Appendix 1

Welcome and introduction

Knovel Corrosion Content Strategy and

DECHEMA Corrosion Handbook
S. Gurke

Minutes of EFC WP15 Corrosion in the Refinery Industry 13 April 2017

 Appendix 2

List of participants

NAME SURNAME COMPANY COUNTRY

Baak Michael Borealis Polyolefine GmbH AUSTRIA
Bour Beucler Valerie Nalco Champion FRANCE
Brandl Ramona OMV GERMANY
Ciccomascolo Francesco Böhler Welding Holding GmbH GERMANY
Claesen Chris J Nalco Champion BELGIUM
De Landtsheer Gino Borealis BELGIUM
Dubois Francois AXENS - IFP Technology Group FRANCE
Escorza Erick Tenaris Dalmine ITALY
Fullin Luna Tenaris Dalmine ITALY
Gabetta Giovanna Eni ITALY
Gierlinger Matthias Borealis Polyolefine GmbH AUSTRIA
Hofmeister Martin Bayernoil Raffineriegesellschaft mbH GERMANY
Holmes Tracey Special Metals UK
Kuhn Michael PPG UK
Mannucci Michele Termisol Termica S.r.l. ITALY
Marcolin Giacomo Tenaris Dalmine ITALY
Poldi Matteo Eni ITALY
Preuss Karsten Shell Deutschland Oil GmbH GERMANY
Rehberg Thomas KAEFER Isoliertechnik GmbH & Co. KG GERMANY
Renaud Lionel Total raffinage Chimie FRANCE
Ropital François IFP Energies nouvelles FRANCE
Schempp Philipp Shell Deutschland Oil GmbH GERMANY
UNITED ARAB
Suleiman Mabruk Takreer EMIRATES
van Roij Johan Shell Global Solutions International B.V. NETHERLANDS

Minutes of EFC WP15 Corrosion in the Refinery Industry 13 April 2017

 Appendix 3

EFC WP15 Activities

(F. Ropital)

Minutes of EFC WP15 Corrosion in the Refinery Industry 13 April 2017

 Presentation of the activities of WP15

European Federation of Corrosion (EFC)

• Federation of 29 National Associations

• 21 Working Parties (WP) and 1 Task Force

• Annual Corrosion congress « Eurocorr »

• Thematic workshops and symposiums

• Working Party meetings (for WP15 twice a year)

• Publications

for more information http://www.efcweb.org

EFC WP15 Spring meeting 13 April 2017 Frankfurt - Germany

1

EFC Working Parties

http://www.efcweb.org
• WP 1: Corrosion Inhibition
• WP 3: High Temperature
• WP 4: Nuclear Corrosion
• WP 5: Environmental Sensitive Fracture
• WP 6: Surface Science and Mechanisms of corrosion and protection
• WP 7: Education
• WP 8: Testing
• WP 9: Marine Corrosion
• WP 10: Microbial Corrosion
• WP 11: Corrosion of reinforcement in concrete
• WP 12: Computer based information systems
• WP 13: Corrosion in oil and gas production
• WP 14: Coatings
• WP 15: Corrosion in the refinery industry
(created in sept. 96 with John Harston as first chairman)
• WP 16: Cathodic protection
• WP 17: Automotive
• WP 18: Tribocorrosion
• WP 19: Corrosion of polymer materials
• WP 20: Corrosion by drinking waters
• WP 21: Corrosion of archaeological and historical artefacts
• WP 22: Corrosion control in aerospace
• Task Force on Corrosion in CO2 Capture Storage (CCS) applications
• Task Force on Corrosion reliability of Electronics
EFC WP15 Spring meeting 13 April 2017 Frankfurt - Germany
2

1
 EFC Working Party 15 « Corrosion in Refinery » Activities
http://www.efcweb.org/Working+Parties-p-104085/WP%2B15-p-104111.html

Chairman: Francois Ropital Deputy Chairman: Johan Van Roij

Information Exchange – Forum for Technology

Sharing of refinery materials /corrosion experiences by operating company
representatives (ie corrosion atlas).
Sharing materials/ corrosion/ protection/ monitoring information by providers

Eurocorr Conferences : organization of refinery session and joint session with

other WPs (2018 Krakow-Poland, 2019 Seville-Spain)

WP Meetings
One WP 15 working party meeting in Spring,
One meeting at Eurocorr in September in conjunction with the conference,

Publications - Guidelines

Education – qualification – certification

List of "corrosion refinery" related courses on EFC website ?
Proposal of courses within Eurocorr ?
EFC WP15 Spring meeting 13 April 2017 Frankfurt - Germany
3

EFC Working Party 15 « Corrosion in Refinery »

List of the WP15 spring meetings :

10 April 2003 Pernis - NL (Shell)

8-9 March 2004 Milan -Italy (ENI)
17-18 March 2005 Trondheim- Norway (Statoil)
31 March 2006 Porto Maghera - Italy (ENI)
26 April 2007 Paris - France (Total)
15 April 2008 Leiden -NL (Nalco)
23 April 2009 Vienna - Austria (Borealis)
22 June 2010 Budapest - Hungary (MOL)
14 April 2011 Paris - France (EFC Head offices)
26 April 2012 Amsterdam - NL (Shell)
9 April 2013 Paris - France (Total)
8 April 2014 Mechelen - Belgium (Borealis)
14 April 2015 Leiden -NL (Nalco)
26 April 2016 Paris - France (Total)
13 April 2017 Frankfurt - Germany (EFC Head offices)

EFC WP15 Spring meeting 13 April 2017 Frankfurt - Germany

4

2
 Publications from WP15
• EFC Guideline n°40 « Prevention of corrosion by cooling waters » available from
http://www.oxbowbooks.com/oxbow/working-party-report-on-control-of-corrosion-
in-cooling-waters.html

•EFC Guideline n° 55 Corrosion Under Insulation New edition nov. 2015

http://store.elsevier.com/product.jsp?isbn=9780081007143&pagename=search

•EFC Guideline n° 46 on corrosion in amine units A revision is in progress by a task

force

•Future publications – task forces : suggestions ?

• best practice guideline to avoid and characterize stress relaxation cracking ?
• impact of upstream inhibitors in refinery corrosion ?
• other suggestions ?

EFC WP15 Spring meeting 13 April 2017 Frankfurt - Germany

5

WP15 Corrosion Atlas Web page

http://www.efcweb.org/Working+Parties/WP+Corrosion+in+the+Refinery+Industry/WP+15+Refinery+Corrosion+Atlas.html

EFC WP15 Spring meeting 13 April 2017 Frankfurt - Germany

6

3
 Eurocorr 2017 & 20th ICC Congress
Prague Czech Republic 3-7 September 2017

Eurocorr 2017 (3-7 September) will be coupled with the 20th

International Corrosion Council (ICC) congress (that takes place every 3
years in different parts of the world

Authors will be informed by the end of April

Refinery corrosion session on Tuesday 5th September afternoon and

Wednesday 6th morning

Annual WP15 working party meeting during Eurocorr on Wednesday 6th

September – to be confirmed -

http://eurocorr.org/EUROCORR+2017_+20th+ICC+_amp_+Process+
EFC WP15 Spring meeting 13Safety+Congress+2017-p-71180.html
April 2017 Frankfurt - Germany
7

Information :
Future conferences related to refinery corrosion

•3-7 September 2017

EUROCORR 2017 Prague Czech Republic

•28-30 November 2017

Stainless Steel World Conf 2017 Maastricht NL

•15-19 April 2018

CORROSION 2018 NACE Conf Phoenix AZ

9-13 September 2018

EUROCORR 2018 Krakow Poland

8-13 September 2019

EUROCORR 2019 Seville Spain

Look at the Website: www.efcweb.org/Events

EFC WP15 Spring meeting 13 April 2017 Frankfurt - Germany
8

4
 Appendix 4

Austenitic stainless steel bismuth-free flux-

cored wires for high-temperature applications

(F. Ciccomascolo)

Minutes of EFC WP15 Corrosion in the Refinery Industry 13 April 2017

Stainless Steel Bismuth Free Flux-cored Wires
for High Temperature Applications
Elin M. Westin
Ronald Schnitzer
Francesco Ciccomascolo
Andrea Maderthoner
Kaj Grönlund
Gunilla Runnsjö

|
 Voestalpine Böhler Welding Overview
We are part of voestalpine AG
Tool steel & leading Turnouts, rails,
position for high-speed processed wire,
steel & special seamless tubes &
forged parts welding consumables

Special Steel Division Metal Engineering Division

Welding: 545 Mio EUR | 2,397 Employees

Steel Division Metal Forming Division

Premium steel High-quality metal
strip, electrical processing solutions,
steel strip, heavy precision steel strip &
plate, cast products special components

