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Corrosion Under Insulation Behavior Of Phenolic Epoxy Coatings Under Contacting And Contact-Free Insulations

Picture for Corrosion Under Insulation Behavior Of Phenolic Epoxy Coatings Under Contacting And Contact-Free Insulations
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CUI (Corrosion under insulation) refers to localized corrosion under thermal insulations, which pose integrity risks to the hydrocarbon facilities. 1 CUI is reportedly a driver behind 40-60% of failures in the facility piping. Smaller-sized piping (i.e., diameter < 4”) are even more prone to CUI, whereas reportedly 81% of failures in small-sized piping are due to CUI. 2 CUI-related failures and associated efforts comprise 10% of a facility’s maintenance budget. Management of CUI risks has always been challenging as it involves maneuvering numerous governing factors. The key driving factor behind CUI is the aerated moisture that comes from soaked thermal insulations.

Product Number: 51322-17535-SG
Author: Ahmad Raza Khan Rana, Graham Brigham, Omar Chaar, George Jarjoura
Publication Date: 2022
Industries: Corrosion Monitoring and Control , Coatings and Linings
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$20.00
$20.00

CUI (corrosion under insulation) is reportedly a contributor to the failure of insulated piping and process equipment. Protective coatings are among various effective measures to manage the CUI of industrial assets. Phenolic epoxy is among the widely used coatings under thermal insulations. This research work involves CUI testing of phenolic epoxy coating for 192 hours as per applicable ASTM standard G189-07 using cyclic wet operating conditions. The resulting weight loss from the test was converted to corrosion rate followed by microscopic checks. The as-coated (i.e., new) surface and post-test coatings were characterized using microscope and surface topography to account for damage modes and surface roughness. Phenolic epoxy coating under contacting insulation suffered a higher material loss rate, dis-bonding, and holiday defects tendency in comparison to contact-free insulation with low-point drainage.

CUI (corrosion under insulation) is reportedly a contributor to the failure of insulated piping and process equipment. Protective coatings are among various effective measures to manage the CUI of industrial assets. Phenolic epoxy is among the widely used coatings under thermal insulations. This research work involves CUI testing of phenolic epoxy coating for 192 hours as per applicable ASTM standard G189-07 using cyclic wet operating conditions. The resulting weight loss from the test was converted to corrosion rate followed by microscopic checks. The as-coated (i.e., new) surface and post-test coatings were characterized using microscope and surface topography to account for damage modes and surface roughness. Phenolic epoxy coating under contacting insulation suffered a higher material loss rate, dis-bonding, and holiday defects tendency in comparison to contact-free insulation with low-point drainage.

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Picture for Corrosion Under Insulation Performance Of Insulation Stand-Offs And Non-Metallic Membranes
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Corrosion Under Insulation Performance Of Insulation Stand-Offs And Non-Metallic Membranes

Product Number: 51322-17618-SG
Author: Ahmad Raza Khan Rana, Graham Brigham, Omar Chaar,George Jarjoura
Publication Date: 2022
$20.00

Corrosion under thermal insulations namely CUI (Corrosion under insulation) is among the key damage mechanisms which poses integrity risk to the hydrocarbon facilities. CUI is reportedly known as the reason behind 40-60% of failures in the facility piping whereas small bore piping (i.e., NPS < 4”) are even more sensitive to CUI failures, where up to 81% of reported failures in small-sized piping are known to be from CUI.  Monetary spending to inspect and fix CUI-related failures cost 10% of overall maintenance budget in a typical medium-sized oil refinery.  CUI risk is influenced by numerous operational and environmental factors which impedes its management in a typical AIM (Asset integrity management) program.
Picture for Understanding Insulation Chemistry Proven to Inhibit Corrosion Under Insulation (CUI)
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Understanding Insulation Chemistry Proven to Inhibit Corrosion Under Insulation (CUI)

Product Number: 51317--8876-SG
ISBN: 8876 2017 CP
Author: David Shong
Publication Date: 2017
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Since 2002, a corrosion inhibiting chemistry package has been an integral part of two specific industrial insulations. This paper explains, at a molecular level, how this package engages a two-pronged defense (physical coating and pH buffering) against CUI.
Corrosion Under Insulation (CUI) Management – A Case History
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Corrosion Under Insulation (CUI) Management – A Case History

Product Number: 51219-196-SG
Author: David A. Hunter
Publication Date: 2019
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Pond investigated pressure vessel tank failures which are causing recurring maintenance of $250,000 per year. This challenging project had limitations of space, operational time pressures/vessel availability requirements, cost and replacement variables. This presentation will chronical problems and discuss best practices of specifications, material selection, surface preparation, and application inspection that would have prevented the aforementioned outcome. This paper discusses the fundamentals of composite coatings, industry accepted design standards for their use, and examples of typical uses for these materials that solve problems in varied industries.
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