Corrosion-under-insulation (CUI) guidelines

Format:

Book

Author/Creator:

Winnik, S

Contributor:

Winnik, S, Contributor.

Language:

English

Physical Description:

1 online resource (163 pages)

Edition:

2nd ed.

Place of Publication:

[Place of publication not identified] Woodhead Publishing 2016

Language Note:

English

Summary:

Corrosion-under-insulation (CUI) refers to the external corrosion of piping and vessels that occurs underneath externally clad/jacketed insulation as a result of the penetration of water. By its very nature CUI tends to remain undetected until the insulation and cladding/jacketing is removed to allow inspection or when leaks occur. CUI is a common problem shared by the refining, petrochemical, power, industrial, onshore and offshore industries. In the first edition of this book published in 2008, the EFC Working Parties WP13 and WP15 engaged together to provide guidelines on managing CUI with contributions from a number of European refining, petrochemical and offshore companies. The guidelines are intended for use on all plants and installation that contain insulated vessels, piping and equipment. The guidelines cover a risk-based inspection methodology for CUI, inspection techniques and recommended best practice for mitigating CUI, including design of plant and equipment, coatings and the use of thermal spray techniques, types of insulation, cladding/jacketing materials and protection guards. The guidelines also include case studies. The original document first published in 2008 was very successful and provided an important resource in the continuing battle to mitigate CUI. Many members of the EFC corrosion community requested an update and this has taken between 18-24 months to do so. Hopefully this revised document will continue to serve the community providing a practical source of information on how to monitor and manage insulated systems. Revised and fully updated technical guidance on managing CUI provided by EFC Working Parties WP13 and WP 15 Contributions from a number of European refining, petrochemical and offshore companies Extensive appendices that provide additional practical guidance on the implementation of corrosion-under-insulation best practice, collected practical expertise and case studies

Contents:

Front Cover

Corrosion-Under-Insulation (CUI) Guidelines: Revised Edition

Copyright

Contents

Volumes in the EFC series

Introduction

Chapter 1: Introduction

1.1 Purpose of document

References

Chapter 2:Economic consideration

2.1 Statistical analysis

2.2 Size of the issue

2.2.1 Safety and integrity

2.2.2 Environment

2.2.3 Revenue or production loss

2.2.4 Reputation

2.2.5 Collateral damage cost

2.2.6 On-line leak sealing cost

2.2.7 Repair/replacement, fabrication, and installation costs

2.2.8 Fitness for continued service

2.2.9 On-stream inspection and NDE/NDT

2.3 Key performance indicators

Chapter 3:Ownership and responsibility

3.1 Senior management

3.2 Engineering manager

3.3 Maintenance

3.4 Operations

3.5 Inspection

3.6 Members of a project team: CUI program

Chapter 4:The risk-based inspection methodology for CUI

4.1 Introduction

4.2 High-level prioritization

4.2.1 Health &amp

safety consequences (A)

