / Steam tracing

External environment

0> 175 0C

Or < -5 0C

Full QA paint protection

Negligible Not present Inside Building

1 150 – 175 0C

Perlite Foamglass Closed cellFoam (right

>7.1 mmLow

( < 0.1 mm/y)High Integrity

design

Rarely wetted (<10% of the

3-5 – 50 0C

or 120 – 150 0C

Normal QA paint

protection field weld at construction

FiberglassCal Sil,

AsbestosMineral Rock

4 – 7.1 mm or surface location of penetrations

through insulation

Medium (0.1-0.4 mm/y)

Medium Integrity design

Intermittently wetted (~40% of

the time)

5 50 – 120 0CUnpainted or

Unknown

< 4 mm or surface at location of

reinforcement ring & other water traps

High( >0.4 mm/y)

Low Integrity design

Permanently wetted (e.g.

condensation, cooling tower dripping water

Probability Score Table of Carbon Steel

5+5+1+1+1+0+1 = 14Example

Points Operating Temperature

Initial Coating Status Insulation Type External coil /

Steam tracingExternal

environment

0Constantly > 150 0C or Constantly

< 50 0C

Full QA paint protection

Low chloride insulation material

(<10 ppm Cl-)Not present Inside Building

2 High Integrity design

Rarely wetted (<10% of the

4 120 – 150 0C

Normal QA paint protection field

weld at construction

Medium Integrity design

Permanently wetted (e.g.

condensation, cooling tower dripping water

7 50 – 120 0C Unpainted or Unknown

Higher chloride insulation material

(>10 ppm Cl-)

Low Integrity design

Intermittently wetted (~40% of

the time)

Probability Score Table of Stainless Steel

CUI Criticality ranking

Example

CUI Confidence Questions Yes Interm NOCladding and Insulation conditions

+1 0 -1-Cladding/Insulation fully maintained : Yes-Cladding/Insulation normal : Interm-Cladding/Insulation in poor condition : NO

Multiple reliable inspections for CUI have been carried been carried out

+1 0 -1-Frequent inspection and selective delagly fallowed by appropriate remedial action : Yes

-Inspection irregular / not standard : Interm- No proper inspections : No

Monitoring CUI promoting condition

+1 0 -1

- The pressure of all possible CUI promoting condition (see susceptibility categories) has been established and quantified : Yes

- The operating temperature is monitored and constantly in identified rouge and coating condition is know / established : Interm

- The operating temperature is not established or the coating condition is not know : No

CUI Confidence rating

0 -1 + 0 = - 1

Examplescore

Strategy Matrix for Carbon Steel

Example

Strategy 3

Strategy Matrix for Stainless Steel

Strategies for Carbon steel

Strategies for Stainless Steel

Strategy 3

100 % NDE and delegging of all susceptible area within 6 years

Delegging of susceptible within 6

Delag 100% within 1 year

Delag more selective area

Within 1 year

Repair and Paint

Piping > 8 in

Significant CUI found

100 % delegging , repair and paint within 1 year

Adjust confidence with +1

Every 6 years

Strategy flowchart

Consequence of failure rating

Probability Score Table

CUI Confidence rating

Strategy Matrix

Risk Evaluation and Identification

Medium HighMedium Noinspection

Strategy Matrix

Strategy 3Strategy 2No inspection

10BW–0203-2B-1P2-H3-13.5K

Inspection

10BW–0205-3B-1S1(V)-H2

Inspection

1BW–0203-1.5B-1S1(V)-H

Inspection

1BW–0201-6B-P2-H

Inspection

1BW–0211-8B-P2-H

Inspection

1BW–0212-8B-P2-H

Inspection

25SC-0004-6B-3S1-H3

Inspection

1S-0001-4B-P2-H

Inspection

Strategy 3

100 % NDE and delegging of all susceptible area within 6 years

Delegging of susceptible within 6

Delag 100% within 1 year

Delag more selective area

Within 1 year

Repair and Paint

Piping > 8 in

Significant CUI found

100 % delegging , repair and paint within 1 year

Adjust confidence with +1

Every 6 years

Strategy flowchart1S-0001-4B-P2-H-5K

Inspection

Risk management

Corrosion

Think of module

Friendship

Thank You

N/A = not available

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