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How to Manage Corrosion Under Insulation (CUI) Problem?
APCCC18November 7, 2018Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.
What is CUI?
Its Effects
Shared Practice:
CUI Inspection Methodology
Quick Win for CUI
Topics
2Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.
What is CUI?
3Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.
Insulated Piping
API 570, Piping Inspection Code, Third Edition.Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary. 4
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.
Insulated Equipment
5
Insulation System
Goh Gim Choon, Materials & Corrosion Overview, Shell Global Solutions. 6
Corrosion Under Insulation (CUI)
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary. 7
CUI Corrosion Rates
NACE Standard RP0198, The Control of Corrosion Under Thermal Insulation and Fireproofing – A Systems Approach, NACE International.
CUI corrosion rates are higher than expected.
8
API RP 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry, Second Edition.
External Chloride Stress Corrosion Cracking (ECSCC)
9
API TR 938-C, Use of Duplex Stainless Steels in the Oil Refining Industry.
SCC Tendency of Austenitic & Duplex SS
10
Its Effects
11Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.
Effects of CUI/CUF
https://www.eddyfi.com.API RP 583, Corrosion Under Insulation and Fireproofing, Second Edition. 12
B.J.Fitzgerald et al., CUI Conference in London, 14-1-2004.
CUI of Piping
13
K. Yamamoto, Safety & Reliability of Aged Plants in Chemical Process Industries, Japan, 2017.
A Story of Piping CUI in Japan
14
A Story of Piping CUI in Map Ta Phut
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.
68% is CUI32% is ECSCC
15
A Story of Piping CUI in Map Ta Phut
73% is CUI27% is ECSCC
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary. 16
A Story of Piping CUI in Map Ta Phut
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.
73% is CUI27% is ECSCC
17
18
Shared Practice:CUI Inspection Methodology
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.
Purpose:
1. Effectively identify where to damage as a result of CUI.2. Recommend the optimum inspection and/or monitoring methods.
Simplified Methodology Flowchart
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary. 19
Designed Check Sheet (Carbon & Low Alloy Steels)
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary. 20
PARAMETER 0 1 3 5
Operating
Temperature
<-4 °C
or
>177 °C
-4 to 38 °C
or
133 to 177 °C
39 to 77 °C
or
111 to 132 °C
78 to 110 °C
or Cycling Service from
>177 °C to <110 °C
Coating/Age
Quality coating
within 8 years
or system age
<15 years
Quality coating
within 15 years,
or system age
<30 years
General coating
8-15 years
General coating age >15
years,
system age >30 years, or
unknown
Jacketing/
Insulation Condition
System age
<5 years without
deficiencies
Average condition with good
maintenance (such as
sealed, no gaps, CML ports
with plugs)
Average condition with
some deficiencies
Damaged condition
with several deficiencies
Heat Tracing None
High integrity steam system
or
electric tracing
Steam system with medium
integrity
Steam system with visible
leaks
External
EnvironmentNo sweating Arid and inland All other locations
Coastal/marine, cooling
tower overspray, or local
external water source
exposure (deluge system,
dripping steam condensate)
Insulation
TypeInsulating coating
Expanded perlite, foam
glass,
closed cell foam
Fiberglass, perlite, mineral
fiber
(Insulation has <10 ppm Cl)
Calcium silicate, mineral
fiber with >10 ppm Cl, or
unknown
Line Size or
Nozzle SizeEquipment >6 in. >2 in. to 6 in. ≤2 in.
CUI Assessment (Carbon & Low Alloy Steels)
PARAMETER
RATING TOTAL<7 7 to <14 14 to 20 >20 to 27 >27
LIKELIHOOD
RATINGNegligible Low Medium High Extreme
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.API RP 583, Corrosion Under Insulation and Fireproofing, Second Edition. 21
Designed Check Sheet (Austenitic and Duplex SS)
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary. 22
CUI Assessment (Austenitic and Duplex SS)
PARAMETER
RATING TOTAL<7 7 to <14 14 to 20 >20 to 27 >27
LIKELIHOOD
RATINGNegligible Low Medium High Extreme
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.API RP 583, Corrosion Under Insulation and Fireproofing, Second Edition.
PARAMETER 0 1 3 5
Operating
Temperature
<47 °C
or
>204 °C
47 to 60 °C 122 to 204 °C 61 to 121 °C
Coating/Age
Quality
coating
within 8 years
Quality coating
within 15 years
General coating
8-15 years
General coating >15 years,
or unknown
Jacketing/
Insulation ConditionNo deficiencies
Average condition with good
maintenance (such as
sealed, no gaps, CML ports
with plugs)
Average condition with
some deficiencies
Damaged condition
with several deficiencies
Heat Tracing None
High integrity steam system
or electric tracing (Cl free
covering)
Steam system with medium
integrity
Steam system with visible
leaks, or electrical with PVC
covering
External
EnvironmentNo sweating Arid and inland All other locations
Coastal/marine, cooling
tower overspray, or external
water source exposure
(deluge system, dripping
steam condensate)
Insulation
TypeInsulating coating
Expanded perlite, foam
glass,
closed cell foam
Fiberglass, perlite, mineral
fiber
(Insulation has <10 ppm Cl)
Calcium silicate, mineral
fiber with >10 ppm Cl, or
unknown
Line Size or
Nozzle SizeEquipment >6 in. >2 in. to 6 in. ≤2 in.