4.2.2 Environmental consequences (B)

4.2.3 Economic consequences (C)

4.2.4 Impact on reputation (D)

4.3 Data validation

4.3.1 The need for data validation

4.3.2 Different aspects of a data validation

4.3.3 Implementation of data validation

4.3.4 CUI and mothballing of equipment

4.4 Challenging the need for insulation

4.5 Using RBI to design CUI inspection plans

4.5.1 Preparation of an RBI analysis

4.5.2 Susceptibility factors

4.5.2.1 Operating temperature

4.5.2.2 Coating status

4.5.2.3 Cladding/insulation condition

4.5.2.4 Available corrosion allowance

4.5.2.5 External coil/steam tracing

4.5.2.6 External environment

4.5.3 Qualitative RBI analysis

4.5.4 Semiquantitative RBI analysis

4.5.4.1 Consequence of CUI failure.

4.5.4.2 Probability of CUI failure

4.5.4.3 Risk of CUI failure

Chapter 5:Inspection activities/strategy

5.1 General considerations

5.2 Typical locations on piping circuits susceptible to CUI

5.3 Typical locations on equipment susceptible to CUI

5.3.1 Vessels, columns, and tanks

5.3.2 Heat exchangers

5.4 Examples of risk-based inspection plans

5.4.1 Evaluated risk level: High/extreme

5.4.2 Evaluated risk level: Medium-high

5.4.3 Evaluated risk level: Medium

5.4.4 Evaluated risk level: Low

5.4.5 Evaluated risk level: Negligible

Chapter 6:Nondestructive examination and testing techniques for CUI

6.1 NDE/NDT techniques

Chapter 7:Recommended best practice to mitigate CUI

7.1 Background

7.1.1 Key parameters

7.1.2 Assumptions

7.2 Current CUI prevention methods

7.3 How to achieve a life expectancy of over 25 years

7.3.1 CUI preventive measures: Recent approaches

7.3.2 Material upgrade possibilities

7.4 Benefits of TSA

7.5 Use of personnel protective guards

7.6 Use of aluminum foil to mitigate Cl-ESCC of austenitic stainless steel

Chapter 8:Design for the prevention of CUI

8.1 Introduction

8.2 Challenge the requirement for insulation

8.3 Plant layout

8.4 Mechanical considerations: Equipment and tanks

8.5 Mechanical considerations: Piping

8.6 Materials of construction

8.7 Coatings and wrappings

8.7.1 Organic coatings

8.7.2 TSA coatings

8.7.3 Insulation coatings

8.7.4 Aluminum wrapping

8.8 Insulation system

8.9 Weatherproofing

8.10 Implementation

Appendix A: Cost: Economic evaluation

Appendix B: Quality assurance

Appendix C: Additional guidelines on the implementation of CUI best practice

C.1 Maintenance and remediation issues.

C.1.1 Roles and responsibilities of maintenance and operations

C.1.1.1 Maintenance

C.1.1.2 Operations

C.1.2 Safety considerations

C.1.3 SHE concerns with asbestos and lead paint removal

C.2 Minimum standards

C.3 Types of insulation service

C.3.1 Equipment in cyclic service

C.3.2 Equipment in sweating service

C.3.3 Equipment adjacent to cooling towers

C.3.4 Equipment close to freezing point

C.3.5 Deluge systems

C.3.6 Steam tracing

C.4 Surface preparation

C.4.1 Overview

C.4.2 Scaffolding

C.4.3 Surface preparation

C.4.4 Grit blasting

C.4.5 Wet abrasion (jet cleaning)

C.4.6 Water washing at pressure

C.4.7 Wet abrasive blasting at low pressure

C.4.8 Steam cleaning

C.4.9 Vacuum blasting

C.4.10 Mechanical surface preparation

C.4.10.1 Mechanical brushing

C.4.10.2 Descaling

C.4.10.3 Pin hammer

C.4.10.4 Sanding with grinding discs

C.4.11 Nondust (vacuum) grit blast technology

C.4.11.1 Sponge jet

C.4.11.2 Solid carbon dioxide (CO 2)

Appendix D: Coatings

D.1 Introduction

D.2 Protective coatings and protective coating selection

D.3 Thermal spray aluminum

D.4 Excerpt from NACE SP0198-2010 Section 4 protective coatings

Appendix E: Application of thermal sprayed aluminum

E.1 Thermal spray application

E.1.1 Oxy-fuel wire spray-Flame spray

E.1.2 Twin wire electric arc

E.2 Use of organic topcoats

E.3 Application strategies

E.4 TSA specification

E.5 Definitions

E.6 Referenced codes, standards, and specifications

E.7 Coating philosophy

E.8 Coating system

E.9 TSA material

E.10 Seal coat

E.11 Design

E.12 Surface preparation

E.13 Weather and surface conditions

E.14 Application process

E.15 Specific requirements for on-site TSA application

E.16 Piping field welds.

E.17 Inspection and acceptance

E.18 Documentation

Appendix F Insulation material types and forms

F.1 Mineral fiber

F.2 Low density glass fiber

F.3 Calcium silicate

F.4 Cellular glass

F.5 Ceramic fiber paper

F.6 Glass rope insulation

F.7 Self-setting cement

F.8 Flexible reusable insulation cover mattresses

F.9 Preformed rigid polyurethane foam (polyurethane-polyisocynaurate)

F.10 Flexible elastomeric foam

F.11 Flexible elastomeric foam ( EPDM)

F.12 Polyethylene

F.13 Perlite

F.14 Vermiculite

Appendix G: Cladding/jacketing materials

G.1 Metallic cladding materials

G.1.1 Aluminized steel sheeting

G.1.2 Aluminum-zinc coated sheeting

G.1.3 Galvanized steel sheeting

G.1.4 Stainless steel jacketing

G.1.5 Aluminum sheeting

G.2 Nonmetallic materials

G.2.1 UV -cured, fiber-reinforced materials

G.2.2 Chlorosulfonated polyethylene

Appendix H: Use of protection guards

H.1 Design considerations

H.2 Method guidance notes

Appendix I: NDE/NDT techniques

I.1 Visual inspection

I.2 Manual ultrasonic thickness measurement through inspection openings

I.3 Radiography

I.3.1 Profile radiography

I.3.2 Flash radiography

I.4 Real-time radiography

I.5 Guided wave ultrasonic measurements

I.6 Pulsed eddy current

I.7 Digital radiography

I.8 Infrared thermography

I.9 Neutron backscatter

I.10 Dye penetrant testing

Index

Back Cover.

Notes:

Bibliographic Level Mode of Issuance: Monograph

ISBN:

0-08-100714-0