under in insulation? AOG 20 2017 17 Graham Ca Carli lisle - - PowerPoint PPT Presentation

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under in insulation? AOG 20 2017 17 Graham Ca Carli lisle - - PowerPoint PPT Presentation

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OH&S practic ices as a cause of corrosion under in insulation? AOG 20 2017 17 Graham Ca Carli lisle Princ rincipal Co Corrosion and Coa Coatin ing Engin ginee eer 2. WHY 1. THERMAL INSULATE PROPERTIES OF TOPICS 3. TYPES OF

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OH&S practic ices as a cause of corrosion under in insulation?

AOG 20 2017 17

Graham Ca Carli lisle Princ rincipal Co Corrosion and Coa Coatin ing Engin ginee eer

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TOPICS

  • 4. OH&S β€œSAFE TO

TOUCH” specs

  • 5. ISSUES WITH

INSULATION

  • 7. MAINTAINING

COMPLIANCE

  • 2. WHY

INSULATE

  • 3. TYPES OF

INSULATION

  • 10. CASE HISTORY

MEG VSESSELS

  • 11. CONCLUSION
  • 8. THERMAL

INSULATION COATINGS

  • 9. TESTING
  • 1. THERMAL

PROPERTIES OF MATERIALS

  • 6. MITIGATION

OF CUI AOG 2017

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AOG 2017

Heat transfer

Conduction Radiation Convection

  • www. coolcosmos.ipac.caltech.edu
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AOG 2017

Thermal conductance

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AOG 2017

Thermal conductance

π‘Ήβ„Žπ‘“π‘π‘’ π‘”π‘šπ‘π‘₯ = βˆ’π’ Ξ”π‘Όπ‘’π‘—π‘”π‘”π‘“π‘ π‘“π‘œπ‘‘π‘“ π‘—π‘œ π‘’π‘“π‘›π‘žπ‘“π‘ π‘π‘’π‘£π‘ π‘“ π‘΄π‘›π‘π‘’π‘“π‘ π‘—π‘π‘š π‘’β„Žπ‘—π‘‘π‘™π‘œπ‘“π‘‘π‘‘ k = thermal conductivity, where 𝑙 = π‘™π‘š + 𝑙𝑓 Q is measured in W/m2 and k in W/m-K Therefore, in a time rate of steady state heat flow through a unit area of a material π·π‘π‘œπ‘’π‘£π‘‘π‘’π‘π‘œπ‘‘π‘“ = 𝑙 𝑀

W.D. Callister, Chapt. 19- Materials Science and Engineering

Normal lattice positions for atoms Positions displaced because of vibrations

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AOG 2017

Thermal inertia

Photograph courtesy of Lockheed Missiles & Space Company, Inc.

Silica fibre insulation Internal temperature = 12500C (white-hot)

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AOG 2017

Why insulate? Thermal energy conservation

  • Use materials with low thermal

conductivities

  • Limit transfer of thermal energy
  • Insulate hot process from heat loss
  • Isolate cold process from heat gain

www.aerogel.org

To provide: οƒΌ Operational stability οƒΌ Energy efficiency οƒΌ Equipment reliability

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AOG 2017

Personal protection

B o s c h u n d s i e m e n s h a u s g e r Γ€ t e g r u p p e ISO 13732-1

1. No Burn 2. Burn Threshold 3. Burn

Time in secs

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AOG 2017

Types of insulation-Inorganic

Calcium Silicate Mineral wool Foam glass Perlite Vermiculite Aerogel

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AOG 2017

Types of insulation-Organic

Polyisocyanurate Polyurethane Rigid phenolic foam Various Elastomers Polyethylene

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AOG 2017

OH&S Specifications for β€œSafe to Touch”

Surfaces operating at temperatures in excess of 60ΒΊC (140ΒΊF) shall be fitted with personnel protection, consisting of SS 316 metal mesh guard. οƒΌ Operating above 60-700C

οƒΌ Any area that is accessible οƒΌ 2.1m vertically above grade or from platforms οƒΌ 0.9m horizontally from periphery of platforms, walkways or ladders.