23
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.
Data Collection
24
Prelim Summary
Damage Mechanism Likely Location SusceptibilityP&IDPage
Corrosion Under Insulation (CUI) 4” PG 101. 01 D24 4C Negligible 1
Corrosion Under Insulation (CUI) 3” BF 102. 05 D24 4A Low 2
Corrosion Under Insulation (CUI) 3”-HG23129-A071H Medium 3
Corrosion Under Insulation (CUI) 2”-MD25020-S2A02 High 4
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary. 25
Site Survey
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.API RP 583, Corrosion Under Insulation and Fireproofing, Second Edition.API RP 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry, Second Edition.
Pipe Shoe Small Branch Connection (Tee)
Damaged Jacketing Termination of Insulation on Vertical Pipe
26
Summary
Damage Mechanism Likely Location SusceptibilityP&IDPage
RepresentativeLocation
Inspection and Monitoring Methods
VT
(V
isu
al
Insp
ecti
on
)
PE
C (
Pu
lse
d E
dd
y C
urr
en
t)
UT
M (
Ult
raso
nic
Th
ick
ne
ss M
ea
su
rem
en
t)
LR
UT
(Lo
ng
Ra
ng
e U
ltra
so
nic
Te
sti
ng
)
RT
(R
ad
iog
rap
hic
Te
sti
ng
)
EC
(E
dd
y C
urr
en
t)
PT
(Liq
uid
Pe
ne
tra
nt
Te
sti
ng
)
IR (
Infr
are
d T
he
rmo
gra
ph
y)
Ne
utr
on
Ba
ck
sca
tte
r
On
-lin
e M
on
ito
rin
g(e
.g.,
Wir
ele
ss U
T S
en
so
r, A
E S
en
so
r)
Pro
ce
ss M
on
ito
rin
g
OSI (Onstream Inspection)
Corrosion Under Insulation (CUI)
4” PG 101. 01 D24 4C Negligible 1 Pipe Shoe OSI OSI OSI OSI
Corrosion Under Insulation (CUI)
3” BF 102. 05 D24 4A Low 2Small Branch Connection
(Tee)OSI OSI OSI
Corrosion Under Insulation (CUI)
3”-HG23129-A071H Medium 3 Damaged Jacketing OSI OSI OSI OSI
Corrosion Under Insulation (CUI)
2”-MD25020-S2A02 High 4Termination of Insulation
on Vertical PipeOSI OSI OSI OSI OSI
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary. 27
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.
Example (1.25Cr-0.5Mo Steel (T >177°C))
28
PARAMETER 0 1 3 5
Operating
Temperature
<-4 °C
or
>177 °C
-4 to 38 °C
or
133 to 177 °C
39 to 77 °C
or
111 to 132 °C
78 to 110 °C
or Cycling Service from
>177 °C to <110 °C
Coating/Age
Quality coating
within 8 years
or system age
<15 years
Quality coating
within 15 years,
or system age
<30 years
General coating
8-15 years
General coating age >15
years,
system age >30 years, or
unknown
Jacketing/
Insulation Condition
System age
<5 years without
deficiencies
Average condition with good
maintenance (such as
sealed, no gaps, CML ports
with plugs)
Average condition with
some deficiencies
Damaged condition
with several deficiencies
Heat Tracing None
High integrity steam system
or
electric tracing
Steam system with medium
integrity
Steam system with visible
leaks
External
EnvironmentNo sweating Arid and inland All other locations
Coastal/marine, cooling
tower overspray, or local
external water source
exposure (deluge system,
dripping steam condensate)
Insulation
TypeInsulating coating
Expanded perlite, foam
glass,
closed cell foam
Fiberglass, perlite, mineral
fiber
(Insulation has <10 ppm Cl)
Calcium silicate, mineral
fiber with >10 ppm Cl, or
unknown
Line Size or
Nozzle SizeEquipment >6 in. >2 in. to 6 in. ≤2 in.
PARAMETER
RATING TOTAL<7 7 to <14 14 to 20 >20 to 27 >27
LIKELIHOOD
RATINGNegligible Low Medium High Extreme
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.API RP 583, Corrosion Under Insulation and Fireproofing, Second Edition.
