belzona cui presentation - imxpo exhibition india
TRANSCRIPT
DEVELOPMENTS IN HEAT ACTIVATED PROTECTIVE
COATINGS AND REPAIR COMPOSITES TO ADDRESS CORROSION UNDER
INSULATION ISSUES IN THE HYDROCARBON INDUSTRY
Presentation
Presenter
Mr Ron Campbell
Senior Vice President
Belzona Asia Pacific
Corrosion Under Insulation – Root Causes and Effects
Water Ingress
Trapped during construction
Leakage of weather-proofing
Sprinkler Systems
Exacerbating Factors
Chemicals
Contaminants in the insulation material ( Chlorides)
Atmospheric pollutants ( Acid Rain )
Decomposition of organic materials ( Bird Droppings )
Spillage ( Production Chemicals and Cleaners )
Temperature
Equipment operating at 5 – 200 C
Cyclic wetting/drying (concentration mechanism)
Corrosion Under Insulation – Root Causes and Effects
Carbon steels
Accelerated corrosion/pitting
SCC (low risk: hot nitrate)
Stainless steels
Crevice/pitting corrosion
SCC (high risk: chloride + T>60 C)
Other Metallic substrates
Comparatively little experience
Corrosion Under Insulation – Root Causes and Effects
Vertical risers act
As watersheds
Joints in saddles
Lobster backs
Low elevation
Saddles trap water
Heat sink attracts vapour
Mid joints
Water penetration into Insulation is the primary cause of CUI – if the water
can be prevented from entering the Insulation – CUI can be negated.
Corrosion Under Insulation – Root Causes
Type Water Extract Chloride
Calcium silicate alkaline (pH 7-10) possibly high
Fibre glass
Cellular glass
Ceramic fibre
Mineral wool neutral (pH 6-7) low (~2 mg/l)
Organic foams acid (pH 2-3) possibly high
Corrosion Implications of Insulation Types
Chemical extraction from Insulation can accelerate CUI
Corrosion Under Insulation – Results
CUI exists in every Hydrocarbon Processing Plant Worldwide
How can CUI problems be Repaired and then Negated – On Line ?
Corrosion Under Insulation – Product Solutions
Non-Compliant Repair and Protection
Where there is no internationally recognized
standard required for the application
but they are effective and have been and are
currently in use within industries worldwide
and are widely accepted based on historical
performance.
Compliant Repairs
Where there is a accepted International
Standard for the use of composite materials
for repair of pipe - work and tanks and
where the client requires certification:
- ASME PCC-2-2008
- ISO / TS 24817
Corrosion Under Insulation – Product Solutions
“ Non – Compliant Solutions “
Non – Compliant Solution – Build a New One !
Corrosion Under Insulation – Product Solutions
Can Be applied to Hot Surfaces
Surface Temperatures of 30C – 180C
Minimal Surface Preparation
High Adhesion
Resist Insulation Saturation / Immersion
Simple to Use
Long Service Period
Product Development Parameters
Product Profiles
Single Component Heat Activated Repair Material ( 70 – 180 C )
Single Component Heat Activated Coating Material ( 70 – 180 C )
Two Component Heat Activated Coating Material ( 30 – 80 C )
Adhesion on cold surfaces is best achieved through
mechanical locking ( Surface Roughening / Blasting )
Coating
Substrate
Corrosion Under Insulation – Product Profile
Adhesion on hot surfaces achieved by
penetration of pores in metal which increase in
size on heating
Corrosion Under Insulation – Product Profile
Contaminated Porous Metal Substrate
Adhesion on contaminated hot metal surfaces
Achieved by displacement of moisture …
… Absorption of contaminant oil …
… And penetration of pores before cure in
place which provides a mechanical lock
Heat Activated Coating
Corrosion Under Insulation – Product Profile
Corrosion Under Insulation – Simulated Testing
Custom Built CUI test Rig
Disposable steel sleeve fitted over a
cylindrical oil-filled heater Sleeve is
manually prepared and then coated
in-situ with test coating Coated pipe
then surrounded with a cylinder of
insulation material (glass fibre)
and a cylinder of metal cladding
Water (or salt water) is then introduced
into the rig via a hole in the cladding
Test temperature (and coating temperature) can be selected
Rig dismantled and coating examined for attack periodically
Accurately replicates CUI environment, but more aggressive due to frequency
and amount of water added
Corrosion Under Insulation – Simulated Testing
Corrosion Under Insulation – Simulated Testing
Corrosion Under Insulation – Performance Testing
Partially rusty test sleeve manually abraded using P36 abrasive paper is placed over heater
Test coating is applied onto the hot sleeve
End flange is bolted on and sealed
Mineral fiber insulation taped into place
Outer cladding/water funnel attached/sealed
Corrosion Under Insulation – Performance Testing
Two litres of water added each week
1 litre of water and 1 litre of 5% salt water solution
Results ( Heat Activated Coating System )
No attack or corrosion at 70ºC to 90ºC
Negligible attack/corrosion at 100ºC to 150oC
Very slight surface erosion in full immersion area
Corrosion Under Insulation – Performance Testing