11,2 Billion EUR | 47,418 Employees

2 | 4/12/2017
 More than 145 years of know-how

mergers & acquisitions

of best-in-class welding companies:
Thyssen, Böhler, UTP, Avesta Welding,
Soudokay, Fontargen, Fileur, Maruti

in the steel
industry a voestalpine
since 1870 company
since 2007

in the welding
consumables business
since 1926

3 | 4/12/2017
 Work with us around the globe
AUSTRIA | BELGIUM | BULGARIA
| BRAZIL | CANADA | CHINA |
 12 production sites
GERMANY | FINNLAND | FRANCE
 customers in over | GREECE | INDONESIA | INDIA |
150 countries ITALY | KOREA | MEXICO
| NETHERLANDS | NORWAY |
 43 locations in
over 25 countries ROMANIA | RUSSIA | SERBIA
| SINGAPORE | SPAIN | SWEDEN |
 over 1,000 selected SWITZERLAND | TURKEY
distribution partners
| UNITED ARAB EMIRATES |
UNITED KINGDOM | UNITED
STATES OF AMERICA

4 | 4/12/2017
 Comprehensive portfolio

Products Alloys / Grades

 Covered electrodes  Unalloyed and low

alloyed
 Solid wires/TIG rods
 Aluminium
 Flux cored wires
 Nickel-based alloys
 Sub arc wire and flux
 Special alloys
 Strips for strip cladding (nickel, copper, cobalt)
 Solders, pastes, fluxes  Stainless steel
 Post-weld cleaning  High strength
chemicals and pickling  High / low temperature
pastes  Corrosion resistant
 Thermal spraying  Heat resistant
powders

5 | 4/12/2017
 3 Business Units - 3 Brands

6 | 4/12/2017
Effect of bismuth when welding with FCAW

Flux system of stainless steel FCAW usually contains bismuth

Small amount of bismuth (as Bi2O3) improved slag detachability
Bismuth content about 180-200 ppm
Bismuth has no detrimental effect when operating at working temperatures
lower than 400°C.
Following aspects have been detected when welds are exposed at high
temperature:
 intergranular cracks at temperatures ≥700°C
 reduced hot ductility >650°C
 Decreased creep ductility and premature creep failure
 fracture surface shows presence of bismuth/bismuth oxides

Crack sensitivity and loss of ductility due to segregation of bismuth or bismuth

oxyde at grain boundaries

|
7
 Consequences in the Petrochemical Industry
Requirements
API RP 582 “Welding Guidelines for the Chemical, Oil, and Gas Industries”
Since 2nd Edition, Dec. 2009
6.4.2.3 When austenitic stainless steel type FCAW weld materials are exposed to
temperatures above 1000 °F (538 °C) during fabrication and/or during service:

a) materials shall have a formulation that does not intentionally add bismuth, and bismuth
in the deposited weld metal shall not exceed 0.002 % (20 ppm);

b) materials shall have a maximum FN of 9 FN.

Majors and Engineering Companies in Petrochemical started to adopt this recommendation in

their specifications.

AWS A5.22:2012 or ASME BPVC sect. II part C SFA 5.22 (since Edition 2013)
A8.1.4 Bismuth(Bi) in Flux Cored Stainless Steel Electrodes
…..stainless steel electrodes containing Bismuth additions should not be used for such high
temperature services or post weld heat treatment above about 900 °F (500 °C). Instead
stainless steel flux cored electrodes providing no more than 20 ppm (0.002%) Bi in the weld
metal should be specified …

|
8
 Impact of FCWs Bi-free requirement in
Petrochemical Industry

• Petrochemical C.P.E. working temperature usually below 1000°F (538°C) with

exception of FCC Regenerators (@ 716°C -protective layer made in alloy 308H)
• BUT when creep resistant steels are used, PWHT is carried out at
temperatures above 1000°F (538°C)
• Main C.P.E. equipment HC Reactors, HDS Reactors, Effluent Heat Exchangers
are made in gr. 11. gr .22, gr. 22V needing PWHT

Therefore
• When stainless steel FCAW wires are used for cladding C.P.E. they must be Bi-
free type to meet the requirement of API RP 582

Challenge: development of stainless steels FCAW wires with a slag system

without Bi addition preserving same weldability and slag detachability of the
usual wires

|
9
Heat Treatment- Actual / Simulation

620 C for gr.22

 PWHT Temperatures:
 680°C (gr. 11), 690°C (gr. 22), 705°C (gr. 22V)
 PWHT times applied in WQT:
 8 h -10 h according the applied nominal PWHT in fabrication (3 – 4 h for gr. 11)
 24-32 h for simulating the equipment fabrication/repairing history.

|
10
 Hydrocracking Unit

|
12
 Hydrocracking Unit

|
13
 Hydrotreating Unit

|
14
 Hydrotreating Unit

|
15
 Fluid Catalytic Cracking Unit (FCCU)

|
16
How to create a protective layer
 ESW Weld Overlay
 Clad Plates
 FCAW/SMAW/GTAW/SAW
for completion, i.e.:
 Inside nozzles, fittings
and restoration
 Weld overlay build-up
of the internal
“supports”

Example on a dish-end

|
17
Advantages in cladding with SS FCAW

 High deposition rates and  Risk of porosity and

productivity lack of fusion minimized
 Easy handling  Low and easy post weld work
 Smooth bead appearance  Low shielding gas costs

|
18
S.S. FCWs for High Temperature Service
Joining Application

Welding of

 AISI 347, 347H, 321, 321H

pipes

 AISI 304H pipes

|
19
Range of Böhler Bi-free wires for FCAW
Designation EN AWS

Böhler E 347L H-FD T 19 9 Nb R M (C) 3 E347T0-4 (1)

Böhler E 347 H PW-FD T 19 9 Nb P M (C) 1 E347T1-4 (1)

Böhler E 309L H-FD T 23 12 L P M (C) 1 E 309LT0-4 (1)

Böhler E 309L H PW-FD T 23 12 L P M (C) 1 E309LT1-4 (1)

Böhler E 308 H-FD TZ 19 9 H R M (C) 3 E 308HT0-4 (1)

Böhler E 308 H PW-FD T Z 19 9 H P M (C) 1 E308HT1-4 (1)

T0 type optimized for flat/horizontal welding: recommended for cladding

T1 type featuring fast-freezing slag system supporting welding pool when
welding in out of position. Solution for joining (e.g. piping)

|
20
 Chemical composition of
SAS 2 PW-FD, SAS 2 PW-FD (LF)
and E 347 H PW-FD
Typical values of all weld metal
Shielding gas: Ar + 18% CO2
SAS 2 PW-FD (Standard)
C Si Mn Cr Ni Nb Ferrite*
0.030 0.8 1.3 19.0 10.5 0.45 10

SAS 2 PW-FD (LF)

C Si Mn Cr Ni Nb Ferrite *
0.030 0.6 1.4 18.5 10.5 0.45 6

E 347 H PW-FD (without Bi)

C Si Mn Cr Ni Nb Ferrite *
0.045 0.6 1.5 18.5 10.5 0.45 6

* Ferrite measured with Fischer Ferrtscope MP30

|
21
Comparison of the notched impact
toughness

|
22
Comparison of the notched impact toughness

|
23
Comparison of the notched impact toughness

|
24
 E 347L H-FD and E 309L H-FD “T0” type:
targeted solution for cladding creep resistant
steels
Typical values of all weld metal
Shielding gas: Ar + 18% CO2

E 347L H-FD

C Si Mn Cr Ni Nb Ferrite
0.030 0.6 1.4 18.5 10.5 0.4 6

E 309L H-FD

C Si Mn Cr Ni Ferrite
0.030 0.6 1.3 22.8 12.5 14

|
25
Two-layer Cladding on base material
10CrMo 9 10 (ASTM A387 gr. 22)
Welding Parameter:
Interpass-Temperature.: max. 150°C
Shielding gas: Ar + 18% CO2
Amperage: 230 – 240 A
Wire feed speed: 12 m/min
Overlapping: ~50%
1st Layer E 309L H-FD 2304880
2nd Layer E 347L H-FD Sample 6335