19
CUI Assessment
29
Summary
Damage Mechanism Likely Location SusceptibilityP&IDPage
RepresentativeLocation
Inspection and Monitoring Methods
VT
(V
isu
al
Insp
ecti
on
)
PE
C (
Pu
lse
d E
dd
y C
urr
en
t)
UT
M (
Ult
raso
nic
Th
ick
ne
ss M
ea
su
rem
en
t)
LR
UT
(Lo
ng
Ra
ng
e U
ltra
so
nic
Te
sti
ng
)
RT
(R
ad
iog
rap
hic
Te
sti
ng
)
EC
(E
dd
y C
urr
en
t)
PT
(Liq
uid
Pe
ne
tra
nt
Te
sti
ng
)
IR (
Infr
are
d T
he
rmo
gra
ph
y)
Ne
utr
on
Ba
ck
sca
tte
r
On
-lin
e M
on
ito
rin
g(e
.g.,
Wir
ele
ss U
T S
en
so
r, A
E S
en
so
r)
Pro
ce
ss M
on
ito
rin
g
OSI (Onstream Inspection)
Corrosion Under Insulation (CUI)
4” PG 105. 01 D34 4C Medium 5 Pipe Supports OSI OSI OSI
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary. 30
Result
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary. 31
Quick Win for CUI
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary. 32
PARAMETER 0 1 3 5
Operating
Temperature
<-4 °C
or
>177 °C
-4 to 38 °C
or
133 to 177 °C
39 to 77 °C
or
111 to 132 °C
78 to 110 °C
or Cycling Service from
>177 °C to <110 °C
Coating/Age
Quality coating
within 8 years
or system age
<15 years
Quality coating
within 15 years,
or system age
<30 years
General coating
8-15 years
General coating age >15
years,
system age >30 years, or
unknown
Jacketing/
Insulation Condition
System age
<5 years without
deficiencies
Average condition with good
maintenance (such as
sealed, no gaps, CML ports
with plugs)
Average condition with
some deficiencies
Damaged condition
with several deficiencies
Heat Tracing None
High integrity steam system
or
electric tracing
Steam system with medium
integrity
Steam system with visible
leaks
External
EnvironmentNo sweating Arid and inland All other locations
Coastal/marine, cooling
tower overspray, or local
external water source
exposure (deluge system,
dripping steam condensate)
Insulation
TypeInsulating coating
Expanded perlite, foam
glass,
closed cell foam
Fiberglass, perlite, mineral
fiber
(Insulation has <10 ppm Cl)
Calcium silicate, mineral
fiber with >10 ppm Cl, or
unknown
Line Size or
Nozzle SizeEquipment >6 in. >2 in. to 6 in. ≤2 in.
PARAMETER
RATING TOTAL<7 7 to <14 14 to 20 >20 to 27 >27
LIKELIHOOD
RATINGNegligible Low Medium High Extreme
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.API RP 583, Corrosion Under Insulation and Fireproofing, Second Edition.
Quick Win for Piping
33
Equipment Type Potential Locations Photos
Piping
(≤2 in.)
Deadlegs (Vents and Drains)
Instrument Connections
Vibrating Piping Systems
Examples of Susceptible Areas (Piping)
34
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.API RP 583, Corrosion Under Insulation and Fireproofing, Second Edition.
PARAMETER 0 1 3 5
Operating
Temperature
<-4 °C
or
>177 °C
-4 to 38 °C
or
133 to 177 °C
39 to 77 °C
or
111 to 132 °C
78 to 110 °C
or Cycling Service from
>177 °C to <110 °C
Coating/Age
Quality coating
within 8 years
or system age
<15 years
Quality coating
within 15 years,
or system age
<30 years
General coating
8-15 years
General coating age >15
years,
system age >30 years, or
unknown
Jacketing/
Insulation Condition
System age
<5 years without
deficiencies
Average condition with good
maintenance (such as
sealed, no gaps, CML ports
with plugs)
Average condition with
some deficiencies
Damaged condition
with several deficiencies
Heat Tracing None
High integrity steam system
or
electric tracing
Steam system with medium
integrity
Steam system with visible
leaks
External
EnvironmentNo sweating Arid and inland All other locations
Coastal/marine, cooling
tower overspray, or local
external water source
exposure (deluge system,
dripping steam condensate)
Insulation
TypeInsulating coating
Expanded perlite, foam
glass,
closed cell foam
Fiberglass, perlite, mineral
fiber
(Insulation has <10 ppm Cl)
Calcium silicate, mineral
fiber with >10 ppm Cl, or
unknown
Line Size or
Nozzle SizeEquipment >6 in. >2 in. to 6 in. ≤2 in.
PARAMETER
RATING TOTAL<7 7 to <14 14 to 20 >20 to 27 >27
LIKELIHOOD
RATINGNegligible Low Medium High Extreme
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.API RP 583, Corrosion Under Insulation and Fireproofing, Second Edition.
Quick Win for Pressure Vessels
35
Equipment Type Potential Locations Photos
Pressure Vessels
(Water Collection Points)
Bottom of Horizontal Vessels
Termination of Insulation at
Saddles
Insulation Support Rings
Examples of Susceptible Areas (Pressure Vessels)
36
Copyright PTT Maintenance and Engineering Company Limited, All Rights Reserved – Proprietary.API RP 583, Corrosion Under Insulation and Fireproofing, Second Edition.