The document outlines a program to minimize occurrences and severity of corrosion under insulation (CUI) at an oil refinery. It identifies 12 common problems that can lead to CUI and recommends solutions. General recommendations include using calcium silicate insulation for temperatures over 350°F, cellular glass below 350°F, and continuing use of aluminum jacketing with a moisture barrier and removable/reusable blankets where needed. Implementing the solutions and recommendations would enhance safety by reducing CUI and extending the life of insulated pipes and equipment at the refinery.
1. Program for CUI Prevention
at a Refinery
Gordon H. Hart, P.E.
Artek Engineering, LLC
Bring on the Heat 2013
New Orleans, LA
June 6, 2013
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2. Project Objectives
• Make recommendations to an oil refinery on
methods for minimizing occurrences and severity
of Corrosion Under Insulation
• Maintain as many existing materials, procedures,
and practices as practical while reducing CUI
• Minimize insulation first cost and life cycle cost
• Maximize life of pipe & equipment and of
insulation systems
• Enhance safety at the refinery
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3. Primary Methods
• Identify practices that should be continued
• Identify practices that should be changed and
recommend new practices
• Identify practices that should be discontinued
• Recommend new practices to minimize water
intrusion into thermal insulation
• Premise: there is no single “silver bullet”
solution to reducing CUI
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4. References
1. NACE Standard Practice 0198-2010: “Control
of Corrosion Under Thermal Insulation and
Fireproofing Materials—A Systems
Approach”
2. API Recommended Practice 583, 2nd Draft
(Sept, 2012), “Corrosion Under Insulation
and Fireproofing”.
3. Several articles from journals
4. ASTM material specifications
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5. Background
• Refinery site for over 100 years
• Two units constructed in late ‘60’s, early ‘70’s using
asbestos-reinforced calcium silicate insulation with
aluminum jacket (with much still in place)
• Several other units constructed since then mostly using
asbestos-free cal-sil insulation
• Use of cellular glass insulation, for pipes with operating
temps < 450°F, started in 2010
• Removable/Reusable blankets used on many heat
exchanger heads & valve bodies but not on flanges
• Use of protective coatings has started recently
• Steam tracing is being replaced by electric tracing
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8. What are some of the problems?
• Pipe thinning due to CUI at certain locations (i.e.,
a pipe is only as strong as its weakest point)
• Limited budget for X-ray examination of pipes
and only smaller pipes can be done
• Limited budget for insulation maintenance and
replacement
• Most older pipes & equipment were never coated
for protection for CUI
• Some pipes were insulated that may not need it
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12. Problem # 2: Use of low compressive
strength insulation on many fittings
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13. Solution to Problem # 2: use high
compressive strength insulation at fittings
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Use of low CS insulation at elbows, on left, and high CS insulation at elbows, on right
34. General Recommendation # 1:
Use calcium silicate for temps ≥ 350°F
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Features & Benefits: (1) very high, 100 psi compressive strength, (2) non-
combustible (3) chemically inhibited and hence does not contribute to
corrosion of steel when wet (4) maintains high strength up to 1200°F (5) long
history of successful use at temps ≥ 350°F
35. General Recommendation # 2:
Use cellular glass for temps < 350°F
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Features & Benefits: (1) does not absorb water (2) fairly high, 60 psi
compressive strength, (3) non-combustible (4) does not contribute to
corrosion of steel
36. General Recommendation # 3: Continue using
aluminum jacket w/ polysurlyn moisture barrier
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Features & Benefits: (1) resistant to corrosion from HCs (2) inside moisture barrier
is resistant to galvanic & pitting corrosion (3) when sealed, keeps out water
37. General Recommendation # 4:
continue using R/R blankets where
accessibility is needed
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Features & Benefits: (1) removable &
reusable insulation allows for
mechanical maintenance (2)
insulates effectively (3) does not
absorb & hold water against steel
surfaces (4) durable materials
38. Other General Recommendations – either
replace with specified materials or
5. Seal damaged aluminum jacket with caulk
(prevents water intrusion)
6. Seal lap joints at 90° & gaps with metalized PSA
tape or replace (prevents water intrusion)
7. Use protective coatings where operating
temperature allows (protects steel from
corrosion)
8. Use temporary wrap insulation that is suitable
for operating conditions (does not hold water
against steel surfaces and meets temperature
requirements)
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39. Thank you for your attention
• Are there any questions?
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