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When Undercover Agents are Tested to the Limit: Coatings in Action (CIA) and Corrosion Under Insulation (CUI) at High Temperature

When Undercover Agents are Tested to the Limit: Coatings in Action (CIA) and Corrosion Under Insulation (CUI) at High Temperature
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This paper is a “high temperature” sequel to previous investigations of four specialty inorganic coatings said to prevent corrosion under wet insulation conditions with temperature cycling both in the CUI range of -5°C to 175°C and up to ca 400°C. 

Product Number: 41213-774-SG
Author: Mike O’Donoghue, Vijay Datta, Adrian Andrews, Sean Adlem
Publication Date: 2013
Industries: Pipelines, Tanks, and Underground Systems , Coatings , Coatings and Linings
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This paper is a “high temperature” sequel to previous investigations of four specialty inorganic coatings said to prevent corrosion under wet insulation conditions with temperature cycling both in the CUI range of -5°C to 175°C and up to ca 400°C. In the present work, two of the specialty coatings have been tested again, viz a one coat system of a titanium modified inorganic copolymer (TMIC) with aluminum flake pigmentation and a two coat system of a high performance modified silicone with MIO (Coating A). Carbon and stainless steel pipes were abrasive blasted to SSPC-SP10 near white metal and coated by spray application. The pipes were then insulated in high-water retention insulation (calcium silicate, CalSil) and subjected to a CUI microenvironment of cyclic wetting and heating for 6 weeks where the maximum temperature of each cycle was ca 560°C - 600°C. Laboratory investigations were undertaken to compare and contrast the CUI performance of TMIC vs Coating A and to more accurately determine the temperature profile of the coated steel pipe under wet insulation.

This paper is a “high temperature” sequel to previous investigations of four specialty inorganic coatings said to prevent corrosion under wet insulation conditions with temperature cycling both in the CUI range of -5°C to 175°C and up to ca 400°C. In the present work, two of the specialty coatings have been tested again, viz a one coat system of a titanium modified inorganic copolymer (TMIC) with aluminum flake pigmentation and a two coat system of a high performance modified silicone with MIO (Coating A). Carbon and stainless steel pipes were abrasive blasted to SSPC-SP10 near white metal and coated by spray application. The pipes were then insulated in high-water retention insulation (calcium silicate, CalSil) and subjected to a CUI microenvironment of cyclic wetting and heating for 6 weeks where the maximum temperature of each cycle was ca 560°C - 600°C. Laboratory investigations were undertaken to compare and contrast the CUI performance of TMIC vs Coating A and to more accurately determine the temperature profile of the coated steel pipe under wet insulation.

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Picture for When Undercover Agents Can’t Stand the Heat” The CIA and the Nether World of Corrosion Under Insulation (CUI)
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When Undercover Agents Can’t Stand the Heat” The CIA and the Nether World of Corrosion Under Insulation (CUI)

Product Number: 41212-694-SG
Author: Mike O’Donoghue, Vijay Datta, Adrian Andrews, Sean Adlem , Matthew Giardina,Nicole de Varennes, Bill Johnson
Publication Date: 2012
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Corrosion under insulation (CUI) is a costly and complex problem for industry to contend with successfully. This paper describes a suite of accelerated laboratory tests undertaken in part to evaluate some of the claims made for engineered coatings touted to possess high heat resistance to 400°C and simultaneous anticorrosion properties. 
Picture for Corrosion Under Insulation on Industrial Piping – A Holistic Approach to Insulation System Design
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Corrosion Under Insulation on Industrial Piping – A Holistic Approach to Insulation System Design

Product Number: 51319-13042-SG
Author: Mark Swift
Publication Date: 2019
$20.00

Corrosion Under Insulation (CUI) on industrial piping is a major issue for oil and gas industry. The potential influence of applied thermal and acoustic insulation materials is normally assessed through a series of individual laboratory tests on the insulation materials themselves but very rarely on the applied system. Moreover the tested physical values do not necessarily and readily reflect the potential influence that a given insulation material or system has on the risk of CUI.A more sophisticated approach is proposed which takes into account not only the applied insulation system but also the CUI failure behaviour and water or water vapour ingress and retention processes. This approach allows the individual risk assessment of the applied insulation systems against different scenarios of water ingress to be performed. Other influencing factors for the risk assessment include the configuration of the insulation system (e.g. insulation materials aluminium barrier foil outside claddings) and specified construction or installation methods.It is hoped that the approach proposed in this paper will enable the reader to improve their knowledge of insulation materials and their influence on CUI risk and furthermore be able to better identify vulnerable areas on the facility where CUI is likely to occur thereby allowing appropriate CUI management strategies to be developed and implemented.
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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