Steel test panels prepared by abrading manually (no profile)HA Coating applied onto hot panels and oven cured Panels exposed for 1000 hours at 35ºC (95ºF) in saturated salt fog atmosphere
ResultsNo field blistering or corrosionMinimal corrosion creep under the
scribe mark
Substrates:
Unprepared, uncorroded steel direct from the manufacturersSurface covered in firmly attached millscale
Unprepared steel ground using belt sander (with P36 abrasive)Clean metal surface exposed, but negligible profile
Wire-Brushed Rusty Steel
Started with rusty steel panel (ISO 8501-1 grade C)TSteel weathered externally for 3 monthsRusted to ISO 8501-1 grade C, i.e. significant rusting with some pitting
Loose surface rust brushed away, but no other preparation
horoughly abraded with wire brush to ISO 8501-1 St 2Pitted surface covered in firmly attached rust
Abraded Rusty Steel
Started with rusty steel panel (ISO 8501-1 grade C)Initially abraded with wire brush, then further abraded by hand with P36 abrasive paper to ISO 8501-1 St 3Surface a combination of firmly attached rust with some clean steel showing through
Unprepared Steel
Ground Steel
Rusty Steel
Corrosion Under Insulation – Performance Testing
Adhesion
3200 psi
2280 psi
2320 psi
830 psi
1240 psi
2410 psi
2800 psi
2940 psi
3490 psi
1380 psi
1720 psi
2600 psi
Blasted SA2.5
Unprepared
Ground
Rusty
Wire Brushed
Manually Abraded
Two Pack HA / Single Pack HA
Corrosion Under Insulation – Performance Testing
Corrosion Under Insulation – Application Histories
Equipment :
Process pipe work handling waste
gas at a temperature of 130C
Problem :
Loss of wall thickness and
unable to shut down the process
Client : Shell UK
Date : Year 2000
Solution:
Manual preparation followed by repair and
protective coating with single component
heat activated system
Corrosion Under Insulation – Application Histories
Equipment :
Process vessel in refinery operating
at 90 – 120C
Problem :
Corrosion and loss of wall thickness
Client : Total Fina Elf , UK
Date : Year 2004
Solution:
Manual preparation followed
protective coating with single component
heat activated system
Corrosion Under Insulation – Application Histories
Equipment :
Fractionator Tower T102 operating
at 120C
Problem :
Loss of wall thickness and
unable to shut down the process
Client : Exxon , Singapore
Date : Year 2001
Solution:
Manual preparation followed by repair and
protective coating with single component
heat activated system
Corrosion Under Insulation – Application Histories
Equipment :
De-asphalting Column operating at
120 C
Problem :
Severe corrosion and
unable to shut down the process
Client : Shell , New Zealand
Date : Year 2003
Solution:
Water Jetting preparation followed by
protective coating with single component
heat activated system
Corrosion Under Insulation – Application Histories
Equipment :
Steam Extraction pipe from
Geothermal well operating at 165C
Problem :
Loss of wall thickness and
unable to shut down the process
Client : Chevron Power , Philippines
Date : Year 2002
Solution:
Manual preparation followed by repair
by sleeve bonding and protective
coating with single component
heat activated system
Corrosion Under Insulation – Application Histories
Equipment :
Process line on FPSO operating
at 95C
Problem :
Pitting Corrosion and
unable to shut down the process
Client : Kerr McGee , China
Date : Year 2007
Solution:
Manual preparation followed by repair and
protective coating with single component
heat activated system
Corrosion Under Insulation – Application Histories
Equipment :
Distillation Columns operating at
100 - 135 C
Problem :
Pitting corrosion and
unable to shut down the process
Client : ConocoPhillips , UK
Date : Year 2008
Solution:
Water Jetting preparation followed by
protective coating with single component
heat activated system
Corrosion Under Insulation – Application Histories
Equipment :
Gas Process pipe work operating at
90 – 115C
Problem :
Pitting corrosion and
unable to shut down the process
Client : Offshore Gas Company , UK
Date : Year 2005
Solution:
Water Jetting preparation followed by
repairs to pitting and protective
coating with and single component
heat activated system
Corrosion Under Insulation – Client Testimonials
Emlyn Roberts
Works Engineer
Total Refinery , UK
Bertrand Van Der Hayden
Fixed Equipment Reliability
Inspector
Caltex South Africa
The absorber column at the Vector Kapuni Gas Treatment Plant in Taranaki required
painting. It was not possible to take the column out of service long enough to complete
the painting programme using normal painting specs. The column runs at approximately
100 degree C so the search began for a product that could be applied at this
temperature while the plant remained online. Belzona 5851 was the pick of the products
as it had already proven itself at Marsden Point. Belzona 5851 has now been in service
for about 2 ½ years and as the pictures show remains in good condition. We have since
applied the same product to our Regeneration tower which also runs at similar
temperature with no problems encountered.
