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10022 Corrosion Under Insulation-Testing of Protective Systems at High Temperatures

Picture for 10022 Corrosion Under Insulation-Testing of Protective Systems at High Temperatures
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Product Number: 51300-10022-SG
ISBN: 10022 2010 CP
Author: Kristian Haraldsen
Publication Date: 2010
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Corrosion under insulation (CUI) has been a continuous challenge for on- and off-shore installations, requiring continuous focus on maintenance work. Pilot scale accelerated testing has been performed to study and evaluate the effects of CUI on different coating systems and service conditions. A test loop has been constructed, where 115 mm o.d. pipe spools were combined in a loop which is internally heated using steam. The coated and insulated pipe spools were exposed at controlled internal temperatures and intermittently wetted by fresh seawater. Two test lines with 8 pipe spools have been run in parallel.

Different aspects of CUI, including methods of steel pretreatment, coating application conditions, coating types and insulation design have been studied. Special focus has been on high temperature service conditions and the effect of moist and intermittently wet condition. High temperature coatings have been compared with a traditional coating system and thermally sprayed aluminum coating. The effect of coating application during service with steel temperatures up to 150°C has been studied.

Due to the harsh exposure conditions, both tested coating systems were heavily degraded and a fair comparison of the coating systems is difficult. A positive effect of distance insulation was the most significant result from the test, and both tested coating systems showed markedly improved quality using distance insulation. The different application temperatures showed significant differences, and the results were in general better for the coatings applied at ambient conditions. Only minor differences were observed between the different steel pre-treatment methods.

Key Words: Corrosion, insulation, high temperature, CUI
Corrosion under insulation (CUI) has been a continuous challenge for on- and off-shore installations, requiring continuous focus on maintenance work. Pilot scale accelerated testing has been performed to study and evaluate the effects of CUI on different coating systems and service conditions. A test loop has been constructed, where 115 mm o.d. pipe spools were combined in a loop which is internally heated using steam. The coated and insulated pipe spools were exposed at controlled internal temperatures and intermittently wetted by fresh seawater. Two test lines with 8 pipe spools have been run in parallel.

Different aspects of CUI, including methods of steel pretreatment, coating application conditions, coating types and insulation design have been studied. Special focus has been on high temperature service conditions and the effect of moist and intermittently wet condition. High temperature coatings have been compared with a traditional coating system and thermally sprayed aluminum coating. The effect of coating application during service with steel temperatures up to 150°C has been studied.

Due to the harsh exposure conditions, both tested coating systems were heavily degraded and a fair comparison of the coating systems is difficult. A positive effect of distance insulation was the most significant result from the test, and both tested coating systems showed markedly improved quality using distance insulation. The different application temperatures showed significant differences, and the results were in general better for the coatings applied at ambient conditions. Only minor differences were observed between the different steel pre-treatment methods.

Key Words: Corrosion, insulation, high temperature, CUI
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Corrosion Under Insulation (CUI) in pipingc systems consumes a significant percent of the maintenance budget in the petrochemical industry. Prevention of CUI by the use of (1) thermal spray aluminum, (2) stainless steel pipe, (3) expanded metal cages for personnel protection instead of insulation and (4) aluminum foil wrapping are discussed in terms of long term protection, installed cost and Life cycle cost.
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