corrosion under insulation
TRANSCRIPT
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Corrosion
Under
Insulation
Present by : Patiphon Suksawat
Loop steam drum
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Contents
Introduction
Organization
How to Implement CUI ?
My Inspiration
My gain
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Patiphon Suksawat
Wasan Cheeppensuk Atip Nualnet
Komsan Bangkrut Nawa Bunsayang Narong Sakulprasitsiri
ORGANIZATION
Leader
Consultant
CUI team
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- 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) ?
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External damage
Carbon steels orlow alloy steels
Stainlesssteels
Subject to thinningSubject to stress corrosion cracking
What is CUI (Corrosion Under Insulation) ?
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• CUI is the mainly problem in petrochemical plant.
• Current Inspection Program is not consider corrosion under insulation problem.
• Increase Reliability of Plant.
Reference TPE
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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
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Schedule
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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
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Flange Tee
Valve
Common Locations on Piping Systems Susceptible to CUI
Internal Use Only – Do not distribute Support pointInsulation has deteriorated
Vent
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
No
No
Yes
Yes
Internal Use Only – Do not distribute - 13 -
Check Sheet
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PE-302
PE-502
PM-500 A,B
PD-1205
TA-203A
TD-1203
TD-1201
TD-1210
TE-201
Loop steam drum
Internal Use Only – Do not distribute - 15 -
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
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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
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Collection Data
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Collection Data
Internal Use Only – Do not distribute
Collection Data
Internal Use Only – Do not distribute - 20 -
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
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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
type)
>7.1 mmLow
( < 0.1 mm/y)High Integrity
design
Rarely wetted (<10% of the
time)
3-5 – 50 0C
or 120 – 150 0C
Normal QA paint
protection field weld at construction
FiberglassCal Sil,
AsbestosMineral Rock
wool
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
score
5+5+1+1+1+0+1 = 14Example
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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
time)
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
score
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CUI Criticality ranking
Example
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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
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Strategy Matrix for Carbon Steel
Example
Strategy 3
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Strategy Matrix for Stainless Steel
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Strategies for Carbon steel
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Strategies for Carbon steel
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Strategies for Stainless Steel
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Strategy 3
100 % NDE and delegging of all susceptible area within 6 years
Delegging of susceptible within 6
years
Delag 100% within 1 year
Delag more selective area
Within 1 year
Repair and Paint
Piping > 8 in
Significant CUI found
Significant CUI found
100 % delegging , repair and paint within 1 year
Adjust confidence with +1
Yes
Yes
Yes
No
No
No
Every 6 years
Every 6 years
Strategy flowchart
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Consequence of failure rating
Probability Score Table
CUI Confidence rating
CUI Criticality ranking
Strategy Matrix
Risk Evaluation and Identification
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30%
20%
50%
CUI Criticality ranking
Medium HighMedium Noinspection
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33%
18%
50%
Strategy Matrix
Strategy 3Strategy 2No inspection
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10BW–0203-2B-1P2-H3-13.5K
Inspection
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10BW–0205-3B-1S1(V)-H2
Inspection
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1BW–0203-1.5B-1S1(V)-H
Inspection
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1BW–0201-6B-P2-H
Inspection
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1BW–0211-8B-P2-H
Inspection
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1BW–0212-8B-P2-H
Inspection
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25SC-0004-6B-3S1-H3
Inspection
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1S-0001-4B-P2-H
Inspection
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Strategy 3
100 % NDE and delegging of all susceptible area within 6 years
Delegging of susceptible within 6
years
Delag 100% within 1 year
Delag more selective area
Within 1 year
Repair and Paint
Piping > 8 in
Significant CUI found
Significant CUI found
100 % delegging , repair and paint within 1 year
Adjust confidence with +1
Yes
Yes
Yes
No
No
No
Every 6 years
Every 6 years
Strategy flowchart1S-0001-4B-P2-H-5K
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Inspection
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Risk management
Corrosion
Think of module
Friendship
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Thank You
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Internal Use Only – Do not distribute
Internal Use Only – Do not distribute
N/A = not available