Chemistry from the surface of the 1st and 2nd layer

C Si Mn Cr Mo Ni Nb Ferrite
measured

1st layer 0.048 0.529 1.30 19.80 0.148 10.33 <0.004 8.9 FN

2nd layer 0.034 0.593 1.49 19.28 0.083 10.21 0.39 6.5- 7.5 FN

Undiluted chemistry from the wires

C Si Mn Cr Mo Ni Nb Ferrite
measured

E 309L H-FD 0.034 0.579 1.36 23.13 0.041 12.62 0.012 14.8 FN
2304880
E 347L H-FD 0.033 0.586 1.43 18.78 0.0392 10.24 0.439 6.7 FN
6335

|
27
1st layer with E309L H FD

|
28
None Destructive Testing after the
1st layer

|
29
2nd layer with E347L H FD

|
30
Hot Tensile Testing: all weld metal of alloy 347

700
ULTIMATE TENSILE STRENGTH UTS[MPa]

600

500

400 SAS 2-FD

AWS: E347T0-4/-1
standard
E347L H FD
300 AWS: E347T0-4/-1
Bi-free

200

100

0
20 °C 500 °C 700 °C

|
31
Hot Tensile Testing: all weld metal of alloy 347

45
ELONGATION A5%
40

35

30

25 SAS 2-FD
AWS: E347T0-4/-1
standard

20 E347L H FD
AWS: E347T0-4/-1
Bi-free

15

10

0
20 °C 500 °C 700 °C

|
32
Hot Tensile Testing: all weld metal of alloy 347

60
AREA REDUCTION Z%

50

40

SAS 2-FD
AWS: E347T0-4/-1
30 standard
E347L H FD
AWS: E347T0-4/-1
Bi-free
20

10

0
20 °C 500 °C 700 °C

|
33
347 type: Fracture Analysis –
Hot Tensile 700 °C

SAS 2-FD E 347L H-FD

The amount of the spots with „brittle fracture matrix“ in the SAS-2 FD
(with bismuth) specimen is slightly prevailing than in the E 347L H-FD
specimen

|
34
Element distribution in EPMA mapping of SAS
2-FD all-weld metal (conventional Bi-added
FCW)

EPMA mapping shows that bismuth is present as particles and not as bismuth
oxide Bi2O3.

|
35
Hot cracking test MVT

No cracks on E 347L H-FD (Bi-free) samples;

(PWHT: 705°C/40h)

|
36
 E 308 H-FD & E 308 H PW-FD
Shielding gas: Ar + 18% CO2

C Si Mn Cr Ni FN**

0.05 0.6 1.3 19.4 10.4 6

* measured with Fischer Feritscope MP 30

Impact Toughness
Tensile Test
ISO-V [J]
Rp0.2 Rm A5 Z Test temperature
[N/mm²] [N/mm²] [%] [%] +20 [°C]
E 308 H-FD 355 555 55 60 94 90 87

E 308 H PW-FD 373 558 46.3 47.2 106 108 90

Lateral expansion
[°C] +20

E 308 H-FD 1.51 1.48 1.43

E 308 H PW-FD 1.69 1.73 1.60

|
37
E 308 H PW-FD
All Weld Metal Tensile Tests 1/3

|
38
E 308 H PW-FD
All Weld Metal Tensile Tests 2/3

|
39
E 308 H PW-FD
All Weld Metal Tensile Tests 3/3

|
40
Conclusion

High Temperature ductility loss/ cracking sensitivity is due to the

segregation of elemental bismuth at grain boundary (not bismuth
oxyde)
Comparison of new bismuth-free flux cored wires for joining and overlay
welding to conventional wires have been shown
Bismuth-free wires showed improved resistance to embrittlement after
PWHT at 700°C and higher impact toughness
Hot tensile tests confirmed significantly higher elongation values for the
bismuth-free wires and showed no cracks in MVT tests
Welding and slag removal is equal to the standard wires

|
41
 Appendix 5

Stainless steel bundle failure

(M. Poldi)

Minutes of EFC WP15 Corrosion in the Refinery Industry 13 April 2017

 Hydrocarbon reboiler failure
April 2017

Hydrocarbon reboiler failure– Data and event list

 Heat exchanger description: 

 Tube side: heating medium mineral oil.
 Shell side: light condensate.
 Operative pressure: 18.5 barg.
 Operative temperature:  223°C.
 Tube material: SA213 ‐TP316L (SML5).

 Events:

 Change of Shell side fluid from light condensate to light oil.
 The light oil could carry traces of wet Cl.
 Series of three unplanned SD.

 Failure:

 After one month from the fluid switch, cracks and rupture of different tubes has been observed.
 Preliminary RCA identifies SCC from Cl the rupture mechanism.

1
Hydrocarbon reboiler failure – Failed surfaces

Cracks on the 
tube bundle

Hydrocarbon reboiler failure– Failure hypothesis bullet points

I. Stress Corrosion Cracking brought the component to rupture in about a month.

II. Without the unplanned events, the heat exchanger should be able to work at 
regime without SCC initiation even with a fluid (light oil), different from the 
project one and with the presence of wet Cl. 

III. The corrosion mechanism was active only during transitional phases (the three 
unplanned SD events).

2
 Appendix 6

Cracks in dissimilar welds at primary

reformer outlet

(Matthias Gierlinger)

Minutes of EFC WP15 Corrosion in the Refinery Industry 13 April 2017

Cracks in dissimilar
welds at reformer outlet
- Linz Ammonia plant

Matthias Gierlinger
([email protected])

Borealis Innotech Process Technology

13.04.2016
EFC WP15 Spring Meeting
History of steam reformer O-201 in Linz

• Commissioning in 1974
• 258 reformer tubes and six bottom collectors; Uhde design
• First leakage reported in 1989, after ~15 years in operation
• Total record of four leakages
• Implementation of NDT program (UT) in 1997
• Repairs and/or change of tubes in SD/TA ever since
• 2016 repair of 17 reformer tubes in SD
and ~ 70 with significant
NDT-indications © by Borealis

2| Cracks in dissimilar welds | 13 April 2017

 Damage description
• Crack indications between weld metal (~Inconel 82)
and 15Mo3, max. depth 1,5mm
Materials: 36X, Inconel82, 15Mo3
• Pores/small crack indications on weld metal and on Pressure: >30bar
Media: Steam, CO/CO2, CH4, H2
spin cast material 36X Metal Temperatures:
• ~360°C on outer wall at defect
• ~230°C on outer wall outside insulation
below defect
© by Borealis

© by Borealis
Inner surface of removed weld joint with UT-indications after PT,
15Mo3 towards bottom, 36X towards top of picture

3| Cracks in dissimilar welds | 13 April 2017

Stress corrosion cracking on stainless side
© by Borealis

© by Borealis

Strongly branched intergranular SCC, cracks oxide

filled (grey), some crack flanks parallel opened
(black)
© by Borealis Intergranular corrosion and cracks in weld
metal (right) next to 36X base metal (left), some
intergranular attack also in 36X base metal,
depth ~0,8mm

Parallel opened crack

flanks indicating
influence of significant
tensile stress

Process side shown in top side of pictures

4| Cracks in dissimilar welds | 13 April 2017

 General corrosion and cracks on 15Mo3-side
© by Borealis
© by Borealis

Crack initiation between weld metal (left) and

15Mo3 base metal (right), depth ~300µm, Crack along border between weld metal (left)
general corrosion on 15Mo3 side and 15Mo3 base metal (right), depth ~1mm

© by Borealis © by Borealis

Martensitic/
Bainitic structure
in heat affected
zone (HAZ) close
to weld metal Hardening effect in HAZ visible, values of ~190HV in
martensitic/bainitic area (closest to weld metal, area A)
indicate either soft annealing effect from service conditions
or decreased hardness due to pre heating for welding,
Process side shown in top side of pictures hardness of unaffected base metal (area C) is ~160HV

5| Cracks in dissimilar welds | 13 April 2017

 Failure mechanism
Literature:
• The likeliest failure root cause is identified as condensation This failure mechanism has been
observed already in the past in
at the welds leading to: reformer plants with the Uhde-
• carbonic acid corrosion with partial hydrogen cracking design [1, 2, 3]
on the 15Mo3 side of the weld
• as well as stress corrosion cracking (SCC) from
accumulation of process impurities in the stainless
materials (weld metal and 36X close to the weld).
• During the carbonic acid corrosion reaction hydrogen is
released and partly diffusing into the material. It is assumed
that this can lead to embrittlement when lowering the
temperature.
• Crack propagation is expected mainly during shut down due
to the induced tensile load during the contraction of the
materials and the embrittling effect at decreased
Morphology of carbonic acid
temperature. During normal operation slow crack corrosion attack in the HAZ of the
propagation can be assumed. 15Mo3 side and crack propagation
along the weld interface [1] , the
same morphology was found in
Borealis’ Linz site

1. Osama El Ganainy, Failure of Dissimilar Metals Weld in Reformer Tubes, AIChE – Safety in Ammonia Plants & related Facilities Symposium, 1984
2. G. Matthew Webb and W.K. Taylor, Reformer Tubes: Not a Commodity, AIChE – Safety in Ammonia Plants & related Facilities Symposium, 2005
3. Andrew Walker and Neil Mackenzie, Dissimilar Weld Cracking and Repairs on Primary Reformer Exit Headers, AIChE – Safety in Ammonia Plants & related Facilities
Symposium, 1995

6| Cracks in dissimilar welds | 13 April 2017

Leak before break evaluation

• For safety reasons the leak before break scenario

had to be verified.

