Corrosion Under Insulation

Part I
SABIC Saudi CUI Forum
By

Dik Betzig
Hi-Temp Coatings Technology Co.
bz@hitempcoatings.com
P +01 978 635 1110
C +01 978 844 0238
F +01 978 635 1124

Biography

Dik Betzig
BS ChE University of Massachusetts
MSE UMass Lowell, Nypro Institute of Polymer Chemistry
1978-1982 Engineered Polymer Systems, Clinton, MA
Product Development Manager
Engineered plastic compounding and extrusion. Specializing in crystal and
amorphous heat & chemical resistant resins, SBS, Nylon 66,
polycarbonates Kynor,
1982-1995 Case International, Chicago
VP General Manager/Pomco, Port Manatee, FL
Specialty concrete infrastructure: Slurry walls, Precast & post mentioned
concrete structures, Bridges, Stadiums and correctional facilities.
1995-2006: Dampney Company Inc., Boston MA
VP of Product Development & Research
Manufacturer of specialty high temperature liquid coatings for IM & OEM
2006-Present: Hi-Temp Coating Technology, Acton, MA
VP Technical Sales and R&D
Developer and manufacturer of hi temperature coatings for Industrial
applications.
Specializing in petrochemical, power generation and specialty OEM.

Understanding &
specifying solutions to
corrosion under
insulation

Introduction
In many process plants it is normal procedure to insulate
areas operating above 60C (140F), which are
accessible to operators and presents a safety risk for
burns and skin damage. At higher operating conditions it
is necessary to insulate in order to prevent heat losses
and improve the efficiency of the process.
Typically, insulation used has been based on Rockwool,
Foam Glass or Calcium Silicate. These materials have
different degrees of water uptake but all require cladding
to seal from the weather and prevent water penetrating
cracks and joints and reaching the steel surface.

The Problem

CUI can cause catastrophic accidents.

Shell Norco Refinery blew up as a direct result of
corrosion under insulation
Vast property damage and contamination
Shell bought the entire town of Good Hope, LA.
Cost of ethylene glycol antifreeze went up by 25%

Shell Narco Plant, TX

Mechanism of CUI

Availability of oxygen

As temperature increases, the amount of oxygen dissolved in

solution decreases as the boiling point is reached, resulting in
reduced corrosion rates. However, on a surface covered by
insulation a poultice effect is created which holds the moisture by
capillary action.

High temperature
For high temperature equipment water entering an insulation
material and defusing inward will eventually reach a region of dryout at the hot pipe or equipment wall. Next to the dry-out region a
zone adjacent to the pores of the insulation are filled with saturated
salt solution. When a thermal process change occurs salt solution
moves into the metal wall.

Concentration of dissolved species

When precipitation becomes trapped by insulation, corrosive
chlorides and acidic sulfides concentrate and accelerate corrosion.
The drying/wetting cycles in CUI associated problems are a strong
accelerator of corrosion damage. Formation of aggressive chemistry
can lead to the worst corrosion problems including stress, corrosion,
cracking, and premature equipment failure.

Reasons for CUI Problem

Corrosion is hidden
Inspection is limited, costly & difficult
Equipment runs at variable state
No Insulation is 100% waterproof
Wet insulation = high corrosion
Costly shut-down for equipment
There is never enough budget

Inspection of CUI
Visual procedure is to cut plugs in the
insulation that can be removed and allow
for ultrasonic testing. Corrosion tends to
be localized and this process is ineffective.
Eddy current techniques
X-ray and TV monitoring
Electromagnetic devices

Prevention of CUI
Careful selection of insulation materials
Use of protective coatings with dual
Corrosion control mechanism.
Special coating systems with proven
performance

Coating Choices for CUI

Novolac epoxies and vinylesters

Inorganic zinc
Epoxy modified silicone
Modified silicones
Silicone aluminum
IPN silicones [interpenetrating network]
Inorganic hybrids [silicone/ceramic]
TSA - Thermal spray aluminum

Novolac Epoxies & Vinylesters

Operating temperatures 20C ~ 180C

Life claimed (varies with temperature)
Mechanism is inhibitive/barrier
Good abrasion resistance
Good chemical resistance
Steady-state environment
Poor thermal cycling
Film thickness 6-10 mils (150-250 microns)
Two-component

