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DEVELOPMENTS IN HEAT ACTIVATED PROTECTIVE

COATINGS AND REPAIR COMPOSITES TO ADDRESS CORROSION UNDER

INSULATION ISSUES IN THE HYDROCARBON INDUSTRY

Presentation

Presenter

Mr Ron Campbell

Senior Vice President

Belzona Asia Pacific

Corrosion Under Insulation – Root Causes and Effects

Water Ingress

Trapped during construction

Leakage of weather-proofing

Sprinkler Systems

Exacerbating Factors

Chemicals

Contaminants in the insulation material ( Chlorides)

Atmospheric pollutants ( Acid Rain )

Decomposition of organic materials ( Bird Droppings )

Spillage ( Production Chemicals and Cleaners )

Temperature

Equipment operating at 5 – 200 C

Cyclic wetting/drying (concentration mechanism)


Carbon steels

Accelerated corrosion/pitting

SCC (low risk: hot nitrate)

Stainless steels

Crevice/pitting corrosion

SCC (high risk: chloride + T>60 C)

Other Metallic substrates

Comparatively little experience


Vertical risers act

As watersheds

Joints in saddles

Lobster backs

Low elevation

Saddles trap water

Heat sink attracts vapour

Mid joints

Water penetration into Insulation is the primary cause of CUI – if the water

can be prevented from entering the Insulation – CUI can be negated.

Corrosion Under Insulation – Root Causes

Type Water Extract Chloride

Calcium silicate alkaline (pH 7-10) possibly high

Fibre glass

Cellular glass

Ceramic fibre

Mineral wool neutral (pH 6-7) low (~2 mg/l)

Organic foams acid (pH 2-3) possibly high

Corrosion Implications of Insulation Types

Chemical extraction from Insulation can accelerate CUI

Corrosion Under Insulation – Results

CUI exists in every Hydrocarbon Processing Plant Worldwide

How can CUI problems be Repaired and then Negated – On Line ?

Corrosion Under Insulation – Product Solutions

Non-Compliant Repair and Protection

Where there is no internationally recognized

standard required for the application

but they are effective and have been and are

currently in use within industries worldwide

and are widely accepted based on historical

performance.

Compliant Repairs

Where there is a accepted International

Standard for the use of composite materials

for repair of pipe - work and tanks and

where the client requires certification:

- ASME PCC-2-2008

- ISO / TS 24817


“ Non – Compliant Solutions “

Non – Compliant Solution – Build a New One !


Can Be applied to Hot Surfaces

Surface Temperatures of 30C – 180C

Minimal Surface Preparation

High Adhesion

Resist Insulation Saturation / Immersion

Simple to Use

Long Service Period

Product Development Parameters

Product Profiles

Single Component Heat Activated Repair Material ( 70 – 180 C )

Single Component Heat Activated Coating Material ( 70 – 180 C )

Two Component Heat Activated Coating Material ( 30 – 80 C )

Adhesion on cold surfaces is best achieved through

mechanical locking ( Surface Roughening / Blasting )

Coating

Substrate

Corrosion Under Insulation – Product Profile

Adhesion on hot surfaces achieved by

penetration of pores in metal which increase in

size on heating


Contaminated Porous Metal Substrate

Adhesion on contaminated hot metal surfaces

Achieved by displacement of moisture …

… Absorption of contaminant oil …

… And penetration of pores before cure in

place which provides a mechanical lock

Heat Activated Coating


Corrosion Under Insulation – Simulated Testing

Custom Built CUI test Rig

Disposable steel sleeve fitted over a

cylindrical oil-filled heater Sleeve is

manually prepared and then coated

in-situ with test coating Coated pipe

then surrounded with a cylinder of

insulation material (glass fibre)

and a cylinder of metal cladding

Water (or salt water) is then introduced

into the rig via a hole in the cladding

Test temperature (and coating temperature) can be selected

Rig dismantled and coating examined for attack periodically

Accurately replicates CUI environment, but more aggressive due to frequency

and amount of water added



Corrosion Under Insulation – Performance Testing

Partially rusty test sleeve manually abraded using P36 abrasive paper is placed over heater

