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Topic-2: Corrosion Under Isolation (More About The Procedure, And/or Example of Certain CUI Plan) "

This document discusses corrosion under insulation (CUI) on an amine absorber column. A small hole was found on the mantle near the vacuum ring, caused by CUI. The root cause was determined to be inappropriate insulation design that allowed rainwater to flow under the insulation sheet. Standards and guidelines on CUI risk assessment, detection, and mitigation are referenced. Key learnings include the importance of insulation design/installation to prevent water trapping, and using appropriate coatings and insulation maintenance to prevent CUI.

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69 views

Topic-2: Corrosion Under Isolation (More About The Procedure, And/or Example of Certain CUI Plan) "

This document discusses corrosion under insulation (CUI) on an amine absorber column. A small hole was found on the mantle near the vacuum ring, caused by CUI. The root cause was determined to be inappropriate insulation design that allowed rainwater to flow under the insulation sheet. Standards and guidelines on CUI risk assessment, detection, and mitigation are referenced. Key learnings include the importance of insulation design/installation to prevent water trapping, and using appropriate coatings and insulation maintenance to prevent CUI.

Uploaded by

tcsabai
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Topic-2

 „Corrosion under isolation (more about


the procedure, and/or example of
certain CUI plan)”

 Problem: Localized pitting corrosion and


local loss of wall thickness

 Temperature range of CUI is: -12°C and


175°C are operating temps on carbon
steel, most severe when the metal
temps is between 100°C and 120°C

 Solution?
 CUI and deadleg corrosin Map
(where water can collect)
 Proper cotings
 Plannedd nspection and isolation
repair
Standards

 NACE Standard RP0198-2004, The Control of Corrosion


Under Thermal Insulation, and Fireproofing – A Systems
Approach, NACE International, Houston TX
 API Publication 570, Piping Inspection Code – Inspection,
Repair, Alteration, and Rerating of In-Service Piping Systems,
American Petroleum Institute, Washington D.C.
 API Publication RP571, Damage Mechanisms Affecting Fixed
Equipment in the Refining Industry, American Petroleum
Institute, Washington D.C.
 API Publication RP581, Risk Based Inspection, American
Petroleum Institute, Washington D.C.
Detection CUI risk flowchart

CUI and deadleg corrosin Map


(where water can collect)
Using proper (tested)cotings
Planned inspection and
isolation repair
CUI Probability, Susceptibility, Consequence

 Determining CUI Susceptibility: Confidence Rating


– Operating Temperature
– Initial Coating Status • cladding & insulation condition
• number & quality of CUI
– Insulation Type
inspections
– Wall Thickness & Surface Features • knowledge of CUI promoting
– External Coil/Steam Tracing conditions
– External Environment
– Determining Internal Corrosion/Erosion Rate
 Determining CUI Consequence:
– Environmental consequences
– Health & Safety consequences
– Economic consequences (including production loss!)
ASM, NACE, API CUI temperatures vs corrosion rate of Carbon
Steel
Likehood of failure analysis by API 581 and RBI
CUI management check list, inspection and solution of MOL

 Input data: Inspection methods


– Pipe/equipment name
• Visual inspection
– Number of isometry
• UT /Radiographic inspection
– Number of corrosion loop (if have) • Holiday detection of
– Is insulation justified (yes/no)? painting/coating
– Type of insulating material?
– Is there any damage to the insulation
– Environmental factors
– Typical operating temperature [°C]?
– Cyclic operation (yes/no)? (Cyclic heat load/effect?)
– Should improve the insulation (yes/no)?

Solution
Apply asset integrity techniques
Risk based inspection and maintenance
API 570 Inspection strategy #19
Back up

A
What happened?
On 9th February 2019 the operator
felt a smell of hydrogen sulfide
around the low pressure amine
absorber column No. K801
During examination of the column he
noticed that amine is slightly leaking
from the insulation close to the
vacuum ring
After removing the insulation a small
hole was found on the mantle, close
to the vacuum ring

Root cause
The insulation design was not appropriate at
vacuum ring. The ring wasn’t covered by the
plate of the insulation
The rain-water flowed under the insulation
sheet and this caused CUI (Corrosion under
insulation)
Operating parameters of
absorber column No. K801 : Vacuum ring
t = 35-40 °C
p= 0,5 barg
Technological function: low pressure amine absorber
Medium: MDEA solution and hydrocarbon gases with
sulfur content
Mantle material: HII DIN17155 (equivalent to
P265GH)

Corrosion
under
insulation
(CUI)

Vacuum ring
Corrective actions:
The hole was temporary repaired with Stick-o-steel metal filled epoxy, bandaged and patched
with titan paste.
The repaired mantle part was painted.
The disassembled insulation is properly reinstalled (cover the vacuum ring with the aluminum
plate of the insulation).
Final repair will be executed during the catalyst replacement of the unit in summer. The plan
is to replace one part of the mantle above the vacuum ring.

Location of the leakage After temporary repair


Learnings:
Design and condition of insulation system, insulation type, temperature and
environment are critical factors
 Poor design and/or installation that allow water to become trapped will increase
CUI
 CUI can be found on equipment with damaged insulation or insulation termination
points such as flanges, pipe supports, insulation plugs for inspection.
 Insulating materials that hold moisture can be more of a problem (closed cell foam
glass will not hold water/vapors, mineral wool will hold a good amount of water).
 Equipment that operates below the water dewpoint tends to condensate water on
the metal surface, thus providing a wet environment and increasing corrosion
 Contaminants such as chlorides can increase the risk of corrosion.
(Marine environment, close to cooling tower and stack emission can accelerate
corrosion.)

Prevention is best achieved by using appropriate paints/coating


on the metal surface and maintaining insulation to prevent moisture ingress.

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