Beruflich Dokumente
Kultur Dokumente
10/14/2011
CONFIDENTIAL
10/14/2011
CONFIDENTIAL
10/14/2011
CLADDING
Role of Cladding and Vapour Barriers: Contain Isolation Material To keep insulation dry. Mechanical Protection
Aluminised steel Aluminium Stainless steel Polyester etc. GRE wrap Tapes
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DAMAGED CLADDING
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INSULATION MATERIAL
Water leachable salt content. chlorides, sulphate, acidic materials in fire retardants Water retention, permeability, wettability. Insulation foams that react with water to form acids
Rockwool PU Foam
FoamFoam-glass
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WATER SOURCES
1. 2. 3.
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WATER SOURCES
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TEMPERATURE
Higher temperature: Increased corrosion rate High salt concentration Reduced life coatings
Lower temperature:
Condensation
Cyclic temperatures, Temperature gradients increase risk for Corrosion Under Insulation.
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TEMPERATURE
Carbon Steel -5 to 60C Moderate 50-120C Severe 120-150C Moderate 150-250C Cold spots >250C No risk
Stainless steel:
Stress Corrosion Cracking <50C 50-120C 120-150C >150C no SCC High Moderate no SCC
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Application
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COATING STATUS
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Difficult to seal Cold spots (Hot spots) Maintenance e.g. valves Water traps
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EQUIPMENT SHAPE
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THE CUI INSPECTION GUIDELINE CONSISTS OF TWO STEPS: Step 1: Step 2: A criticality ranking requiring limited input data. A detailed assessment and inspection plan for the high ranking items.
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The Susceptibility to CUI is determined with the dedicated questions in the Criticality Matrix for CUI. This provides a worst case assessment. The Consequence of Failure is copied from the internal corrosion failure. The Criticality Matrix gives the Criticality Ranking for CUI.
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10
1. Determine the Probability based on the cumulative score from the Susceptibility table. 2. Re-address the Criticality based on this Probability rating. 3. Determine the Confidence Rating for CUI using the dedicated Confidence Rating questionnaire. 4. Establish the Inspection/Maintenance Strategy for CUI based on the Criticality and Confidence Rating.
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Susceptibility Susceptibility C C riticality riticality R Rating ating Consequence onsequence C Confidence onfidence C Factor Factor
IS 0 IS1 IS1 IS2 IS2 Inspection Inspection IS3 IS3 Strategies Strategies IS4 IS4 IS5 IS5
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11
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CUI PREVENTION
Only insulate where necessary Use screens for personnel protection Use insulating coatings Use waterproof cladding (plastics, laminates) Use immersion coating or TSA Use non-contacting insulation
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50 - 120 C
* In cyclic service (or temporarily temperature changes), the range of the most critical temperature reached shall be taken.
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rarely wetted High Integrity (<10% of the time) Design Medium Integrity Design frequently wetted (~40% of the time) permanently wetted (e.g. cooling tower, dripping water, condensation)
4 7.1 mm or Surface at Location of Penetrations through Insulation 4 or Surface at Location of Reinforcement Rings & Other Water Traps
* The most susceptible area of the equipment determines the rating. **Can be taken from RBI study for internal corrosion.
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13
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Insulation type
Low chloride insulation material (<10ppm Cl-)
External environment
Points
Not present
Inside building Rarely wetted (<10% of the time) Permanently wetted (e.g. cooling tower, dripping water, condensation) frequently wetted (~40% of the time)
120 - 150 C
50 - 120 C
Unpainted or unknown
* In cyclic service (or temporarily temperature changes), the range of the most critical temperature reached shall be taken.
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H M L N
L L N N
MH M
H
MH M
E H
MH M
E E H
MH
L N
CONSEQUENCE CATEGORY
NO/SLIGHT MINOR DAMAGELOCAL DAMAGE MAJOR DAMAGE EXT. DAMAGE DAMAGE (<10K) (10-100K) (0.1-1M) (1-10M) ( >10M) NO/SLIGHT INJURY NO/SLIGHT EFFECT NEGLIGIBLE MINOR INJURY MAJOR INJURY SINGLE FATALITY MINOR EFFECT LOW LOCALISED EFFECT MEDIUM MAJOR EFFECT HIGH MULTIPLE FATALITIES MASSIVE EFFECT EXTREME
CONSEQUENCE CLASS
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Yes +0.1
Intermediate No 0 -0.1
+0.1
-0.1
+0.1
-0.1
For Confidence Rating add scores; minimum: -0.2, maximum: +0.2 Confidence Rating: -0.2 = very low, - 0.1 = low, 0 = medium, +0.1 = high, +0.2 = very high *In case of new equipment or piping, a 0 (zero) score shall be given for this aspect
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15
Years of protection
100% coverage (including field welds); according to the appropriate engineering standards 100% coverage (including field welds); not completely in accordance with the appropriate engineering standards No 100% coverage or unknown; poor or unknown quality
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CONFIDENCE RATING CRITICALITY VERY LOW LOW MEDIUM HIGH VERY HIGH
EXTREME HIGH MEDIUM HIGH MEDIUM LOW NEGLIGIBLE (review only) STRATEGY STRATEGY 0 0 1
STRATEGY 1
STRATEGY 1 STRATEGY
STRATEGY 2 STRATEGY 3 STRATEGY 2 STRATEGY
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Initial Action*
* Recommended maximum timing; an analysis should be performed to determine if the work should be completed within a shorter time frame.
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Equipment shell & nozzles/piping 8": Significan 100% NDE combined with t Delag 100%: 100% delagging of ALL CUI within 6 months possible wet and found susceptible areas: within 1 year* Piping & equipment nozzles 8": 100% delagging: within 1 year* (proceed according to column "Further Results") No significan t CUI found
* 50% of coating/paint protection credit can be applied, Inspection interval starting at the moment the coating/paint protection has ended ** Significant CUI means corrosion damage that requires remedial action.
Copyright of Shell Global Solutions (Malaysia) Sdn Bhd
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17
Equipment shell & nozzles/piping 8": Significan 100% NDE combined with t Delag 100%: selective delagging of CUI within 1 year possible wet and found susceptible areas: every 6 years* Piping & equipment nozzles 8": 100% delagging of ALL possible wet and susceptible areas : every 6 years* No significan t CUI found
* Inspection interval starting at the moment the coating/paint protection has ended ** Significant CUI means corrosion damage that requires remedial action.
Copyright of Shell Global Solutions (Malaysia) Sdn Bhd
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VERY LOW
LOW
MEDIUM
HIGH
VERY HIGH
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Initial Action*
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Cracking found 100% delagging of ALL possible wet and susceptible areas; check coating and perform Eddy Current testing: within 3 months*
No cracking found
100% delagging of ALL wet and susceptible areas; check coating and perform DPI: within 2 years
100% delagging within 3 months; repair & paint; repeat Initial Action: every 5 years* Adjust confidence rating with +0.1; repeat Initial Action: within 3 years
* 50% of coating/paint protection credit can be applied, Inspection interval starting at the moment the coating/paint protection has ended . CONFIDENTIAL 10/14/2011 Copyright of Shell Global Solutions (Malaysia) Sdn Bhd
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CUI PREVENTION
Only insulate where necessary Use screens for personnel protection Use insulating coatings Use waterproof cladding (plastics, laminates) Use immersion coating or TSA Use non-contacting insulation
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