• Cases in literature (slide 6) experienced leak before © by Borealis

break.

• Leakages have already occurred at Borealis’ Linz site

in the past. Leak before break has been observed.

• Crack propagation is expected mainly during shut

downs.

Photo from Linz archives showing

• The low hardness values of the HAZ on the 15Mo3 leak at dissimilar weld with N2-
flushing nozzle installed.
side indicate a low risk for pronounced hydrogen
cracking and do not indicate a risk of brittle failure.

7| Cracks in dissimilar welds | 13 April 2017

Conclusions

• Failure mechanism is believed to be

understood.

• Inspection and repair actions have been

defined.

• Improved welding procedure still needs to

be defined.

8| Cracks in dissimilar welds | 13 April 2017

 Appendix 7

Failure of stripper feed/bottom heat exchanger

SS304L tubes in a naphtha hydrotreatment unit

(F. Dubois)

Minutes of EFC WP15 Corrosion in the Refinery Industry 13 April 2017

 EFC WP15 Corrosion in Refinery
Frankfurt, 13th April 2017

Failure of stripper
feed/bottom HE 304L tubes
in a NHT unit
François Dubois

NHT unit

 Naphtha hydrotreatment NHT

 Hydrotreatment Reactions
• Catalytic reaction in presence of H2
• Sulfur & Nitrogen removal from Naphtha cut by-products are H2S & NH3
• Chloride compounds are hydrotreated to HCl
 Intermittent washing of reactor effluent air cooler (REAC) with
water injection
• Dissolution of precipitated NH4HS solid salts
 3 phase separation
• Liquid HC is heated in Stripper Feed/Bottom heat exchanger
• Warm liquid HC is sent to the stripper
 Stripper
• Degazing H2S and NH3 from Desulfurized Naphtha product

1
Generic NHT Process Flow Diagram

Heater
Reactor
Quench
Gas Stripper

Steam
Fuel Oil

F/E Recycle
Exchangers Gas
Washing
Water Stripper F/B
Exchangers
H2

Feed Product
HCL+V + H2 + H2S + NH3 + HCl + free water

Gabarit de présentation v.1 - Dec. 2013 3

Stripper Feed / Bottom Heat Exchanger

 Original Material of Construction

• Carbon steel with resistance to wet H2S cracking (SSC and HIC)

 Water is separated in the cold separator drum upstream stripper

F/B HE
• Separator designed for the decantation of droplets above 50 µm
• Carry over of smaller water droplets in the liquid HC phase

 Sour water is vaporized in the 1st Stripper F/B HE

• No HCl – Mild corrosive conditions with life time > 5 years for tube bundle
• HCl presence – Corrosive conditions with reduced lifetime < 2 ½ years

2
Stripper Feed / Bottom Heat Exchanger

 Design/Operating conditions
• Tdesign = 49°C to 134°C
• P = 12bara
• Sulfur@design (H2S) = 1%
• Liquid / Mixed phase hydrocarbon at water dew point
• Water droplets carry-over from cold HP 3ph separator drum
• Chloride in NHT unit feedstock < 0.5 ppm

Change of tube material

 CS tube bundle was changed several times with an identical

material (CS HIC resistant) due to accelerated corrosion
• Start-up : 2009
• Turn-around and 1st change of tubes : 2012
• Turn-around and 2nd change of tubes : 2014

 Decision was made to switch tube material to stainless steel

• Selected grade for the new Feed/Bottom HE Tubes : SS 304L

 Change of tube material march 2016

 Failure of Tube bundle after 1 week operation !

 Several other failures in following months

3
SS 304L tubes failure analyses

 General aspect

SS 304L tubes failure analyses

 Pits at tube outer surface

4
SS 304L tubes failure analyses

 Pits at tube outer surface

SS 304L tubes failure analyses

 Cracks

10

5
SS 304L tubes failure analyses

 Cracks : intergranular

11

SS 304L tubes failure analyses

 Cracks : transgranular

12

6
SS 304L tubes failure analyses

 Surface deposits

 Sulfur and chlorides detected

13

SS 304L tubes failure analyses

 Mechanical degradation with plastic deformation and martensite

formation

 Hardness measurements a little high but still within the range

for SS 304L material : 200HV10

14

7
Findings

 Switch back to carbon steel bundle that suffers only rapid

generalized corrosion

 Several mechanisms contributed to the failure of 304L

• Evidence of CL-SCC, wet H2S-SCC, pits
 Exchange of tube material metallurgy from CS to SS without
proper design review
• Differential thermal dilatation and constrains during operation
• Presence of chloride ions in wet H2S environment with water vaporization

 Alternate material (Ni-Cr-Mo) to be considered in this very

corrosive environment

15

Thank you

 And thanks to who performed the analyses

16

8
 Appendix 8

New corrosion inhibitors for cooling water

systems

(V. Bour-Beucler)

Minutes of EFC WP15 Corrosion in the Refinery Industry 13 April 2017

 New High Charge Polymer to improve
corrosion inhibitor performance, TCO
and optimize CW cycle of
concentration

Eurocorr 2017
Frankfurt Spring Meeting

Valerie Bour Beucler

Cooling water system successful

management
 Cooling water successfull management
 A good equilibrium between corrosion, scaling and MIC

1
Regulation and cooling system
 Legionella Control and regulation
 Minimize the risk of legionella

 Biocidal Product Directive / Regulation

 harmonise the European market for biocidal products and their active
substances.

 REACH (European Commity Regulation on Chemical

and their safe Use (EC 1907/2006)
 It deals the Registration Evaluation Authorisation and Restriction of
Chemical substances.

 The Future
 Less non oxidizing biocides
 More oxidizing biocide but with AOX control
- Chlorine dioxide (ClO2), a good alternative
3

Cooling systems traditional treatment

 Recirculating cooling system treatment with pH control

 Corrosion inhibitors
- Anodic and cathodic
- Orthophosphates as anodic corrosion inhibitor

 Polymer
- To reduce tricalcium phosphate (TCP) scaling with phosphate dispersion
- TCP will depend of pH, stress conditions, température, ortho-phosphate,
calcium level and polymer performance and dosage.
- Disperse Al and iron
- Consumption with SS, bleach…

2
 Mechanical stress parameters
Operational parameters Low Moderate High Severe

Skin Temperature (oC) < 50 50 – 60 60 – 70  70

Velocity (ms-1) 1 0.6 – 1.0 0.6 – 0.3 < 0.3
Heat Flux (MJm-2.hr-1) < 25 25 - 50 50 - 75 > 75

Chemical parameters

Langelier < 0.5 0.5 – 1.5 1.5 – 2.5  2.5

Ryznar  6.0 4.5 – 6.0 3.5 – 4.5 < 3.5
Low velocity TCP SSI < 20 20 –1000 1000 – 1500 >1500
Iron (mgl-1) < 1.0 1.0 – 3.0 3.0 – 5.0  5.0

Increase corrosion and scaling risk

Stress...The New Normal

Optimum
Reliability

3
 Stress...The New Normal

Nalco Champion Innovation

Chemistry Control Services

Technical Improved Customer

7
Innovation Reliability Profits

System Reliability - Breakdown

Water Quality - Detail

Mud/Silt
Bio 4%
3%

Debris CS
18% Corrosion
53%
HX Stress
36%

Maintenance
Planning
19%

Scale
Water 36%
Quality
27%
Adm
Corrosion
4%

Technical Improved Customer

8
Innovation Reliability Profits

4
 Innovation request to R&D

 Superior PO4 dispersancy

 Excellent Fe/Al tolerance
 Improved stability & MSDS
 3D TRASAR tag control
BENEFITS:
 Higher pH and cycles
 Reduced water use
 Enhanced stress management
9

High Charge Polymer (HCP)

Polymer effectiveness determines the ability to operate at higher stress and cycle
conditions. Research has determined that polymer efficiency is directly related to
its charge. We have developed a polymer that balances the charge and molecular
weight to maximize dispersant performance

• Superior PO4 dispersancy

• Enhanced stress management
• Higher Fe & Al tolerance
• Higher pH and cycles
• Reduced water use
• Lower consumption
• Improved SDS