Test coating is applied onto the hot sleeve

End flange is bolted on and sealed

Mineral fiber insulation taped into place

Outer cladding/water funnel attached/sealed


Two litres of water added each week

1 litre of water and 1 litre of 5% salt water solution

Results ( Heat Activated Coating System )

No attack or corrosion at 70ºC to 90ºC

Negligible attack/corrosion at 100ºC to 150oC

Very slight surface erosion in full immersion area


Steel test panels prepared by abrading manually (no profile)HA Coating applied onto hot panels and oven cured Panels exposed for 1000 hours at 35ºC (95ºF) in saturated salt fog atmosphere

ResultsNo field blistering or corrosionMinimal corrosion creep under the

scribe mark

Substrates:

Unprepared, uncorroded steel direct from the manufacturersSurface covered in firmly attached millscale

Unprepared steel ground using belt sander (with P36 abrasive)Clean metal surface exposed, but negligible profile

Wire-Brushed Rusty Steel

Started with rusty steel panel (ISO 8501-1 grade C)TSteel weathered externally for 3 monthsRusted to ISO 8501-1 grade C, i.e. significant rusting with some pitting

Loose surface rust brushed away, but no other preparation

horoughly abraded with wire brush to ISO 8501-1 St 2Pitted surface covered in firmly attached rust

Abraded Rusty Steel

Started with rusty steel panel (ISO 8501-1 grade C)Initially abraded with wire brush, then further abraded by hand with P36 abrasive paper to ISO 8501-1 St 3Surface a combination of firmly attached rust with some clean steel showing through

Unprepared Steel

Ground Steel

Rusty Steel


Adhesion

3200 psi

2280 psi

2320 psi

830 psi

1240 psi

2410 psi

2800 psi

2940 psi

3490 psi

1380 psi

1720 psi

2600 psi

Blasted SA2.5

Unprepared

Ground

Rusty

Wire Brushed

Manually Abraded

Two Pack HA / Single Pack HA


Corrosion Under Insulation – Application Histories

Equipment :

Process pipe work handling waste

gas at a temperature of 130C

Problem :

Loss of wall thickness and

unable to shut down the process

Client : Shell UK

Date : Year 2000

Solution:

Manual preparation followed by repair and

protective coating with single component

heat activated system


Equipment :

Process vessel in refinery operating

at 90 – 120C

Problem :

Corrosion and loss of wall thickness

Client : Total Fina Elf , UK

Date : Year 2004

Solution:

Manual preparation followed




Equipment :

Fractionator Tower T102 operating

at 120C

Problem :



Client : Exxon , Singapore

Date : Year 2001

Solution:





Equipment :

De-asphalting Column operating at

120 C

Problem :

Severe corrosion and


Client : Shell , New Zealand

Date : Year 2003

Solution:

Water Jetting preparation followed by




Equipment :

Steam Extraction pipe from

Geothermal well operating at 165C

Problem :



Client : Chevron Power , Philippines

Date : Year 2002

Solution:

Manual preparation followed by repair

by sleeve bonding and protective

coating with single component



Equipment :

Process line on FPSO operating

at 95C

Problem :

Pitting Corrosion and


Client : Kerr McGee , China

Date : Year 2007

Solution:





Equipment :

Distillation Columns operating at

100 - 135 C

Problem :

Pitting corrosion and


Client : ConocoPhillips , UK

Date : Year 2008

Solution:





Equipment :

Gas Process pipe work operating at

90 – 115C

Problem :

Pitting corrosion and


Client : Offshore Gas Company , UK

Date : Year 2005

Solution:


repairs to pitting and protective

coating with and single component


Corrosion Under Insulation – Client Testimonials

Emlyn Roberts

Works Engineer

Total Refinery , UK

Bertrand Van Der Hayden

Fixed Equipment Reliability

Inspector

Caltex South Africa

The absorber column at the Vector Kapuni Gas Treatment Plant in Taranaki required

painting. It was not possible to take the column out of service long enough to complete

the painting programme using normal painting specs. The column runs at approximately

100 degree C so the search began for a product that could be applied at this

temperature while the plant remained online. Belzona 5851 was the pick of the products

as it had already proven itself at Marsden Point. Belzona 5851 has now been in service

for about 2 ½ years and as the pictures show remains in good condition. We have since

applied the same product to our Regeneration tower which also runs at similar

temperature with no problems encountered.

