SUCCESSFUL METHODS FOR MITIGATION OF CORROSION UNDER INSULATION - - PowerPoint PPT Presentation

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SUCCESSFUL METHODS FOR MITIGATION OF CORROSION UNDER INSULATION - - PowerPoint PPT Presentation

Aug 24, 2022 17 likes •334 views

SUCCESSFUL METHODS FOR MITIGATION OF CORROSION UNDER INSULATION (C.U.I.) AND OTHER CREVICE CORROSION USING SURFACE CONVERSION TECHNOLOGY Patrick J, Dunn Sr. Vice President Mechanical Products Division Polyguard Products, Inc. P.O. Box 755

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SUCCESSFUL METHODS FOR MITIGATION OF CORROSION UNDER INSULATION (C.U.I.) AND OTHER CREVICE CORROSION USING SURFACE CONVERSION TECHNOLOGY

Patrick J, Dunn Sr. Vice President – Mechanical Products Division Polyguard Products, Inc. P.O. Box 755 Ennis, Texas 75120 pjd@polyguardproducts.com

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Corrosion Under Insulation (CUI)

 CUI has been recognized as a problem in many industries  Insulation is a necessary component of the system and is

designed to:

 Save energy  Control process temperatures  Protect workers from high temperatures

 NACE Standard RP0198-981 is a good source of

information, but electrolytes will eventually find their way into even the best system

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Corrosion Under Insulation

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Selecting the Correct Coating System

 Performance

 Operating T emperatures  Moisture Resistance  Anti-Corrosion Properties

 Application

 Surface Prep  Dry/ Cure Time  Labor & Equipment Requirements

 T

  • tal Cost

 Product  Application  Ease of Maintenance  Comparison of TOTAL installed cost is recommended

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Anti-Corrosion Gel

 Performance

 Operating T

emperatures – up to 350°

 Moisture Resistance – Hydrophobic  Anti-Corrosion Properties – Mineralization & Buffering

T echnology

 Application

 Surface Prep – SP-2 or better  Dry/ Cure Time - None  Labor & Equipment Requirements - Minimal

 Cost

 Installed cost is typically lower than other systems

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Technology

 The technology works in three basic ways

 Barrier system – The specially formulated products have

great adhesion characteristics and are hydrophobic to help keep moisture away from the substrate.

 M ineralization - Growing an engineered surface, or surface

conversion – creating a surface which resists corrosion even if moisture gets to it .

 Buffering system – If moisture migrates through the gel, it

is buffered to a high pH which is alkaline enough not to corrode metal.

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Basic Science

Metal surface: Oxides Metal carbonates Metal hydroxides METAL Polymerized metal silicate lattice METAL Protected surface Extended surface Mineral formation METAL Metal surface METAL

Surface conversion technology, also known as mineralization, is the ability to grow very thin minerals on metal surfaces. The mineral forms when reactants are delivered to the surface of a metal or metal containing

  • article. Substrates contribute ions that form a thin layer of

mineral, which chemically bonds to the surface of the metal and has been measured to be 50-200 angstroms thick. Lattice-forming oxides anchor to this surface layer and polymerize into a three-dimensional inorganic framework until the final surface is formed. Patents and patent applications cover unique formulations as well as the mineralized layer that is formed.

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Surface Formation

Untreated steel surface M ineralized steel surface

10 um 10 um

The presence of the mineralized layer can be confirmed by conventional analytical surface methods such as x-ray Photoelectron Spectroscopy (XPS)

  • r

Atomic Force M icroscope (AFM )

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  • Automotive

– T echnology has been used in automotive applications for approximately 30 years. – Crevice Corrosion on Brake Cables

  • Industrial Applications

– First industrial application was with the US Navy. Solved their #1 and #2 corrosion maintenance problem. – Watertight Door Latching Mechanisms – Deck Edge Elevator Wire Ropes

History of the Technology

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1 1

2 Y ear Salt Water Immersion Test

Samples were prepared with fiberglass pipe insulation, surface conversion gel technology and placed in a 5% aerated salt bath.

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2 Y ear Salt Water Immersion Test

Samples were removed at timed intervals to determine protection of substrate

10 DAYS 81 DAYS 138 DAYS 365 DAYS

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1 3

2 Y ear Salt Water Immersion Test

TWO YEAR IMMERSION 55mil PER YEAR CORROSION RATE

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1 4

2 Y ear Salt Water Immersion Test

One uninsulated pipe in the test proved that the Gel does not undercut

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Undercutting Test

2000 hrs ASTM B117 Salt Spray Gel Protected Steel Panel 2000 hrs ASTM B117 Salt Spray Gel Removed

One unique property of gel surface conversion technology is that the gel will not undercut like a hardening barrier coating will.

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Isothermal Testing

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Weight Loss Testing

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Corrosion Under Insulation (CUI)

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Corrosion Under Insulation (CUI)

Ammonia Piping Remediation

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CUI - North Slope 2003

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CUI - North Slope

2010 Inspection

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CUI – Bundled Pipe

Corrosion Remediation of Bundled Pipe System (BIR)

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CUI – Bundled Pipe (BIR)

X-Ray Inspection Through Insulation

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CUI – Bundled Pipe (BIR)

Remove Metal Jacket Remove Insulation

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CUI – Bundled Pipe (BIR)

Removal of Aged Mastic

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CUI – Bundled Pipe (BIR)

Physical Inspection of Pipes Removal of Rust Scale with wire brush and pot scrubber

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CUI – Bundled Pipe (BIR)

Install of Corrosion Gel Uniform Thickness Trowel

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CUI – Bundled Pipe (BIR)

Install Stand-offs and Insulation Install Metal Jacketing

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DOWNHOLE CORROSION PROTECTION

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Benefits of the Technology:

 Practical products and applications  Multiple delivery systems  Ease of application  Insensitive to surface preparation and application

conditions (SP-2 Hand T

  • ol Cleaning or better)

 Superior anti-corrosion performance  Environmentally benign  Easy to inspect

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Companies With Product Installations

  • OxyChem
  • Equistar
  • Union Carbide
  • Cytec
  • Phillips
  • MODOT-Missouri Dept of Transportaton
  • Nicor
  • Tesoro Refinery
  • Monarch Foods
  • Safeway
  • U.S. Navy
  • Kraft Foods
  • Dow Chemical
  • Schepps Dairy
  • ConocoPhillips - downhole
  • Coors Brewing
  • Canada Hydro
  • Indiana University – Chiller Pipe
  • Southgate Foods
  • Wal-Mart
  • Scotia Bank Toronto (CHW)
  • Shepps Dairy
  • Chevron
  • Budweiser
  • General Mills
  • Nestle
  • Green Giant
  • British Petroleum
  • Best Brands Foods
  • Philadelphia Gas
  • Fred Meyer Foods
  • Unocal – AK Oil Platforms
  • Dot Foods
  • ExxonMobil
  • Sakhalin Island Steam Lines

Phase I Phase II

  • Downhole Wells Alaska
  • Alta-Dena Dairy
  • Conagra
  • Tyson Foods
  • Tyson Chicken
  • Tyson Fresh Meats
  • Kroger
  • US Cold Storage
  • Publix Grocers
  • Tombstone Pizza

The entities listed above have used and/or specified surface conversion technology on one or more projects, however, the naming of these entities do not imply advertisement or public endorsement of the product.