Novolac Expoxies
Developed from Novolac hot-product tank lining
epoxies.
Have all the advantages and disadvantages of
ancestor tank linings.
Maximum operating temperature ~ 180 C
Film embrittlment at this temperature, fails above it.
Two-component, relatively low solids materials, short
pot life.
Surface preparation of SSPC SP 10 is mandatory
Recoat Intervals (minimum and maximum) are critical
Exact film thickness is critical
Thick films fail very quickly

Novolac Epoxies

Maximum Operating Temperature:

400 F./204 C.
Maximum DFT per Coat:
4 mils/100
Recoatable with self for CUI ?
Yes
Maximum Total DFT for CUI Service:
8 mils/200
Surface Prep Required for CUI:
SSPC SP 10
Single Component, No Catalyst
NO (Complex Application)*
Usable on Stainless Steel to prevent stress cracking? Yes**
Tie-in and Field Repair/Recoat with Self?
Yes
Corrosion Resistant at Ambient Temperatures?
Yes
Survives Intermittent Immersion in Hot Salt Water?
Yes
Anodic/ metal content sacrifices in Electrolyte?
No
Apply to hot surfaces? Maximum Temperature:
Yes(300F/150 C.
Suitable for Cyclic Cryogenic Service?
No

*Maximum Dry Film Thickness and Recoat Intervals are Critical

**Maximum Operating Temperature is very low for SS units.

Inorganic Zinc

Operating temperatures 20C ~ 400C

Life claimed (varies with temperature)
Mechanism is anodic sacrificial
Good abrasion resistance
Film thickness 3 mils (75 microns)
Two-component
Good thermal cycling

Inorganic Zinc Coating (IOZ)

Inorganic Zinc has been a staple of CUI systems for
decades
In the 1970s and 1980s IOZ over-coated with Thin Film Silicone
was a CUI standard

Inorganic Zinc is an ANODIC Sacrificial Coating system

In CUI service, IOZ sacrifices wherever moisture reaches the
steel
Polarity reversal in sodium chloride at 70/80C becomes anodic
and protects the zinc which is slightly acidic or alkaline
The zinc is more soluble in warm water present and any move
from neutral ph will cause an increase in solubility

Several major refinery accidents have been traced to

perforation of IOZ- coated insulated (CUI) equipment.

Inorganic Zinc Coatings (CUI)

Maximum Operating Temperature:

750 F./400 C.
Maximum DFT per Coat:
3 mils/75
Recoatable with self for CUI ?
NO
Maximum Total DFT for CUI Service:
3 mils/75
Surface Prep Required for CUI:
SSPC SP 6
Single Component, No Catalyst
NO
Usable on Stainless Steel?
NO
Tie-in and Field Repair/Recoat with Self?
NO
Corrosion Resistant at Ambient Temperatures?
Yes
Survives Intermittent Immersion in Hot Salt Water?
FAILS
Anodic/ metal content sacrifices in Electrolyte?
YES
Apply to hot surfaces? Maximum Temperature:
NO
Suitable for Cyclic Cryogenic Service?
NO

Results from Inorganic Zinc

Epoxy Modified Silicone

Operating temperatures 20C ~ 180C

Life claimed 3-10 years
Mechanism is inhibitive
Good abrasion resistance
Corrosion inhibitive mechanism
Steady-state environment
Poor thermal cycling
Moderate chemical resistance
Film thickness 10-12 mils (200-250 microns)
Two-component

Modified Silicones

Operating temperatures 20C ~ 250C

Life claimed 3-10 years
Mechanism is inhibitive
Thermo plastic
Fair abrasion resistance
Film thickness 4-5 mils (100-125 microns)
Single-component

Silicone Aluminum

Operating temperatures 20C ~ 650C

Modest abrasion resistance
Mechanism is barrier protection
Life claimed (varies with temperature)
Single-component
Good thermal cycling
Dry-heat environment
Film thickness 2-4 mils (50-100 microns)

Thin Film Silicones

Thin film Silicone Coatings survive temperatures to 1000 F./538 C.

Have minimal film build, typically 1.5 mil/37 per coat maximum
Number of coats is restricted to two or three at most.

These coatings work well on exposed hot surfaces but fail in CUI.
The thin film has no resistance to immersion or steam interface.
The thin film has no corrosion resistance at ambient temperatures.

These coating systems were superseded by polysiloxane, which has

higher DFT, but fails rapidly in cyclic service.