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AOG 2017

Alternative personal protection

Expanded diamond SS mesh Physical hard barriers Perforated SS mesh (L) Perforated SS mesh (S) Bound wire HDG mesh

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AOG 2017

Corrosion associated with insulation-General & Localised

General & localised corrosion from moisture ingress due to damaged cladding and failed joint

  • M. Chauviere, MoniCorr Inc.

www.flowgeeks.com

Chloride (Sulphide) induced stress corrosion cracking

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AOG 2017

Corrosion associated with insulation-Galvanic Corrosion

  • M. Chauviere, MoniCorr Inc.

Galvanic corrosion from dissimilar metals due to no isolation between cathode and anode

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AOG 2017

Corrosion associated with insulation-Crevice Corrosion

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Mitigation of CUI

Insulation specification

  • Closed cell foams/Aerogels (hydrophobic)
  • Low chloride
  • Low moisture

Design detail to prevent water ingress

  • Top hats to shed water
  • Arrange cladding to shed water
  • Drain points at the base of long vertical sections
  • Waterproof seals on pipe hangers and supports
  • Avoid joints in steam tracing lines

Dry construction

  • Dry storage during shipment and storage
  • Protection during construction

AOG 2017

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Mitigation of CUI

οƒΌ Protect the substrate

  • Organic coatings (carbon and stainless steels)
  • Aluminium foil (austenitic stainless steel)
  • Inhibited insulation (silicates for the SCC of austenitic S.S.)

οƒΌ Prompt maintenance/repair of damaged cladding οƒΌ Warm air drying (recent development - limited application) οƒΌ Review the need for insulation:

  • Lower temperatures later in life
  • Use guards rather than insulation for personnel protection
  • But, beware the possibility of introducing internal dew-point

corrosion risks

AOG 2017

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Mitigation of CUI- Inspection

οƒΌ Removable β€œwindows” in cladding/insulation οƒΌ Remove insulation (common practice) οƒΌ With insulation in place:

  • Neutron back-scatter
  • Other novel NDE techniques

οƒΌ Thermal imaging

  • Detects insulation breakdown (implies water present)

οƒΌ Radiography

  • Detects corrosion thinning of pipe/vessel wall

AOG 2017

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Maintaining compliance-PP

Removing insulation or SS mesh

1. OH&S to consider thermal inertia properties of various materials in specifications 2. Use thermal insulation coatings to protect and modify surface

AOG 2017

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Thermal insulation coatings

Binders

  • Acrylic
  • Water Based Epoxy
  • Hybrid Acrylic/Epoxy
  • Polyurethane

Pigments

  • Hollow glass microspheres
  • Silica aerogels

AOG 2017

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Testing of thermal insulation coatings

Acrylic Coating Insulation Technology Approximate Thermal Conductivity (mW/m-K) Average Application Thickness- one coat (mm) Thermal Resistance per Pass (x103m2K/W) A Aerogel 35 1.5 42.9 B Ceramic microspheres 70 0.5 7.1 C Ceramic microspheres 100 0.375 3.8 D Ceramic microspheres 100 0.375 3.8 E None 300 0.1 0.3

  • P. Pescatore et. al., PCI Journal, 03/07/2013
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Test Procedure Average Values Obtained Comparative Bench Mark Values References Corrosion resistance: Cyclic wet/dry test (Prohesion)- G85-11 and D1654 – 08 No visible corrosion or coating defects after 500 hours of exposure. Rating of: 9 for plate 1 9 for plate 2 9 for plate 3 No visible corrosion or coating defects after 500 hours of exposure. 9 for epoxies The Effect of Four Commercially Available Steel Decontamination Processes

  • n the Performance of

External Coatings NACE corrosion paper, San Antonia Conference, 2014. Performance of Dry Film-Moisture vapour transmission rate- D1653-13 14 g/m2/24hr Low < 15g (m2d)-1 EN ISO 7783-2:2001 Flexibility of cured film- D522-93a(2008) 500 mm Pass (cold) 50 mm Pass (hot) No published values Flexibility and Toughness, John Fletcher and Joseph Walker in Paint and Coating Testing Manual-15th. Edition

