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

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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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. 

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
Industry: Coatings
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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. Thermal spray aluminum (TSA) was used as the benchmark to assess the coating performance of three liquid applied coatings in cyclic temperature and corrosive microenvironments. All four coatings were applied to carbon steel pipe. The liquid-applied coatings consisted of a titanium modified inorganic copolymer (TMIC), and two materials based upon modified silicone technology. The coated and insulated pipe was heated to temperatures  from 90°C to 445°C. Investigations were carried out (a) to evaluate the resistance of the coatings to CUI Cyclic conditions at 95°C to 445°C, followed by cyclic immersion in a salt solution and heating at 200°C, (b) on a repair patch of the TMIC on TSA, (c) to compare and contrast the performance of the coatings using EIS  (Electrochemical Impedance  Spectroscopy), and (d) using optical microscopy and SEM (scanning  electron  microscopy) to investigate the porosity of each coating system as a function of temperature at 100°C, 200°C,300°C,  and 400°C. In light of select case histories and the present accelerated laboratory studies, the importance of the CIA will be manifested in the undercover realm of CUI - not as in the case of the Central Intelligence Agency, but rather in the realm of “Coatings in Action”.

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. Thermal spray aluminum (TSA) was used as the benchmark to assess the coating performance of three liquid applied coatings in cyclic temperature and corrosive microenvironments. All four coatings were applied to carbon steel pipe. The liquid-applied coatings consisted of a titanium modified inorganic copolymer (TMIC), and two materials based upon modified silicone technology. The coated and insulated pipe was heated to temperatures  from 90°C to 445°C. Investigations were carried out (a) to evaluate the resistance of the coatings to CUI Cyclic conditions at 95°C to 445°C, followed by cyclic immersion in a salt solution and heating at 200°C, (b) on a repair patch of the TMIC on TSA, (c) to compare and contrast the performance of the coatings using EIS  (Electrochemical Impedance  Spectroscopy), and (d) using optical microscopy and SEM (scanning  electron  microscopy) to investigate the porosity of each coating system as a function of temperature at 100°C, 200°C,300°C,  and 400°C. In light of select case histories and the present accelerated laboratory studies, the importance of the CIA will be manifested in the undercover realm of CUI - not as in the case of the Central Intelligence Agency, but rather in the realm of “Coatings in Action”.

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

Product Number: 41213-774-SG
Author: Mike O’Donoghue, Vijay Datta, Adrian Andrews, Sean Adlem
Publication Date: 2013
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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. 
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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.
Picture for 08036 Evaluation of Steel and TSA Coating in a Corrosion Under Insulation (CUI) Environment
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08036 Evaluation of Steel and TSA Coating in a Corrosion Under Insulation (CUI) Environment

Product Number: 51300-08036-SG
ISBN: 08036 2008 CP
Author: Russell D. Kane, Monica M. Chauviere, and Keith Chustz
Publication Date: 2008
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A laboratory investigation of corrosion under insulation (CUI) using methods given in ASTM G189 for cyclic temperature, wet/dry conditions. Two long term exposure tests of three material conditions and two insulative materials (mineral wool and calcium silicate insulations).
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