Bob van den Beuken
Maintenance Team Leader
Mechanical
Vector Kapuni , New Zealand
- CUI Systems proven in Service over a period of 10 years -
Up to 35°C Two Pack Epoxy System
30°C - 80°C Two Pack Heat Activated System
70°C - 150°C Single Pack Heat Activated System
Up to 35°C
30 to 80°C
70 to 180°C
“Effective On-Line Solutions”
Surface application temperatures
Corrosion Under Insulation – Complete Protection
Corrosion Under Insulation – Product Solutions
“ Compliant Solutions “
Corrosion Under Insulation – Product Solutions
ASME PCC-2-2008
ISO / TS 24817
ASME and ISO Standards
• Ensures that composite repairs are no longer an art but is now a
science
• Allow repairs to be designed for individual situations using tested
calculations
• Ensures a quality product and service via Manufacturers auditing
and Application Validation.
Corrosion Under Insulation – Product Solutions
ASME PCC-2 and ISO/TS 24817 allow for the repair of the
following: -
• Thinned wall defects
• Through wall defects
• Straight Pipe
• Complex Geometries, inc. bends, tees, reducers etc.
• Tanks and Vessels
Corrosion Under Insulation – Product Solutions
• ASME PCC-2 only allows for the repair of
tanks and vessels through the application
of a full circumferential repair
• ISO 24817 allows for the same tank or
vessel to be repaired by a patch repair
• Further developments to ASME PCC-2 will
include specific sections dealing with tanks,
vessels and patch repair
Corrosion Under Insulation – Product Solutions
Repairs are design to
design lives of up to 20
years using standard
safety factors
Corrosion Under Insulation – Product Solutions
Repair Life
Following the initial compliance testing further
development and improvements of the Composite
System are on-going :
• Specifically designed resin systems
• Specially treated high density glass reinforcement and
Carbon Fibre Alternatives
• Liquid reinforcement conditioner
Corrosion Under Insulation – Product Solutions
Corrosion Under Insulation – Product Solutions
Composite Repairs are Classified within the Standard
Repairs can only be carried out by Manufacturers Trained and
Validated Personnel :
Class 1 : Manufacturers Trained Validated Applicator
Class 2 : Manufacturers Trained Validated Applicator and Supervisor
Class 3 : Manufacturers Trained Validated Supervisor
Application Requirements
Installers and Supervisors
Trained by repair system manufacturer
Hold points observed
Work procedure carried out as required
by repair system manufacturer and
documented as required by the standard
Repair completed as per design
Corrosion Under Insulation – Product Solutions
Corrosion Under Insulation – Product Solutions
Types of Defects
The standards detail the types of
repairs that can be carried out
using compliant composite
systems
• Each Composite Repair is designed to fit the
requirements of the situation
• By validated authorised Composite Repair Designers
• Designers must complete the Manufacturers Design
Course
Corrosion Under Insulation – Product Solutions
Design Requirements
Visual Inspection and external measurement
or through repair inspection using x-ray
or gamma ray to identify :
Leaking
Degradation
Defect s and defect sizes
Corrosion Under Insulation – Product Solutions
Inspection
Corrosion Under Insulation – Application Histories
Equipment :
Storage Tank
Problem :
Hole in Tank wall due to corrosion
pitting
Client : Power Company , USA
Date : Year 2009
Solution:
Preparation by grit blasting followed
by compliant composite repair
Corrosion Under Insulation – Application Histories
Equipment :
Process line in refinery
Problem :
Pitting Corrosion and
Wall thinning
Client : Esso , UK
Date : Year 2008
Solution:
Grit blast preparation followed
by installation of compliant repair
Corrosion Under Insulation – Application Histories
Equipment :
Demineralised Water Lines
In water treatment plant
Problem :
Weld deterioration on stainless steel
pipe weld areas
Client : EGAT , Thailand
Date : Year 2007
Solution:
Preparation by Grit Blasting and compliant
Composite repair installed.
Corrosion Under Insulation – Application Histories
Equipment :
Production pipe work on Offshore
Platform
Problem :
Corrosion Under Insulation
Pitting and loss of wall thickness
Client : Statoil , Norway
Date : Year 2009
Solution:
Preparation by Grit Blasting and compliant
Composite repair installed.
Corrosion Under Insulation – Application Histories
Equipment :
Produced water process piping
Problem :
CUI resulting in perforations of
piping system
Client : Exxon , Norway
Date : Year 2009
Solution:
Preparation by Grit Blasting and compliant
Composite repair installed.
Corrosion Under Insulation – Summary
Corrosion Under Insulation is a Common
Problem in the Hydrocarbon Processing
Industry
Due to limited shutdown opportunities
more on-line maintenance is required
Solutions that involve no or limited Hot-Work
are available are now available
Engineering authorities now accept
composite repair technology
Applications must be controlled through
training and validation to ensure success
and compliance with International Standards
Thank you for your Attention
QUESTIONS ?
Mr Ron Campbell
Senior Vice President
Belzona Asia Pacific