Bob van den Beuken

Maintenance Team Leader

Mechanical

Vector Kapuni , New Zealand

- CUI Systems proven in Service over a period of 10 years -

TOTAL 5851.doc

Up to 35°C Two Pack Epoxy System

30°C - 80°C Two Pack Heat Activated System

70°C - 150°C Single Pack Heat Activated System

Up to 35°C

30 to 80°C

70 to 180°C

“Effective On-Line Solutions”

Surface application temperatures

Corrosion Under Insulation – Complete Protection


“ Compliant Solutions “


ASME PCC-2-2008

ISO / TS 24817

ASME and ISO Standards

• Ensures that composite repairs are no longer an art but is now a

science

• Allow repairs to be designed for individual situations using tested

calculations

• Ensures a quality product and service via Manufacturers auditing

and Application Validation.


ASME PCC-2 and ISO/TS 24817 allow for the repair of the

following: -

• Thinned wall defects

• Through wall defects

• Straight Pipe

• Complex Geometries, inc. bends, tees, reducers etc.

• Tanks and Vessels


• ASME PCC-2 only allows for the repair of

tanks and vessels through the application

of a full circumferential repair

• ISO 24817 allows for the same tank or

vessel to be repaired by a patch repair

• Further developments to ASME PCC-2 will

include specific sections dealing with tanks,

vessels and patch repair


Repairs are design to

design lives of up to 20

years using standard

safety factors


Repair Life

Following the initial compliance testing further

development and improvements of the Composite

System are on-going :

• Specifically designed resin systems

• Specially treated high density glass reinforcement and

Carbon Fibre Alternatives

• Liquid reinforcement conditioner



Composite Repairs are Classified within the Standard

Repairs can only be carried out by Manufacturers Trained and

Validated Personnel :

Class 1 : Manufacturers Trained Validated Applicator

Class 2 : Manufacturers Trained Validated Applicator and Supervisor

Class 3 : Manufacturers Trained Validated Supervisor

Application Requirements

Installers and Supervisors

Trained by repair system manufacturer

Hold points observed

Work procedure carried out as required

by repair system manufacturer and

documented as required by the standard

Repair completed as per design



Types of Defects

The standards detail the types of

repairs that can be carried out

using compliant composite

systems

• Each Composite Repair is designed to fit the

requirements of the situation

• By validated authorised Composite Repair Designers

• Designers must complete the Manufacturers Design

Course


Design Requirements

Visual Inspection and external measurement

or through repair inspection using x-ray

or gamma ray to identify :

Leaking

Degradation

Defect s and defect sizes


Inspection


Equipment :

Storage Tank

Problem :

Hole in Tank wall due to corrosion

pitting

Client : Power Company , USA

Date : Year 2009

Solution:

Preparation by grit blasting followed

by compliant composite repair


Equipment :

Process line in refinery

Problem :

Pitting Corrosion and

Wall thinning

Client : Esso , UK

Date : Year 2008

Solution:

Grit blast preparation followed

by installation of compliant repair


Equipment :

Demineralised Water Lines

In water treatment plant

Problem :

Weld deterioration on stainless steel

pipe weld areas

Client : EGAT , Thailand

Date : Year 2007

Solution:

Preparation by Grit Blasting and compliant

Composite repair installed.


Equipment :

Production pipe work on Offshore

Platform

Problem :

Corrosion Under Insulation

Pitting and loss of wall thickness

Client : Statoil , Norway

Date : Year 2009

Solution:




Equipment :

Produced water process piping

Problem :

CUI resulting in perforations of

piping system

Client : Exxon , Norway

Date : Year 2009

Solution:



Corrosion Under Insulation – Summary

Corrosion Under Insulation is a Common

Problem in the Hydrocarbon Processing

Industry

Due to limited shutdown opportunities

more on-line maintenance is required

Solutions that involve no or limited Hot-Work

are available are now available

Engineering authorities now accept

composite repair technology

Applications must be controlled through

training and validation to ensure success

and compliance with International Standards

Thank you for your Attention

QUESTIONS ?

Mr Ron Campbell

Senior Vice President

Belzona Asia Pacific