3.0 Best Practice - Corrosion Under Insulation

CHT INTEGRATED REFINERY BUSINESS IMPROVEMENT PROGRAM
HPCL Mumbai Corrosion Under Insulation
Copyright of Shell Global Solutions (Malaysia) Sdn Bhd
10/14/2011
CONFIDENTIAL
10/14/2011
FACTORS CONTRIBUTING TO CORROSION UNDER INSULATION

Cladding and insulation condition Insulation type Water source External environment Presence of steam tracing Temperature Coating status, surface preparation, lifetime, coating type Equipment shape: line size, nozzle, attachment
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CLADDING
Role of Cladding and Vapour Barriers: Contain Isolation Material To keep insulation dry. Mechanical Protection
Aluminised steel Aluminium Stainless steel Polyester etc. GRE wrap Tapes
Mastics and sealants are used to close openings.
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DAMAGED CLADDING
Copyright of INSERT COMPANY NAME HERE
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INSULATION MATERIAL
Water leachable salt content. chlorides, sulphate, acidic materials in fire retardants Water retention, permeability, wettability. Insulation foams that react with water to form acids
Rockwool PU Foam
FoamFoam-glass
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MOIST INSULATION MATERIAL
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WATER SOURCES
1. 2. 3.
Condensation External Internal

Damaged steam tracing
Rainfall Steam discharge, Spillage Deluge/sprinkler system, Drift from cooling towers
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WATER SOURCES
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TEMPERATURE
Higher temperature: Increased corrosion rate High salt concentration Reduced life coatings
Lower temperature:
Condensation
Cyclic temperatures, Temperature gradients increase risk for Corrosion Under Insulation.
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TEMPERATURE
Carbon Steel -5 to 60C Moderate 50-120C Severe 120-150C Moderate 150-250C Cold spots >250C No risk
Stainless steel:
Stress Corrosion Cracking <50C 50-120C 120-150C >150C no SCC High Moderate no SCC
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COATING STATUS, TYPE, APPLICATION, AGE

Coating type Primer only Full coat Immersion coat Thermal Al spray

Application
Surface preparation Cold/Hot Maintenance No coating
Coating life varies between 0 and 10 years (approx)

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COATING STATUS
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EQUIPMENT SHAPE: LINE SIZE, NOZZLE, ATTACHMENT

Tees Valves Instruments (Steam) Tracing Equipment Nozzles Stiffeners
Difficult to seal Cold spots (Hot spots) Maintenance e.g. valves Water traps
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EQUIPMENT SHAPE
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CORROSION UNDER INSULATION

Prevention and mitigation of CUI is largely a maintenance issue, whereby the corrosion is prevented in case the insulation and underlying coating is maintained where and when needed. If no maintenance is executed, the coating and insulation will deteriorate and corrosion will start. The actual need for insulation has always to be challenged.
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CUI ASSESSMENT PROGRAMME

Assessment of susceptibility to CUI Detection methods [and reliability] Determination of corrosion severity Criticality Repair procedures
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CUI INSPECTION GUIDELINE

The CUI Inspection Guideline is used during the S-RBI process to determine the Criticality Class, the Confidence Rating and the corresponding Inspection/Maintenance Strategy for Corrosion Under Insulation.
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CUI INSPECTION GUIDELINE
THE CUI INSPECTION GUIDELINE CONSISTS OF TWO STEPS: Step 1: Step 2: A criticality ranking requiring limited input data. A detailed assessment and inspection plan for the high ranking items.
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STEP 1: CUI CRITICALITY RANKING
The Susceptibility to CUI is determined with the dedicated questions in the Criticality Matrix for CUI. This provides a worst case assessment. The Consequence of Failure is copied from the internal corrosion failure. The Criticality Matrix gives the Criticality Ranking for CUI.
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STEP 2: CUI INSPECTION PLAN
1. Determine the Probability based on the cumulative score from the Susceptibility table. 2. Re-address the Criticality based on this Probability rating. 3. Determine the Confidence Rating for CUI using the dedicated Confidence Rating questionnaire. 4. Establish the Inspection/Maintenance Strategy for CUI based on the Criticality and Confidence Rating.
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THE SCHEMATICALLY REPRESENTATION OF THE S-RBI PROCESS FOR CUI.
Susceptibility Susceptibility C C riticality riticality R Rating ating Consequence onsequence C Confidence onfidence C Factor Factor
IS 0 IS1 IS1 IS2 IS2 Inspection Inspection IS3 IS3 Strategies Strategies IS4 IS4 IS5 IS5
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SUSCEPTIBILITY TO CUI FAILURE FOR CS/LOW ALLOY STEEL (1)