  • f the Gardner-Sward

Handbook

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Test Procedure Average Values Obtained Comparative Bench Mark Values References Adhesion of cured film- D4541-09e1 2.53 MPa Un-exposed 4.6 MPa Cyclic wet/dry 2.47 MPa thermal cycling 4.4 MPa EPX4 to various substrates 8.2 MPa NanoPrime to Various substrates (all cohesive failures) 350 psi (2.4 MPa) 5 MPa Nansulate EPX4 data sheet Norsok M-501 Resistance to thermal cycling- D6944 βˆ’ 15 No checking No blistering No cracking No checking No blistering No cracking The Effect of Four Commercially Available Steel Decontamination Processes

  • n the Performance of

External Coatings NACE corrosion paper, San Antonia Conference, 2014. Thermal resistivity of cured film- C335/C335M-10e1 0.071 W/m.K (thermal conductivity) ~0.060 W/m.K at 70% PVC (thermal conductivity) Quantitative analysis of silica aerogel-based thermal insulation coatings, SΓΈren Kiil in Progress in Organic Coatings, 2014

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Validation of β€˜safe-to-touch’

  • H. Mitschke & G. More, Mascoat, NACE PP paper

AOG 2017

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Validation of β€˜safe-to-touch’

  • H. Mitschke & G. More, Mascoat, NACE PP paper

AOG 2017

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Validation of β€˜safe-to-touch’

AOG 2017

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Case study: thermal insulation coatings

OVERVIEW The client had a number of process vessels and piping that operated above the β€˜safe to touch’ temperature, in accessible locations. Previous strategies using traditional insulation/cladding and metallic shields had led to either CUI or bi-metallic corrosion. SOLUTION

  • IAS employed the use of a patented formulation of a thermal insulation

coating

  • Conducted a thermal survey to establish hot-spots and high risk areas
  • Specified the appropriate thickness in order to achieve the required

temperature reduction

  • Applied the Nansulate coating system and ensured hot surfaces complied

with HSE policy Removes the need for traditional insulation Live system application & 30% quicker to apply Small footprint for equipment & reduced logistics Structure Glycol regeneration package Application Type Texture sprayer Operating Environment 3 vessels Surface Preparation Power tool cleaning Diameter 1.1m Operating Temperature 80 -110ο‚°C Safe to Touch Temperature 68ο‚°C Corrosion Type Corrosion under insulation (CUI) Proven Technology

  • Nansulate Heatshield EPX4
  • NanoPrime

AOG 2017

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Case study: Thermal insulation coatings

Test points Glycol Flash Vessel 38-VD-002 (3 coats) Glycol Surge Vessel 38-VL-005 (3 coats) Cold Glycol Heat Exchanger 38-HF-003 (6 coats) Vessel shell Day 1 Day 30 Vessel shell Day 1 Day 30 Vessel shell Day 1 Day 30 Aft 660C 460C 590C 680C 510C 550C 840C 620C 750C Centre 570C 510C 600C 690C 480C 650C 880C 630C 720C Forward 630C 380C 540C 710C 450C 730C 840C 560C 510C Operating temp ~700C ~700C ~900C ~740C ~740C ~940C ~900C ~900C ~1100C

Day 30 Vessel 38 HF 003 (aft end mid level) Magnetic thermometer reading 800C Infrared reading 1030C Day 1 Vessel 38 HF 003 (aft end mid level) Thermocouple reading 620C

AOG 2017

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Conclusion

  • Traditional insulation materials for high/low temperature applications,

critical processes requiring thermal energy conservation

  • Liquid TIC can be used for uninsulated systems requiring improved

efficiencies and operating at -10 to 2050C

  • Liquid TIC for insulated systems are ideally for use where insulation was

predominantly installed for personal protection

  • TIC’s reduce incidence of CUI and as well as protecting the asset
  • Overall cost of installation is lower for TIC compared to traditional insulation

and the ease of insulation of irregular geometries is significantly better

  • TIC’s OH&S complaint???

AOG 2017

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Thank you!

Questions?

Graham Ca Carli lisle Prin rincipal Co Corrosion and Co Coatin ing Engin gineer