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Corrosion under Insulation (CUI) is accelerated corrosion that takes place under insulation typically used to conserve energy, help with process control, and protect workers from temperature extremes. CUI is an issue for facility owners in many industries that use heat or cold in their industrial processes, including chemical processing, refining, fertilizer manufacturing, and power generation. Insulation used in these applications is generally mechanically attached to the substrate vessel or pipeline and is typically covered with cladding. Cladding is typically made out of metal or plastic and is applied to protect the insulation from physical damage and to keep water away from the insulation and substrate.
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The Energy Innovation Center’s approximately 80-year-old concrete floor had significant divots and was badly spalled and cracked. The concrete floor, often referred to as “The Racetrack” due to its oval shape, serves as the main hallway to a newly renovated technology hub and needed significant structural and aesthetic work. The re-finished floor had to offer durable functionality as well as blend into the neo-industrial look of the re-tasked building.
This paper presents the diagnostic work undertaken to determine the cause of failing coating and spalling block on the exterior of a commercial building in northern Illinois. The field assessment methods used to diagnose the problems including non-destructive and destructive methods for determining moisture content in the masonry, infrared thermography, and visual assessments are described.
It is safe to say that water towers have become a predominant location for the placement of cellular telecommunications equipment. Their height and design style make them a “natural” consideration for what the industry calls them, macro sites. And when one carrier locates on a tower you can be sure that others will soon follow.
The United States Army and Marine Corps (USMC) paint their vehicles with the Chemical Agent Resistant Coating (CARC) system. This system consists of a pretreatment, an epoxy primer, and polyurethane topcoat, similar to many other industrial paint systems, but with added functional requirements (e.g., chemical agent resistance, camouflage, and signature reduction) unique to these paints. The systems that utilize these coatings are also designed for specific capabilities, of which corrosion is usually a lower priority. Lastly, the vehicles and equipment of the Army and USMC typically operate in harsh environments, which are highly corrosive.
Pressurized Atlas Cell Testing is commonly understood to be an aggressive accelerated test for lining systems due the combination of pressure, temperature and a thermal gradient across the coating film known as the Cold Wall Effect. This is especially true when Carbon Dioxide (CO2) is added to the gas phase, as CO2 is miscible with oil and soluble in water. A familiar gas mix of 5% CO2, 5% Hydrogen Sulfide (H2S), and 90% Methane (CH4) are used in test protocols to simulate head space conditions of tanks and pressure vessels in oil and gas production conditions.
Wind has been used as an energy source for centuries. Although the first wind turbines were built at end of the 19th century, the modern wind power industry, as we know it today, didn’t emerge until a century later. Today these wind turbines have an expected lifetime of up to 25 years. In addition, they are often placed offshore or in rugged terrain, making repairs extremely difficult and costly. There is a need for both tremendous corrosion and erosion protection to achieve the required lifetime expectancy.
Fabricators and Construction Firms rely on sub-tier vendors to supply a vast array of components and equipment for integration into the products they are supplying their clients. This may include valves, engines, motors, power supplies, tanks, tubs, vessels and other numerous items. The items and components provided by sub-tier vendors are normally prepared and coated prior to being delivered with what are typically referred to as original equipment manufacturer (OEM) coating systems.
This paper presents case histories on two commercial projects that incorporated industrial surface preparation, application and quality control standards and procedures into the work plans to achieve successful results. Highlights of SSPC audits for QP-8 and QP-9 recertification on the projects will also be discussed.
Carbon nanotubes are well-known for their ability to improve critical properties of polymeric materials. Our research objective is to quantify the influence of incorporating multi-walled carbon nanotubes (MWCNT) modified with amine, hydroxyl, or epoxy functionalities on the corrosion performance of epoxy amine coatings on steel substrates.
A previous paper presented by the authors at SSPC 2015 demonstrated the futility and folly of attempting to use accelerated corrosion testing as a tool for predicting real world corrosion performance. The effect of corrosion was shown to be governed by the type of ions and the concentration of oxygen in the corrosion environment. By understanding these two factors, accelerated corrosion testing can, however, be used as an indicator of performance which may be encountered in the real world.
To better understand and quantify the effect of crevice geometry, several crevice configurations simulating service conditions were evaluated including flanges assembled with gaskets, bolts mounted with nuts to plates, and the standard CREVCORR-type crevice formers.