• CH-1918
Technical Improved Customer
Innovation Reliability Profits 10

5
HCP interaction with corrosion

 Superior iron dispersency, limits deposition

 Enhanced availability of corrosion inhibitors by best in class
Zinc & phosphate stabilisation
 Tag polymer control to ensure inhibitor availability, as the
dosing respond to system stress

 Allows higher pH set point, reducing corrosion

11

New HCP

OLD HSP HCP

TECHNOLOGY
Methanol in SDS? YES NO
Formaldehyde in SDS? YES NO
Formulation challenges? YES NO
Acrylamide monomer? YES NO
Chlorine consumption YES* NO
Fe and CaHPO4 dispersion Average Excellent (HCP)

Technical Improved Customer

Innovation Reliability Profits

12

6
 Case History #1
Deposition Rate from 2.9 ug/day to 0.6 ug/day

Technical Improved Customer

Innovation Reliability Profits 13

High Charge Polymer Case History #1:

Delivering water and TCO savings

Maintained Improved PO4 Improved Zn

corrosion rates solubility from solubility from
Reduced at higher 93% to near 40% to near
Increased Reduce
Deposition cycles. 100% 100%
cycles of Polymer
Rate by
concentration Consumption
80%(2.9 to 0.6
Lowered iron (3.9 to 6.1) 20% (evidence of (evidence of
ug/day)
levels (0.41 to old deposit old deposit
0.15 ppm). cleanup) cleanup)

Technical Improved Customer 14

Innovation Reliability Profits

7
Case #2: HX with limited run-length, required
periodic acid cleaning ($10m lost in downtime)

Pre-Trial Baseline HCP Trial

46 days exposure 33 Days exposure

RTM: 104 µg/d RTM: 10.5 µg/d

15

Case Study #3 – Refinery, variable MU, high

Aluminium, periodic acid cleaning

16

8
High Charge Polymer Summary

Maintained Improved
corrosion corrosion
rates at Increased Reduce inhibitor Improved
Reduced SDS
higher cycles. cycles of Polymer availability
Deposition
concentration Consumption

Technical Improved Customer

Innovation Reliability Profits 17

The Next Generation

of
Nalco Champion Innovation

Chemistry Control Services

Questions?

18

9
 Appendix 9

Discussion about corrosion in cooling water

systems as a result of poor water treatment

(G. De Lantsheer)

Minutes of EFC WP15 Corrosion in the Refinery Industry 13 April 2017

Cooling water treatment

Different treatment philosophies between

different contractor can cause major defects

Gino De Landtsheer,
Senior Group Expert Piping & Valves
Borealis

Project & Technical Support (PTS)

Division: Technical Support Group (TS)
Part 1:
Situation sketch

2| Cooling water treatment – possible issues regarding piping & equipment

Situation sketch
 It has been noted that changing contracts between CW treatment companies can have important
impacts to:

a) Use of treatment philosophy , regarding the use of using additives

- Complete different chemical mix is even discovered

- Other dosing scenario’s have been monitored

b) There are different ways of getting to the same result

- But how to get the warranties that the proposed solution will not affect our plants/equipment in a negative way?

- It has been even noted that between different locations with almost the same scope, a complete different treatment
philosophies are discovered

c) What about the responsibilities in case it goes wrong?

- Short notice damages are quite easy, but what about the long term influences in relation to the scheduled/calculated
equipment design life time.

d) Are there knowledge sharing platform available ?

- Libraries with analogue treatment scenario’s could help the plant owner to evaluate proposals in water treatment
scenario's

3| Cooling water treatment – possible issues regarding piping & equipment

Part 2:
Some pictures what can go wrong…..

4| Cooling water treatment – possible issues regarding piping & equipment

Cooling water treatment - issues

5| Cooling water treatment – possible issues regarding piping & equipment

Cooling water treatment - issues

6| Cooling water treatment – possible issues regarding piping & equipment

Cooling water treatment - issues

7| Cooling water treatment – possible issues regarding piping & equipment

Thank you

Unless otherwise specifically stated, this presentation,

any part of it, or any information contained herein may
only be copied, disclosed or used within the Borealis
group of companies. Borealis AG and its affiliates
give no warranty and make no representation as to
the accuracy, completeness or fitness for any
particular use of the information contained herein.

8| Presentation title | 12 April, 2017

 Appendix 10

Denveloping guidelines and initiatives towards

an holistic kind of approach to the CUI problem

(M. Mannucci and T. Rehberg)

Minutes of EFC WP15 Corrosion in the Refinery Industry 13 April 2017

 FESI Presentation

Overview on some existing guidelines on

protective coatings to prevent CUI
NACE SP0198– CINI Manual – AGI Q151 – API
583 – New ISO NP 19277

www.fesi.eu

European Federation of Associations of Insulation Contractors 1

 WHAT IS AND WHAT DOES FESI
• FESI (Fédération Européenne des Syndicats d’Entreprises
d’Isolation) is the independent Federation of the European
insulation contracting sector founded in Paris in 1970.

• FESI represents 20 national insulation associations from

Europe whose members are active in the field of technical
insulation for industry, the commercial building sector, ship
insulation, soundproofing and fire protection.

• FESI represents more than 3.300 European insulation

contracting companies.

FESI 2
www.fesi.eu
 WHAT IS AND WHAT DOES FESI
FESI acts as the European think-tank bringing insulation
specialists together to work on technical matters related to thermal
and cold insulation as well as acoustic protection and to promote
industrial insulation as a Best Available Technique delivering
industry:

 Energy savings
 Emissions reductions
 System efficiency
 Safety
 Workplace improvement
 Cost reductions

FESI 3
www.fesi.eu
 FESI BOARD

President Tobias Zaers (Germany)

Vice President Zuzanna Bieńkowska (Poland)
Vice President Michele Mannucci (Italy)
Secretary General Andreas Gürtler (Switzerland)
Treasurer Kilian Knuchel (Switzerland)
Controller Fritz Stangl (Austria)

FESI 4
www.fesi.eu
 FESI COMMISSIONS

Commission Chairman Secretary

Strategy, Budget and Andreas Gürtler

Tobias Zaers
Direction Commission

Thermal Technical
Michele Mannucci Gabriel Boncalo
Commission
Recruitment and Training
Zuzanna Bieńkowska Agne Rupeikaite
Commission

Acoustic Commission Hans-Joachim Rennecke

FESI 5
www.fesi.eu
 FESI’S THERMAL TECHNICAL COMMISSION

The Thermal Technical Commission (TTC) develops

FESI’s Thermal Technical Documents. It is responsible
for standardization policy, information exchange with
CEN, discussion of prENs with consequence for the
insulation trade in Europe and recommendation of letters
with a technical orientation to be written by FESI
member associations to their respective representatives
in the Standing Committee on Construction (SCC).

FESI 6
www.fesi.eu
 FESI’S TTC PROJECT ON CUI
Our aim is to achieve an updated view on best practices
to minimize CUI, taking in consideration the following
aspects:

• Insulation materials selection and insulation

installation techniques
• Coating system selection and their application
techniques
• Mechanical Design
• Maintenance
• Inspections

FESI 7
www.fesi.eu
 CUI – existing guidelines
• NACE SP0198, standard practice (first edition from 1998), “The Control of Corrosion
Under Thermal Insulation and Fireproofing Materials — A Systems Approach”, current
version from 2010, under revision since 2014
coating system selection table and some design recommendations to avoid moisture
intrusion

• EFC Guideline No. 55 “Corrosion Under Insulation (CUI)” by Stefan Winnik, 2015
same coating selection table as NACE SP0198 recommended practices to mitigate CUI
with focus on RBI, TSA and coatings application and types and forms of insulation
materials

• AGI Q151 “Corrosion protection under insulation” first version from 1991, current
version from 2013,
coating system selection table

FESI 8
www.fesi.eu
 CUI – existing guidelines
• CINI general insulation specification, chapter 1.2.04 and following currently under
revision, “Relation between process temperature and possible corrosion under
insulation”, gives recommended combination of systems and coatings to prevent CUI
coating system selection table

• API 583, 2014, gives design, maintenance, inspection and mitigstion practices to
address corrosion under insulation

• ISO NP 19288 – CUI coating laboratory testing regime

All before mentioned publications do not offer a full

hollistic approach
FESI 9
www.fesi.eu
NACE SP0198: Insulation design considerations

Examples of design guidelines for

insulation system engineering
FESI 10
www.fesi.eu
NACE SP0198: Carbon Steel, corrosion protection