Thin Film Silicone Coating

Maximum Operating Temperature:

1000 F./538 C.
Maximum DFT per Coat:
1.5 mils/37
Recoatable with self for CUI ?
Yes
Maximum Total DFT for CUI Service:
4.5 mils/113
Surface Prep Required for CUI:
SSPC SP 6
Single Component, No Catalyst
Yes
Usable on Stainless Steel to prevent stress cracking? NO
Tie-in and Field Repair/Recoat with Self?
Yes
Corrosion Resistant at Ambient Temperatures?
NO
Survives Intermittent Immersion in Hot Salt Water?
FAILS
Anodic/ metal content sacrifices in Electrolyte?
YES (Aluminum)
Apply to hot surfaces? Maximum Temperature:
Yes (200F.93 C.)
Suitable for Cyclic Cryogenic Service?
NO

IPN Silicones

Operating temperatures 20C ~ 200C

Life claimed 3-10 years
Mechanism is inhibitive/barrier
Modest abrasion resistance
Multi-component
Film thickness 10-12 mils (250-300
microns)

IPN Silicone

This new class of products have been included in the new NACE RP for
offshore structures maintenance.

They combine new resin technology and higher build characteristics

than thin-film silicones and do not exhibit the micro cracking failure on
cyclic service of polysiloxanes.

Characteristics of these products vary considerably, Specialty Coatings

Technologies are listed separately.

IPN Silicone

Maximum Operating Temperature:

800 F./427 C.
Maximum DFT per Coat:
6 mils/150
Recoatable with self for CUI ?
Yes
Maximum Total DFT for CUI Service:
8 mils/200
Surface Prep Required for CUI:
SSPC SP 6
Single Component, No Catalyst
NO
Usable on Stainless Steel to prevent stress cracking? Yes*
Tie-in and Field Repair/Recoat with Self?
Yes
Corrosion Resistant at Ambient Temperatures?
Yes
Survives Intermittent Immersion in Hot Salt Water?
Not Recommended
Anodic/ metal content sacrifices in Electrolyte?
YES (Aluminum)
Apply to hot surfaces? Maximum Temperature:
Yes(250 F.120 C.
Suitable for Cyclic Cryogenic Service?
Yes

*Aluminum content may affect Stainless Steel

Inorganic Hybrids

Operating temperatures 20C ~ 600C

Life claimed [varies with temperature]
Mechanism is anodic barrier
Good abrasion resistance
Film thickness 4-6 mils (100-150 microns)
Good thermal cycling
Multi-component

TSA - Thermal Spray Aluminum

Operating temperatures -100C ~ 500C
Life claimed 25 - 30 years with minimal
maintenance
Mechanism is anodic sacrificial
Excellent abrasion resistance
Film thickness 8-10 mils (200-250
microns)
Sealant required for best performance

TSA Thermal Spray Aluminum

Thermal Spray Aluminum has a good track record on
exposed surfaces such as sheet piling, docks and buoys.
Some specifiers recommend TSA for CUI service
this is a mistake

TSA is an Anodic, Sacrificial Coating system

Once the TSA is sacrificed, electrolytic corrosion
accelerates.
Should be over-coated with inert films
Cannot be easily repaired
Recent testing (NACE 2006) shows TSA in hot salt water
immersion fails quickly

Thermal Spray Aluminum (TSA)

Maximum Operating Temperature:

1170F/610C.
Maximum DFT per Coat:
8 mils/200
Rec-oatable with self for CUI
NO
Maximum Total DFT for CUI Service:
8-12 mils/200
Surface Prep Required for CUI:
SSPC SP 10
Single Component, complex application
Yes
Usable on Stainless Steel to prevent stress cracking NO
Tie-in and Field Repair/Recoat with Self?
NO
Corrosion Resistant at Ambient Temperatures
Yes
Survives Intermittent Immersion in Hot Salt Water
FAILS
Anodic/ metal content sacrifices in Electrolyte
YES
Suitable for Cyclic Cryogenic Service?
Yes

Coating Criteria for New Construction

Incoming steel is abrasive blasted and zinc
coated
Service temperature is determined after zinc
coating
Must provide zinc-compatible hi-temp
systems
Air-dry, storable, transportable topcoats and
systems
Minimal damage to coatings during
installation
Quick and easy field touchup of welds and
damage
Compatible with specified insulation

Generic Products
High Solids Epoxy Novolac
Service temperature to 180C
Film thickness 4 mils (100 microns)

High Build Ethyl Silicate

Service temperature to 500C
Film thickness 5 mils (125 microns)

Silicone Aluminum
Service temperature to 600C
Film thickness 2 mils (50 microns)

Polysiloxane/Silicone
Service temperature to 500 C
Film thickness 406 mils (100-150 microns)

