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(Pipeline, Oil & Gas) A Hot Spread Epoxy Phenolic Coating for CUI Mitigation: From Confusion to Fusi

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  • (Pipeline, Oil & Gas) A Hot Spread Epoxy Phenolic Coating for CUI Mitigation: From Confusion to Fusi
Picture for Coatings + Proceedings 2021-ALL Papers

It is fair to say that maintenance in the worldwide oil and gas industry has changed dramatically over the past ten years.  Facility owners are more than ever looking to reduce shutdown times, to improve plant efficiency and to extend plant lifetimes. With this comes the increased industry understanding about corrosion under insulation (CUI) with its deleterious impact and the ongoing desire for pragmatic high performance and cost-effective coating solutions.

Product Number: 30-COAT_DEC21
Author: Mike O’Donoghue / Vijay Datta / Ian Fletcher
Publication Date: 2021
Industries: Oil and Gas , Pipelines, Tanks, and Underground Systems , Coatings
$0.00
$20.00
$20.00

It is fair to say that maintenance in the worldwide oil and gas industry has changed dramatically over the past ten years.  Facility owners are more than ever looking to reduce shutdown times, to improve plant efficiency and to extend plant lifetimes. With this comes the increased industry understanding about corrosion under insulation (CUI) with its deleterious impact and the ongoing desire for pragmatic high performance and cost-effective coating solutions.

CUI maintenance work can take up to 50% or more of a typical oil and gas facility’s maintenance budget. With such a heavy impact on resources when CUI maintenance needs to be carried out, it is imperative the rehabilitation must be done right, first time.

Factoring in operational losses the cost to shutdown equipment can be up to US$100,000 per hour, so the ability to carry out planned or even emergency maintenance whilst the facility is operating can be very attractive. However, coating piping and equipment which is still in operation causes logistical, technical and practical challenges for traditional coating technologies. Although most traditional coating solutions are capable of application at elevated temperature, few have been deliberately formulated to be applied in this way.

This paper reviews the current protective coating technologies on the market that are used direct to hot process piping for CUI protection applications. Exemplified by a novel hot spread epoxy phenolic coating that represents a fusion in molecular engineering, and fusion to the applied substrate, it is shown how properly formulated protective coatings for hot steel application on low grade surface pre-treatments (a) derive from an understanding of iron (oxyhydr)oxide types, (b) assure facility owners cost reductions in CUI mitigation, (c) help eliminate confusion for owners, engineers and specification authorities with coating selection, and (d) provide valuable coating additions for the maintenance contractor’s armoury.

Applications of the hot spread epoxy phenolic technology to hot rusted steel pipes and vessels in the oil and gas industry are highlighted.

It is fair to say that maintenance in the worldwide oil and gas industry has changed dramatically over the past ten years.  Facility owners are more than ever looking to reduce shutdown times, to improve plant efficiency and to extend plant lifetimes. With this comes the increased industry understanding about corrosion under insulation (CUI) with its deleterious impact and the ongoing desire for pragmatic high performance and cost-effective coating solutions.

CUI maintenance work can take up to 50% or more of a typical oil and gas facility’s maintenance budget. With such a heavy impact on resources when CUI maintenance needs to be carried out, it is imperative the rehabilitation must be done right, first time.

Factoring in operational losses the cost to shutdown equipment can be up to US$100,000 per hour, so the ability to carry out planned or even emergency maintenance whilst the facility is operating can be very attractive. However, coating piping and equipment which is still in operation causes logistical, technical and practical challenges for traditional coating technologies. Although most traditional coating solutions are capable of application at elevated temperature, few have been deliberately formulated to be applied in this way.

This paper reviews the current protective coating technologies on the market that are used direct to hot process piping for CUI protection applications. Exemplified by a novel hot spread epoxy phenolic coating that represents a fusion in molecular engineering, and fusion to the applied substrate, it is shown how properly formulated protective coatings for hot steel application on low grade surface pre-treatments (a) derive from an understanding of iron (oxyhydr)oxide types, (b) assure facility owners cost reductions in CUI mitigation, (c) help eliminate confusion for owners, engineers and specification authorities with coating selection, and (d) provide valuable coating additions for the maintenance contractor’s armoury.

Applications of the hot spread epoxy phenolic technology to hot rusted steel pipes and vessels in the oil and gas industry are highlighted.

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CUI (corrosion under insulation) is a pervasive, difficult and high-liability issue for petrochemical, power, shipping, and other industries. Situational variations (meteorological, geographical, seasonal, etc.) can confound conventionally specified surface preparation attempts to achieve perfect or near-perfect metal hygiene, thus reducing expected coating life by 30 to 75 percent. Because conventional surface preparation processes have historically been unable to adequately relieve microcontamination of metal surfaces, organizations have settled for an uneasy balance between economic and physical feasibilities that exclude the possibility of achieving ideal surface preparation outcomes and rely more heavily upon barrier coatings to supply needed corrosion control.
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