FESI 11
www.fesi.eu
NACE SP0198: Carbon Steel, corrosion protection

FESI 12
www.fesi.eu
EFC 55 CUI guidelines

FESI 13
www.fesi.eu
EFC 55 CUI guidelines

FESI 14
www.fesi.eu
EFC 55 CUI guidelines

FESI 15
www.fesi.eu
EFC 55 CUI guidelines

FESI 16
www.fesi.eu
 AGI Q 151 – Corrosion protection under insulation
• Gives generic system selection for carbon and stainless steel
• All systems (except the touch-up/repair system) require Sa 2½
• For cyclic condition special solutions are suggested

No surface protection system is required:

• Continuously operating equipment & piping below -20°C
• Insulated surfaces operating above 120°C
• Stainless steel surfaces which are continuously operated below +20°C and
will no reach more than +35°C during shut down and which are not cleaned
with warm media

FESI 17
www.fesi.eu
AGI Q151

AGI Q 151
FESI
www.fesi.eu
18
AGI Q151

FESI 19
www.fesi.eu
API 583

FESI 20
www.fesi.eu
API 583

FESI 21
www.fesi.eu
ISO NP 19277 - Qualification testing for protective coating
systems under insulation

22
 ISO NP 19277 - Test regime CUI-1 – CUI-4

• Adhesion testing before conditioning (ISO 2409 or 4624)

Criteria: ISO 2409 0-2 and ISO 4624 cohesive failure, unless over 5MPa
• Neutral salt spray (ISO 9227) for 720/480 hours
• Immersion testing (ISO 2812-2) for 3000/500 hours
• Water condensation (ISO 6270-1) for 480/240 hours
Ambient test criteria “0” in ISO 4628-2, -3, -4, -5, -8
• Adhesion testing after conditioning (ISO 2409 or ISO 4624)
Criteria: ISO 2409 0-2 and ISO 4624 cohesive failure, unless over 5MPa
• Thermal cycling test (20 cycles (max. temp. and ice water))
Test criteria “0” in ISO 4628-2, -3, -4, -5
• Multi-phase CUI cyclic test (1008 hours CUI-2 – CUI-4)
Test criteria “0” in ISO 4628-2, -3, -4, -5, -8
23
Multi Phase CUI test chamber

24
25
 FESI 26
www.fesi.eu
 FESI 27
www.fesi.eu
 FESI 28
www.fesi.eu
FESI Interactive Selection System (FISS) against CUI

• Steel alloy
Operating • Temperature
• Environment
Conditions • Lifetime expectancy

Coating • New build or Rehab

• Lifetime expectancy
System
Insulation • Purpose of insulation
(energy conservation, etc.)
System • Lifetime expectancy

Effective CUI resistant insulation system 29

 FESI Interactive Selection System (FISS) against CUI
> Holistic System approach, but real product combination (not generic)
> Considers the whole insulation system (from cladding to coating)
> Interactive combination of individual materials / material groups and best
practices for individual selection and scoring (best possible system)

FESI 30
www.fesi.eu
Roadmap to FESI Interactive Selection System (FISS)

• Workshop with coating manufacturer 2017,

February 08 – 09
• Workshop with insulation manufacturer 2017,
May 03 – 04
• Evaluation of EU funding possibilities –
ongoing –
• Cooperation with NACE TG 516 on
Laboratory test standard for CUI coatings
• Cooperation with CINI on FISS (FESI
Interactive Selection System) – started

FESI 31
www.fesi.eu
 What we want from you
• Feedback on the initiative
• Ideas, Best Practises &
Problems
• Participation in one of the
next meetings with CINI
• Be available for FISS
peer review

FESI 32
www.fesi.eu
 Appendix 11

Status of monitoring and detection

procedures/techniques to detect CUI

mitigating CUI, ones discovered, how to

challenge, to challenge and to follow-up.

Integration of mitigated CUI areas in RBI

systems, how to re-evaluate?

(G. De Lantsheer)

Minutes of EFC WP15 Corrosion in the Refinery Industry 13 April 2017

Corrosion Under Insulation in process
industry applications

Experience – awareness – controlling

 key factors for a long-term approach
By means of knowledge, sharing of experiences and specific
inspection programs, based on Risk Based Inspection principles,
trying to break the circle of CUI.

Gino De Landtsheer,
Senior Group Expert Piping & Valves
Borealis

Project & Technical Support (PTS)

Division: Technical Support Group (TS)
Cornerstones

Knowledge

Experience

Inspection

Mitigation

2| EFC – WP15 meeting April 13th / Roadmap to manage CUI

Cornerstones

Knowledge

Experience

Inspection

Mitigation

3| EFC – WP15 meeting April 13th / Roadmap to manage CUI

Road map to manage CUI????

4| EFC – WP15 meeting April 13th / Roadmap to manage CUI

Road map to manage CUI

ROAD MAP ????

5| EFC – WP15 meeting April 13th / Roadmap to manage CUI

Points where we can make the difference!!!
Selection & application painting/coating systems
A well–selected/well–applied painting/coating system
must be seen as

 Final layer of defence against corrosion

It is wishfull thinking to assume that insulation systems
will be waterproof (thight) during the expected lifetime.

Coating & insulation systems shall be seen as equal partners

in our continuous fight against CUI

Is the applied coating method still the ‘best in class’

solution / and is aging monitored?

Is the applied coating quality meeting our expectations?

6| EFC – WP15 meeting April 13th / Roadmap to manage CUI

Knowledge – CUI: critical spots
Possible water intrusion in the applied insulation
Low quality in the applied weather protecting sheeting of the insulation / openings due to damaging

Leakage of installed steam tracing / cut-outs in the insulation where the steam tracing is entering the insulation

Possible condensation by process conditions or damaged vapor screens

Each cut-out in the weather protection sheeting (tie-ins / instrument take-offs/connecting points for hangers) is
increasing the risk

Supporting positions, flange locations, valves and end-points of insulation (vertical lines!)

Valve & equipment boxes!

Degenerated sealing materials (UV impact to silicone kit)

Resource of water / humidity

Climate conditions (temperature / humidity / geographical (sea))

Local conditions (firewater system tests / cooling towers / high pressure cleaning / water spils and leaks)

CUI can be very aggresive at locations with frequent and wide band temperature fluctuations in process
temperatures, resulting condensing and vaporasation effects (also known as swetting of piping)

7| EFC – WP15 meeting April 13th / Roadmap to manage CUI

Knowledge – CUI: critical spots
Design and concept related
Wrong (historical) design of the equipment and/or insulation

Poor installation quality

Longitudinal seams of weather protecting sheeting not correct orientated

Critical locations specific to equipment designs, such as supporting / stiffener rings (static equipment) ,
foundations, saddles, supports, lifting lugs

Supporting positions, flange locations, valves and end-points of insulation (vertical lines!)

8| EFC – WP15 meeting April 13th / Roadmap to manage CUI

Knowledge – CUI: critical spots
Design and concept related – Drains / Vents / Instrument connections
Inspection departments have focus on large / critical lines

Small bore piping (≤ 2”) often field fit-up and ‘forgotten’ in the inspection workload

Small bore piping are more difficult to insulated due to large amount of direction changes and
small dimensions
Due to field fit-up small bore piping are often painted in non-ideal conditions (or even not painted!)

In relation to equipment, the wall thicknesses used in these small bore piping configurations are rather thin,
means that fewer amount of ‘spare’ material is available

9| EFC – WP15 meeting April 13th / Roadmap to manage CUI

Knowledge CUI – Corrosion Under Insulation
Activities for prevention

No moisture and no electrolyt

No direct connection between different materials

No insulation (process, energy, protection, condensation)

Correct treatment (corrosion protection)

- Full (3-layer) painting system

- Thermal Spray Aluminium (TSA)
- Insulating coatings

Correct insulation applications

- Up-to-date company guidelines and/or according to CINI (and/or any other standard)
- Supervision / inspection (QA/QC plan!)
- Scheduled maintenance

10 | EFC – WP15 meeting April 13th / Roadmap to manage CUI

Knowledge CUI – Corrosion Under Insulation
Other conditions or sources

Applied coating protections – risks of failure?

11 | EFC – WP15 meeting April 13th / Roadmap to manage CUI

Roadmap to manage CUI
Critical aspects
CUI can stay a long time out of sight, but when it comes to the surface, it is in most of the circumstances too
late!!!!!!
CUI causes Serious safety risks (e.g. leakages : ‘loss of content’, explosions, fire, personal injuries)

CUI causes economical hick-ups (e.g. production loss, force majeur, customer complaints,...)