DETERMINE THE PROBABILITY SCORE BY ADDING POINTS FROM THE INDIVIDUAL COLUMNS IN THE TABLE (NEXT SLIDES). NOTE: Remember to challenge the requirement for insulation - it may be possible to permanently remove it. For Personal Protection perforated sheeting is preferred.
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CUI PREVENTION
Only insulate where necessary Use screens for personnel protection Use insulating coatings Use waterproof cladding (plastics, laminates) Use immersion coating or TSA Use non-contacting insulation
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Operating Temperature* constantly >175 C or < 5 C 150 - 175C 5 - 50 C or 120 -150 C Initial coating status Full QA paint protection Conventional QA Paint protection; field welds at construction unpainted or unknown Insulation type Expanded Perlite, Foamglass, Closed Cell Foam (right type) Fiberglass, Cal Sil, Asbestos, Regular Perlite, Mineral/Rock Wool Points 0 1
50 - 120 C
* In cyclic service (or temporarily temperature changes), the range of the most critical temperature reached shall be taken.
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Wall Thickness & Surface Features* 7.1 mm Internal corrosion / erosion rate** Negligible Low (or < 0.1 mm/yr) External coil / steam tracing Not present External environment inside building Points 0 1
rarely wetted High Integrity (<10% of the time) Design Medium Integrity Design frequently wetted (~40% of the time) permanently wetted (e.g. cooling tower, dripping water, condensation)
4 7.1 mm or Surface at Location of Penetrations through Insulation 4 or Surface at Location of Reinforcement Rings & Other Water Traps
Medium (or 0.1 - 0.4 mm/yr)
High (or > 0.4 mm/yr)
Low Integrity Design
* The most susceptible area of the equipment determines the rating. **Can be taken from RBI study for internal corrosion.
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SUSCEPTIBILITY TO CUI FAILURE FOR STAINLESS STEEL (1)

DETERMINE THE PROBABILITY SCORE BY ADDING POINTS FROM THE INDIVIDUAL COLUMNS IN THE TABLE (NEXT SLIDES). NOTE: Remember to challenge the requirement for insulation - it may be possible to permanently remove it. For Personal Protection use perforated sheeting.
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SUSCEPTIBILITY TO CUI FAILURE FOR STAINLESS STEEL (2)

Operating Initial Temperature* coating status Constantly >150 C or < 50 C Full QA paint protection Conventional QA paint Protection; field welds at construction
Insulation type
Low chloride insulation material (<10ppm Cl-)
External coil / steam tracing
External environment
Points
Not present
Inside building Rarely wetted (<10% of the time) Permanently wetted (e.g. cooling tower, dripping water, condensation) frequently wetted (~40% of the time)
higher chloride insulation material (10ppm Cl-)
120 - 150 C
High Integrity Design Medium Integrity

Design
50 - 120 C
Unpainted or unknown
Low Integrity Design
* In cyclic service (or temporarily temperature changes), the range of the most critical temperature reached shall be taken.
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CUI RRM CRITICALITY CLASS

PROBABILITY CLASS SUSCEPTIBILITY TO CUI FAILURE
H M L N
TOTAL SCORE > 20 TOTAL SCORE 14 - 20 TOTAL SCORE 7 - 13 TOTAL SCORE 0 - 6
L L N N
MH M
H
MH M
E H
MH M
E E H
MH
L N
CONSEQUENCE CATEGORY
ECONOMICS (USD) HEALTH & SAFETY ENVIRONMENT
NO/SLIGHT MINOR DAMAGELOCAL DAMAGE MAJOR DAMAGE EXT. DAMAGE DAMAGE (<10K) (10-100K) (0.1-1M) (1-10M) ( >10M) NO/SLIGHT INJURY NO/SLIGHT EFFECT NEGLIGIBLE MINOR INJURY MAJOR INJURY SINGLE FATALITY MINOR EFFECT LOW LOCALISED EFFECT MEDIUM MAJOR EFFECT HIGH MULTIPLE FATALITIES MASSIVE EFFECT EXTREME
CONSEQUENCE CLASS
MH = Medium High E = Extreme H = High M = Medium L = Low N = Negligible