Future Products
Next generation coatings:
Single-coat system
Suitable for use cryogenic to 500C
Wet & dry cyclic performance
Suitable over wet blasting
Can be used for M&R or new construction
Surface tolerant
Dual mechanism barrier & inhibitive
Chemical resistant

Deficiencies associated with

current CUI coatings
Thin film resulting in pinpoint rusting / corrosion
Lack of coatings that can be applied while the
unit is online & hot
Thermal shock capabilities
The need for surface preparation
Wet & Dry thermal cycles
Heat cure issues
Short recoat windows

Comparison of Current CUI Systems

Novolac
Epoxies

HTC-1027
Primer

TSA
Aluminum

Traditional
Silicones

Inorganic
Zinc

New IPN
Technology

Maximum
Temp.

200 C

600 C
Cont.

600 C
Peaks

500 C

400 C

500 C

Maximum
DFT

12 Mils

30 Mils

8 Mils

4 Mils

3 Mils

8Mils

Re-coatable

No

Yes

No

No

No

Yes

Components

N/A

multi

DFT per coat 4 mils

6 mils

8 mils

1.5 mils

3 mils

6 mils

Wet & Dry

Poor

Excellent

Good

Poor

Poor

Good

Mechanism

Inhibitive

Barrier

Anodic
Sacrificial

Inhibitive

Anodic
Sacrificial

Barrier/
Inhibitive

High-build
Properties

Fair

Excellent

NO

NO

NO

Fair

Abrasion

Good

Fair

Excellent

Poor

Poor

Good

Life claimed
(yrs)

3-10

7-15

20-25

3-10

Varies

7-15

Interval
Critical

Yes

No

N/A

Yes

1 Coat

No

Under Corrosion Insulation

Part II
A Systems Approach

Solving CUI
Clearly then, for most circumstances, corrosion
under insulation can be prevented in two ways:

By using a coating system which will

prevent corrosion in the potentially hot, wet
conditions existing under the insulation.

Design insulation which will not be easily

damaged and will prevent water ingress either
by nature of the insulation or by an alternative
more effective method of cladding.

Standard Testing for [CUI]

Coatings

ASTM B-117 SALT FOG

Scribed panel
2500 hours minimum SALT FOG TEST
No under-creep

UV RESISTANCE
INTERMITTENT IMMERSION

Hot Water Intermittent Immersion Tests

ASTM 2485
Dry thermal cycling test [200oC to failure]

Performance Criteria for (CUI)

Carbon Steel

Resistance to Boiling Water [steam interface]

Heat and Thermal Shock Resistance
Direct Application to Hot Steel (up to 500 F./260C.)
Application to Ambient Steel (new construction)
High Film Build Capability while Applying Directly to Hot
Steel
Application to a less than perfect surface preparation
Prevention of chloride induced stress corrosion cracking
Ideal for cyclic Service, including Cryogenic Temperatures
Simple to Use
Meets tightest current VOC and Environmental regulations

Performance Criteria for Stainless

Provides protection for insulated austenitic
stainless steels against chloride induced
external stress corrosion cracking
Contains a minimum of chloride, sulfides,
and halides
Thickness provides good barrier protection

Independent Testing Protocol by one of the

worlds largest
oil & chemical companies
to prevent corrosion under insulation for
application in their global under insulation
program

Testing Procedure
1) In dry oven at 208C for 16 hours - heat
resistance.
2) Quenched into cold water - thermal shock
resistance.
3) 99C water for 8 hours.
4) Repeat steps Monday through Friday
5) In oven at 208C for 2-1/2 days
6) Quench panel into cold water..

Repeat Test For An Additional 15 Weeks

Panels are periodically checked for cracking,
fracturing, de-lamination, pinholes,
corrosion, micro-cracking, softening,
blistering, etc.

Summery of Test

2240 hours cycling

Thermal quenches 80
Immersion in 99C water 640 hours
Coating survived for 16 weeks

Summary CUI
1. Chemical Plant Equipment
CUI is more accelerated than common
atmospheric corrosion

2. The corrosion rate in the drying and

wetting cycles is at the maximum
immediately before drying
3. Corrosion during thermal cycling is 10-20
times greater than immersion service

Conclusion
Designers should select a CUI system which
best combines:
Current cost effectiveness
Ease of application and insulation
Tolerance for expected future increases in
operating temperatures
Unexpected excursions from normal
Ability to repair after service life without
requiring complete removal of the original
protective system

Questions ???