“It takes 20 years to build a reputation,

and five minutes to ruin it”
(Warren Buffett)

The basic rule

Avoiding CUI starts at the

design and revamp/assembly
of piping, equipment and structurals!

12 | EFC – WP15 meeting April 13th / Roadmap to manage CUI)

Roadmap to manage CUI
LESSONS LEARNT /
RECOMMENDATIONS /
CHANGES + MOC
DECOMMISSIONING NEW
END OF LIFETIME !
LIFETIME CONCEPT
EXTENSION
INSPECTION / INNOVATION /
FAILURE ANALYSIS / NETWORKING /
ASSESSMENT KNOWLEDGE
UPDATING & SHARING

MAINTENANCE - REPAIRS
DESIGN /
OVERHAULS - REVAMPS
ENGINEERING
TURN-AROUNDS

INSPECTION / ISSUE SPECIFICATIONS /

MONITORING / EQUIPMENT & MATERIAL
TROUBLESHOOTING / SELECTION /
IMPROVEMENTS PROCUREMENT SUPPORT
FABRICATION EXPEDITING
PRODUCTION /
CONSTRUCTION
OPERATIONS
INSTALLATION

INSPECTION PLANS / RBI /

DEVELOP PROCEDURES &
BEST PRACTICES /
TRAINING / COMPETENCE

13 | EFC – WP15 meeting April 13th / Roadmap to manage CUI

Roadmap to manage CUI
Necessary interactions to avoid CUI

New equiment Existing equipment

Design & Fabrication & Maintenance & Refurbishment &

engineering construction operations revamps

ASSET INTEGRITY MANAGEMENT

Strategies Best practices Knowledge sharing Communication

+ Development Updating Training
Management Implementation Networking Awareness
support Review

14 | EFC – WP15 meeting April 13th / Roadmap to manage CUI

Roadmap to manage CUI
Necessary interactions to avoid CUI

New equiment Existing equipment

Design & Fabrication & Maintenance & Refurbishment &

engineering construction operations revamps

ASSET INTEGRITY MANAGEMENT

Strategies Best practices Knowledge sharing Communication

+ Development Updating Training
Management Implementation Networking Awareness
support Review

15 | EFC – WP15 meeting April 13th / Roadmap to manage CUI

Roadmap to manage CUI
Design and engineering
As earlier indicated - knowledge where CUI can occur is the primary key to succes

Use of ‘best-practices’ and rules with proven results

Insulation systems
- and the applied painting system below the insulation! -
deserve more attention !!!!!

International standardisation committees

(Nace / ISO / Norsok / EIIF / Feci / …)

 Definition by means of theoretical texts

(low level of practical examples)

Practical guide with proven ‘typicals’

Cini is recognized on a global scale as one
of the most up-to-date guidelines, created
by end-users and applicators

The question is now is if end-users still need to develop their

ow engineering specifications?

16 | EFC – WP15 meeting April 13th / Roadmap to manage CUI

Roadmap to manage CUI
Design and engineering
Easy selection criteria (materials / operating conditions / HSE)

…. But what is now the best insulation set-up for my application?

CINI provides proven‘best practices’

The CINI comittees, with members from end-users, applicators and fabricators,
are sharing knowledge and develop new typical solutions
17 | EFC – WP15 meeting April 13th / Roadmap to manage CUI
Roadmap to manage CUI
Necessary interactions to avoid CUI

New equiment Existing equipment

Design & Fabrication & Maintenance & Refurbishment &

engineering construction operations revamps

ASSET INTEGRITY MANAGEMENT

Strategies Best practices Knowledge sharing Communication

+ Development Updating Training
Management Implementation Networking Awareness
support Review

18 | EFC – WP15 meeting April 13th / Roadmap to manage CUI

Roadmap to manage CUI
Necessary interactions to avoid CUI

New equiment Existing equipment

Design & Fabrication & Maintenance & Refurbishment &

engineering construction operations revamps

ASSET INTEGRITY MANAGEMENT

Strategies Best practices Knowledge sharing Communication

+ Development Updating Training
Management Implementation Networking Awareness
support Review

19 | EFC – WP15 meeting April 13th / Roadmap to manage CUI

Roadmap to manage CUI
Necessary interactions to avoid CUI
Preventing & elimination of each CUI cause
 control of process conditions en IOW (Integrity
Operating Windows)
Existing equipment
 Prevent intrusion of water and/or humidity

 CUI Inspection- and repair program Maintenance & Refurbishment &

 Risk- and damage restriction operations revamps
 Surface protection / Coating !
 Keep insulation / coating in a good shape!!!!!

ASSET INTEGRITY MANAGEMENT

Strategies Best practices Knowledge sharing Communication

+ Development Updating Training
Management Implementation Networking Awareness
support Review

20 | EFC – WP15 meeting April 13th / Roadmap to manage CUI

Roadmap to manage CUI
Surface protection = final layer of defence
Point 1 : preparation of the surface
- Blasting to SA 2,5 or SA3, depending on the paint supplier recommendations
- Very important step to assure a good adhesion of the paint to the surface

Point 2 : coating selection

- Avoid to apply Zinc-Rich coatings under insulation (NACE recommendation)
- Use TSA (Thermal Sprayed Aluminium)
 Ideal in case of prefab of pipe spools and equipment
 More problematic to use this for in-field applications
 Design details to be adapted to avoid sharp edges and corners
 Design shall allow good entrance of the spraying gun (angle of attack = 45-90°)

Point 3 : application of the coating

- Apply in accordance to supplier recommendations
- Respect temperature and humidity limitations
- Respect the amount of layers and the thickness of the applied layers
- Take care to follow the recommendations about drying times

Point 4 : inspection & QA/QC

- Ensure that the specifications and procedures are followed in practice
- Check continuously

21 | EFC – WP15 meeting April 13th / Roadmap to manage CUI

Roadmap to manage CUI
Necessary interactions to avoid CUI

New equiment Existing equipment

Design & Fabrication & Maintenance & Refurbishment &

engineering construction operations revamps

ASSET INTEGRITY MANAGEMENT

Strategies Best practices Knowledge sharing Communication

+ Development Updating Training
Management Implementation Networking Awareness
support Review

22 | EFC – WP15 meeting April 13th / Roadmap to manage CUI

Roadmap to manage CUI
Necessary interactions to avoid CUI

• Collecting experiences and creation of

Lessons Learned Existing equipment
• Change design habbits and adapt design
rules with proven experiences to prevent
CUI
• Creation of application procedures and Maintenance & Refurbishment &
specifications, with training and operations revamps
communication for the reponsible people

ASSET INTEGRITY MANAGEMENT

Strategies Best practices Knowledge sharing Communication

+ Development Updating Training
Management Implementation Networking Awareness
support Review

23 | EFC – WP15 meeting April 13th / Roadmap to manage CUI

Roadmap to manage CUI
Strategies & preventive measures
RBI (Risk Based Inspection)
Consequence
of Failure
(CoF)
Data and
information Risk Matrix / Inspection Mitigation
collection Risk Ranking Plan (if any)

Probability of
Failure
(PoF)

Reassessment

RISK CODE CUI INSPECTION STRATEGY

HIGH H CUI-1
MEDIUM-HIGH MH CUI-2
MEDIUM M CUI-3
LOW L CUI-4

24 | EFC – WP15 meeting April 13th / Roadmap to manage CUI

Roadmap to manage CUI
Strategies & preventive measures
RBI (Risk Based Inspection)

4093
160
CUI 1 INSPECTIONS DONE
4278 2285
CUI 2 INSPECTIONS DONE
3
3866 CUI 3 INSPECTIONS DONE

CUI 4 INSPECTIONS DONE

CUI 1 INSPECTIONS STILL TO DO

7950 CUI 2 INSPECTIONS STILL TO DO

CUI 3 INSPECTIONS STILL TO DO

CUI 4 INSPECTIONS STILL TO DO

6304
NOT SUBJECT TO CUI

TOTAL NUMBER OF PIPING &

EQUIPMENT MAPPED :
69679 97053

CUI INSPECTION STATUS

BOREALIS
31-12-15

25 | EFC – WP15 meeting April 13th / Roadmap to manage CUI

Roadmap to manage CUI
Strategies & preventive measures
RBI (Risk Based Inspection)

100%

80%

60%

40%

20%

0%

100%
CUI 1
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%

26 | EFC – WP15 meeting April 13th / Roadmap to manage CUI

Roadmap to manage CUI
‘CUI – preventing actions
Point 1 : NO insulation = NO CUI!!!
- Check for alternatives in case insulation is required
(cages / insulation coatings (PP applications)