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CONFIDENCE RATING FOR CUI

CUI CONFIDENCE QUESTIONS
Cladding and insulation condition Cladding/insulation fully maintained: YES Cladding/insulation normal: Intermediate Cladding/insulation in poor condition: NO Multiple reliable inspections for CUI have been carried out* Frequent inspection and selective delagging, followed by appropriate remedial action: YES Inspection irregular/not to standard: Intermediate No proper inspections: NO Monitoring CUI promoting conditions The presence of ALL possible CUI promoting conditions (see susceptibility categories) has been established and quantified: YES The operating temperature is monitored and constantly in identified range AND the coating condition is known/established: Intermediate The operating temperature is not established AND/OR the coating condition is not known/established: NO
Yes +0.1
Intermediate No 0 -0.1
+0.1
-0.1
+0.1
-0.1
For Confidence Rating add scores; minimum: -0.2, maximum: +0.2 Confidence Rating: -0.2 = very low, - 0.1 = low, 0 = medium, +0.1 = high, +0.2 = very high *In case of new equipment or piping, a 0 (zero) score shall be given for this aspect
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COATING/PAINT PROTECTION CREDIT
Coverage and Quality of Applied Coating/Paint
Years of protection
100% coverage (including field welds); according to the appropriate engineering standards 100% coverage (including field welds); not completely in accordance with the appropriate engineering standards No 100% coverage or unknown; poor or unknown quality
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CUI MONITORING CS/LOW ALLOY STEEL DETERMINING INSPECTION/MAINTENANCE STRATEGIES
CONFIDENCE RATING CRITICALITY VERY LOW LOW MEDIUM HIGH VERY HIGH
EXTREME HIGH MEDIUM HIGH MEDIUM LOW NEGLIGIBLE (review only) STRATEGY STRATEGY 0 0 1
STRATEGY 1
STRATEGY 1 STRATEGY
STRATEGY 2 STRATEGY 3 STRATEGY 2 STRATEGY
2 STRATEGY 3 STRATEGY 3 STRATEGY 3

STRATEGY 4 STRATEGY
4NO INSPECTIONS NO INSPECTIONS NO INSPECTIONS

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CUI INSPECTION/MAINTENANCE STRATEGIES CS/LOW ALLOY STEEL STRATEGY 0

Initial st 1 Following Resul Action* t Furthe r 2nd Following Action* Results
Initial Action*
Reduce Criticality ! Analyse in detail Consider corrective action

Meanwhile follow strategy 1
* Recommended maximum timing; an analysis should be performed to determine if the work should be completed within a shorter time frame.
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Initial Action Initial 1st Following Action Result** Further Results* *
More significant CUI found No more significant CUI found Significant CUI found No significant CUI found 100% delagging within 6 months; repair & paint; repeat Initial Action: every 3 years* Adjust confidence rating with +0.1; repeat Initial Action: within 3 years
2nd Following Action
Equipment shell & nozzles/piping 8": Significan 100% NDE combined with t Delag 100%: 100% delagging of ALL CUI within 6 months possible wet and found susceptible areas: within 1 year* Piping & equipment nozzles 8": 100% delagging: within 1 year* (proceed according to column "Further Results") No significan t CUI found
Repair & paint; repeat Initial Action: every 3 years*
100% delagging of ALL wet and susceptible areas: within 3 years
* 50% of coating/paint protection credit can be applied, Inspection interval starting at the moment the coating/paint protection has ended ** Significant CUI means corrosion damage that requires remedial action.
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Initial Action Initial 1st Following Action Result** Further Results* *
More significant CUI found No more significant CUI found Significant CUI found No significant CUI found 100% delagging within 1 year; repair & paint; repeat Initial Action: every 6 years* Adjust confidence rating with +0.1; repeat Initial Action: within 6 years
Equipment shell & nozzles/piping 8": Significan 100% NDE combined with t Delag 100%: selective delagging of CUI within 1 year possible wet and found susceptible areas: every 6 years* Piping & equipment nozzles 8": 100% delagging of ALL possible wet and susceptible areas : every 6 years* No significan t CUI found
Delag more selective areas: within 1 year
* Inspection interval starting at the moment the coating/paint protection has ended ** Significant CUI means corrosion damage that requires remedial action.
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CUI MONITORING FOR STAINLESS STEEL DETERMINING INSPECTION/MAINTENANCE STRATEGIES
CONFIDENCE RATING CRITICALITY

EXTREME HIGH MEDIUM HIGH MEDIUM LOW NEGLIGIBLE (review only)
NO INSPECTIONS NO INSPECTIONS
VERY LOW
LOW
MEDIUM
HIGH
VERY HIGH
STRATEGY 0 STRATEGY 1 STRATEGY 1 STRATEGY 2 STRATEGY 2
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CUI INSPECTION/MAINTENANCE STRATEGIES STAINLESS STEEL STRATEGY 0

Initial st 1 Following Resul Action* t Furthe r 2nd Following Action* Results
Initial Action*
Reduce Criticality ! Analyse in detail Consider corrective action

Meanwhile follow strategy 1 * Recommended maximum timing; an analysis should be performed to determine if the work should be completed within a shorter time frame.
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CUI INSPECTION/MAINTENANCE STRATEGIES STAINLESS STEEL STRATEGY 1

Initial Action Initial Result 1st Following Action Further Results
More cracking found No more cracking found Cracking found No cracking found
Cracking found 100% delagging of ALL possible wet and susceptible areas; check coating and perform Eddy Current testing: within 3 months*
Delag 100%; check coating and perform DPI: within 3 months
No cracking found
100% delagging of ALL wet and susceptible areas; check coating and perform DPI: within 2 years
100% delagging within 3 months; repair & paint; repeat Initial Action: every 5 years* Adjust confidence rating with +0.1; repeat Initial Action: within 3 years
* 50% of coating/paint protection credit can be applied, Inspection interval starting at the moment the coating/paint protection has ended . CONFIDENTIAL 10/14/2011 Copyright of Shell Global Solutions (Malaysia) Sdn Bhd
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CUI PREVENTION
Only insulate where necessary Use screens for personnel protection Use insulating coatings Use waterproof cladding (plastics, laminates) Use immersion coating or TSA Use non-contacting insulation
CONFIDENTIAL
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10/14/2011
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3.0 Best Practice - Corrosion Under Insulation

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CHT INTEGRATED REFINERY BUSINESS IMPROVEMENT PROGRAM

HPCL Mumbai Corrosion Under Insulation

Copyright of Shell Global Solutions (Malaysia) Sdn Bhd

Copyright of Shell Global Solutions (Malaysia) Sdn Bhd

FACTORS CONTRIBUTING TO CORROSION UNDER INSULATION

Copyright of Shell Global Solutions (Malaysia) Sdn Bhd

Mastics and sealants are used to close openings.

Copyright of Shell Global Solutions (Malaysia) Sdn Bhd

Copyright of INSERT COMPANY NAME HERE

Copyright of Shell Global Solutions (Malaysia) Sdn Bhd

MOIST INSULATION MATERIAL

Copyright of INSERT COMPANY NAME HERE

Condensation External Internal

Copyright of INSERT COMPANY NAME HERE

Copyright of INSERT COMPANY NAME HERE

Copyright of Shell Global Solutions (Malaysia) Sdn Bhd

Copyright of Shell Global Solutions (Malaysia) Sdn Bhd

COATING STATUS, TYPE, APPLICATION, AGE

Surface preparation Cold/Hot Maintenance No coating

Coating life varies between 0 and 10 years (approx)

Copyright of Shell Global Solutions (Malaysia) Sdn Bhd

Copyright of Shell Global Solutions (Malaysia) Sdn Bhd

EQUIPMENT SHAPE: LINE SIZE, NOZZLE, ATTACHMENT

Copyright of Shell Global Solutions (Malaysia) Sdn Bhd

Copyright of Shell Global Solutions (Malaysia) Sdn Bhd

CORROSION UNDER INSULATION

Copyright of Shell Global Solutions (Malaysia) Sdn Bhd

CUI ASSESSMENT PROGRAMME

Copyright of Shell Global Solutions (Malaysia) Sdn Bhd

CUI INSPECTION GUIDELINE

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CUI INSPECTION GUIDELINE

Copyright of INSERT COMPANY NAME HERE

STEP 1: CUI CRITICALITY RANKING

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STEP 2: CUI INSPECTION PLAN

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THE SCHEMATICALLY REPRESENTATION OF THE S-RBI PROCESS FOR CUI.

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SUSCEPTIBILITY TO CUI FAILURE FOR CS/LOW ALLOY STEEL (1)

Copyright of Shell Global Solutions (Malaysia) Sdn Bhd

Copyright of Shell Global Solutions (Malaysia) Sdn Bhd

SUSCEPTIBILITY TO CUI FAILURE FOR CS/LOW ALLOY STEEL (2)

SUSCEPTIBILITY TO CUI FAILURE FOR CS/LOW ALLOY STEEL (3)

Medium (or 0.1 - 0.4 mm/yr)

High (or > 0.4 mm/yr)

Low Integrity Design

SUSCEPTIBILITY TO CUI FAILURE FOR STAINLESS STEEL (1)

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SUSCEPTIBILITY TO CUI FAILURE FOR STAINLESS STEEL (2)

External coil / steam tracing

higher chloride insulation material (10ppm Cl-)

High Integrity Design Medium Integrity

Low Integrity Design

Copyright of Shell Global Solutions (Malaysia) Sdn Bhd

CUI RRM CRITICALITY CLASS

TOTAL SCORE > 20 TOTAL SCORE 14 - 20 TOTAL SCORE 7 - 13 TOTAL SCORE 0 - 6

ECONOMICS (USD) HEALTH & SAFETY ENVIRONMENT

MH = Medium High E = Extreme H = High M = Medium L = Low N = Negligible

CONFIDENCE RATING FOR CUI

COATING/PAINT PROTECTION CREDIT

Coverage and Quality of Applied Coating/Paint

Copyright of Shell Global Solutions (Malaysia) Sdn Bhd