Point 2 : Adapt your designs, based on proven experiences to avoid CUI

- Avoid points of water intrusions
- Avoid water collecting points
Point 3 : Use a qualitative painting system for new and existing parts as final line of defense
- QA/QC of application, with up to date specifications and procedures
- Integrate re-painting works as part of normal maintenance activities

Point 4 : Inspect existing insulation & avoid damaging by secondary maintenance activities
- Awareness of all people to ‘respect’ the insulation – DON’T STEP ON IT!
- Replacement strategy, without long waiting process
- Inspection of insulation & painting shall be performed on the same level as it is for welding

27 | EFC – WP15 meeting April 13th / Roadmap to manage CUI

Roadmap to manage CUI
‘CUI – preventing actions

Point 5 : Application in accordance with best practice rules

- Keep awareness about the details and the quality of application

Point 6 : Creation of action plans – RBI (Risk Based Inspection)

- Interaction required between engineering – production – maintenance - inspection

Point 7 : Evaluation & exchange of experiences

- Intercompany, but even more important is also to check external resourses

Point 8 : Continuous observation / mandatory declaration for every member of the staff
- Alert / Attentive / Careful

28 | EFC – WP15 meeting April 13th / Roadmap to manage CUI

Roadmap to manage CUI
‘CUI – tackling actions

Step 1 : Start with Fitness-for-Service (FFS)

- Based on API 579-1  determine of the Minimum Allowable Wall Thickness

Step 2 : wall thickness = OK  apply new coating and insulation

- Check if insulation is really necessary
- Check alternatives
- Use QA/QC plans to check application actions
Step 3 : wall thickness ≠ OK  repair or replace
- In case of a temporary repair, an in detail risk analysis is mandatory
- Re-evaluate the original design and modify to best practices

29 | EFC – WP15 meeting April 13th / Roadmap to manage CUI

30 |
Thank you

Unless otherwise specifically stated, this presentation,

any part of it, or any information contained herein may
only be copied, disclosed or used within the Borealis
group of companies. Borealis AG and its affiliates
give no warranty and make no representation as to
the accuracy, completeness or fitness for any
particular use of the information contained herein.

31 |
 Appendix 13

High quality electroslag strip cladding of thin

single layers for 625 alloy

(F. Ciccomascolo)

Minutes of EFC WP15 Corrosion in the Refinery Industry 13 April 2017

 High quality electroslag
strip cladding of thin single
layers for 625 alloy

Mathieu Decherf
Ronny Demuzere
Francesco Ciccomascolo

1 | 4/13/2017
 Why strip cladding ?

One single material cannot

comply with all the specifications

Solutions : combining two materials Cladding

deposit

Outside : unalloyed steel for mechanical properties

Inside : alloyed or low alloyed Cladding for anti- Base metal

wear and anti-corrosion properties

Strip cladding

Submerged arc Electroslag

SASC ESSC

2 |
 Electroslag strip cladding

 Special welding flux

 One side flux feeding
 No electric arc
 Electroconductive slag
 Open weld pool

3 |
 Oil & Gas and Chemical Processing
industry
 One of the most common alloys :

 Alloy 625 clad on ASTM SA516 Grade 55, 60, 65, 70

4 |
 Alloy 625
Oil & Gas and Chemical Processing
(strip cladding)
Subsea Separator / Shell and dish-ends

Customer/ Fab. Shop: CMP Arles, France

Base materials: P500 QL2

 weight 190 tons

 Outside diameter 3600 mm
 thickness 96 mm
 length 15 m

Filler metal:

 Soudotape625 / 60x0,5 mm, 21000 kg

 Flux record EST625-1, 14700 kg
 Single layer deposit: 5,5mm

Engineering: FMC-Norway

Owner : TOTAL

5 |
 Productivity improvement

Demand for higher productivity

Two solutions (state of the art)

Lower number of layers single layer fluxes

Higher deposition rates high speed fluxes

6 |
 Productivity improvement

60 Productivity improvement
through the strip requires :
50  additional investment in
expensive equipment
120mm  a matching geometry of
40
the component to be
Deposition rate [kg/h]

cladded
30 90mm

20
60mm

10
30mm

0
200 700 1200 1700 2200 2700
Welding current [A]

7 |
 What can vaBW offer ?

 Innovative products
 Thinner layers
 Higher travel speed

8 |
 INNOVATION : RECORD EST 625-1 LD

 Electroslag flux for 625 strip cladding allowing to deposit:

 Fe < 7% in one layer
 Fe < 10% in a thin single layer

9 |
 Benefits of RECORD EST 625-1 LD

 Fe < 10% - thin single layer

1 layer
C Mn Si Cr Ni Nb Mo Fe thickne
ss
RECORD EST 625-1
SOUDOTAPE 625 0.025 0.20 0.30 21.5 - 3.5 9.0 7.9 5.0mm
Single layer
RECORD EST 625-1 LD
SOUDOTAPE 625 0.022 0.12 0.35 22.4 - 3.6 9.7 8.0 3.6mm
Single layer (Fe < 10%)

 Strip saving up to ~25%

Welding parameters (60x0,5mm strip) :

 Standard 625 single layer : 1250 A / 24 V / 20 cm/min
 RECORD EST 625-1 LD : 900 A / 24V / 18 cm/min

10 |
 Benefits of RECORD EST 625-1 LD

 Fe < 7% - single layer

Total
C Mn Si Cr Ni Nb Mo Fe thickne
ss
RECORD EST 201
SOUDOTAPE 625 0,020 0,10 0.30 21.5 - 3.0 8.8 2.5 8.4mm
Two layers cladding
RECORD EST 625-1 LD
SOUDOTAPE 625 0.019 0.12 0.32 22.3 - 3.6 9.6 6.1 5.0mm
Single layer (Fe < 7%)

 Only 1 layer

Welding parameters (60x0,5mm strip) :

 Standard 625 two layers : 1100 A / 24 V / 16 cm/min
 RECORD EST 625-1 LD : 1150 A / 24 V / 16 cm/min

11 |
 Slag detachability

Easy slag removal

12 |
 Beads appearance

Flat beads, straight edges, no slag adherences

13 |
 Field test

14 |
 Corrosion tests

RECORD EST 625-1 LD RECORD EST 625

Corrosion rate Corrosion rate

ASTM G48A ASTM G48A

(72h @ 50°C) 0 mm/yr (72h @ 50°C) 0 mm/yr

ASTM G48A ASTM G48A

CPT [°C] 84 CPT [°C] 85

ASTM G28A (120h) ASTM G28A (120h)

Middle of the bead 0,53 mm/yr Middle of the bead 0,68 mm/yr

ASTM G28A (120h) ASTM G28A (120h)

Overlap 0,42 mm/yr Overlap 0,65 mm/yr

15 |
 Side bend tests

As welded After
24h@670°C
Sample 10 mm 10 mm
thickness
Bending angle 180° 180° Sample 10m
m
Mandrel dia. 40 mm 40 mm

Remark No crack No crack

16 |
 Chemical analysis survey

Chemical analysis survey from base material to top surface of cladding

RECORD EST 625-1 LD <7% Fe scenario
100

Mn (%) Cr (%)
90

80 Ni (%) Mo (%)

70
Nb (%) Fe (%)
Element concentraion [%]

60

50

40

30

20

10

0
-500 -250 0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000 4250 4500 4750 5000
Distance from fusion line (0) in [µm]

17 |
 Macrography

Bead profile
Flat surface & fusion
line
Defect free
Total thickness of 5,16
mm
Geometrical dilution of
5.8%

18 |
 Microstructure

RECORD EST 625-1 LD cladding as welded. From left to right: fusion line area, middle of the bead.
Austenitic matrix with some Mo precipitates typical for Alloy 625 - Electrolytic etching 10% Cr2O3

|
19
IWS 2K16
 Microstructure

RECORD EST 625-1 LD cladding after PWHT (24h @ 670°C). From left to right: fusion line area, middle of the bead.
Austenitic matrix with some Mo precipitates typical for Alloy 625 - Electrolytic etching 10% Cr2O3

20 |
 Conclusions

New ESSC solutions for the thin single layer cladding of Alloy 625 has been
developed.

Alloy 625 composition with Fe < 10% requirement can be realized in a thin single
layer with reduced thickness

Alloy 625 composition with < 7% requirement can be realized in a single layer,
where two layers are needed for the traditional industry solution.

The new ESSC strip / flux solutions account for major time savings in terms of clad
surface in meters / hour and for savings in strip / flux consumption and satisfy all
mechanical and corrosion requirements laid down in various standards relevant to
the industry.

21 |
Thank you!
Francesco Ciccomascolo
T. +39/345/3604469
[email protected]

|
22 DATUM TITEL