Corrosion Under Insulaton Awareness Basic Training 2013

Corrosion Under Insulation (CUI)
Awareness Basic Training
Mar, 2013
Darya Ding (Ding Yu)
A&OI, COPC
-1-
CONTENT
• Objective / Background目标/背景
• What is CUI / How it comes to CUI何为CUI /
CUI如何产生
• CUI in Peng Lai Oil Field 蓬莱油田CUI现状
• How we manage CUI issue 我们如何管理CUI
• Early Signs of CUI CUI的早期迹象
-2-
CONTENT
• Objective / Background目标/背景
• What is CUI / How it comes to CUI
• CUI in Peng Lai Oil Field
• How we manage CUI issue
• Early Signs of CUI
-3-
Objective
Understand CUI causes and
consequences了解CUI的产生原因及后果
Promote CUI Awareness in Bohai
Operations. 提升蓬莱作业区人员对保温下腐
蚀的认识
Understand how individual can
contribute to CUI management了解我们
每个人在CUI管理中的作用
-4-
Background
– Service Year of PL offshore facilities:
Aged facilities: service longer than 5 years
As time goes on, and more projects
(MOC/Repair/Maintenance/Inspection…), CUI would be present in new
facilities
五年为CUI易发的重要时间点
-5-
Background
– Service Year (5‐Year)
NACE SP0198‐2010 Standard Practice Control of Corrosion
Under Thermal Insulation and Fireproofing Materials
美国腐蚀工程师协会标准
6.2.3 Age of Equipment
6.2.3.1 How long has the equipment been in service since last
insulated?
Because CUI is an insidious problem, it is helpful to check records
for when the equipment was installed or last insulated. CUI
problems are commonly found to be significant after about five
years
-6-
Background
– Service Year (5‐Year) 美国石油协会检验相关标准
API 570 Piping Inspection Code, Sec.6.4 (table 2) 管线检验
API 510 Pressure Vessel Inspection Code, Sec.6.4.1 压力容器检验
6.4 External Inspection
6.4.1 Unless justified by an RBI assessment, each aboveground
vessel shall be given a visual external inspection at an interval
that does not exceed the lesser of five years or the required
internal/on‐stream inspection.
-7-
Background
Spill Risk Assessment in Sep, 2012 漏油风险评价
To make more
efforts on
valuable tasks
-8-
CONTENT
• Objective / Background
• What is CUI / How it comes to CUI何为CUI /
CUI如何产生
-9-
What is CUI
• Corrosion Under Insulation – CUI
– A particular insidious form of corrosion : may actively
corroded metal underneath an insulation system that
appears to be intact. 腐蚀无法用肉眼直接观测到.
Occurs on the Equipment including all objects in a facility
with external metal surfaces that are insulated or
fireproofed (CUF) and subject to corrosion.发生于与绝缘
层/保温层接触的金属表面.
- 10 -
Insulation Role in CUI
– Equipment insulated for: hot or cold equipment for
personnel protection, acoustic dampening, energy
conservation or process stabilization
绝缘/保温的作用.
Jacketing An annular space or
crevice for retention of
water or other corrosive
media存水
A material that may wick
or absorb water吸水
Insulation material Steel
pipe More introduction in
later section污染物
What CUI Looks Like?
North Sea Australia
Alaska Australia
- 12 -
Source: COPC A&OI NoE Website
Terminate
at flange
- 13 -
Source: CUI Inspection and Maintenance Standard COP V.3
As first viewed by a sharp pair
of eyes walking about the unit…
After stripping insulation; CUI
caused pitting on the elbow
down to anomaly wall
thickness loss
- 14 -
Source: External Corrosion Awareness Training CBT
Weather jacket
overlapped wrong way
on vertical line resulted
in water ingress & CUI
CUI failures can
have high
consequences.
This CUI failure
on a naphtha
line resulted in a
fire & caused
severe damage
to the upper
portion of a
Rupture & leak tower.
here led to fire
- 15 -
Source: External Corrosion Awareness Training CBT
How Comes to CUI
• The Factors acted and towards to CUI
Duration of exposure to Insulation type,
moisture,
Condition of weather
Frequency of the exposure to barriers and caulking,
moisture,
Type of climate,
Corrosiveity of the aqueous
Site maintenance practices
environment,
and
Condition of protective barriers
Leaking steam tracing
(e.g. coating and jacketing )
systems
Equipment design issues,
Service exposure temperature,
- 16 -
Source: API 583 CUI & CUF
How Comes to CUI
• The Factors acted and towards to CUI
Environment 环境
Process Condition工艺条件
Equipment (Piping) Material / Design设备材料及设计
Insulation Material保温材料
Coating涂层
- 17 -
The Factors acted and towards to CUI
Environment
oThe metal contacted aerated water:
Coastal environments wet & water ingress潮湿的海
洋大气环境 / 水的进入
External contaminants污染物（杂质）
- 18 -
Environment
o The metal contacted aerated water:
Coastal environments wet & water ingress
Sources of water under insulation:
Infiltration from external: thru weather proofing
breaks 水通过外部夹克破损后的侵入
Forms of WATER 各种形态的“水”
Weatherproofing BREAKS 外部保温夹克的破损
Condensation: when temp. of the metal surface is
lower than the atmospheric dew point 冷凝作用
- 19 -
Environment: evidence of water
- 20 -
Source: ABU Piping CUI Procedure
Environment
o The metal contacted aerated water:
External contaminants
Sources of external contaminants:
Cooling tower drift, acid rain, atmospheric
emissions 外部污染，如酸雨，大气中的排放物
Go thru weatherproofing directly/indirectly 直接/
间接通过外部保温夹克层进入
- 21 -
Process Condition
o Temperature
10F to 350F / ‐12°C to 175°C for carbon steels(碳钢); 140F to 400F / 60°C
to 204°C for stainless steels（不锈钢）;
Simple Risk Rating:
9 HIGH ‐ Between 30°C and 120°C.
9 MEDIUM ‐ Between ‐4°C and 30°C, also between
120°C and 260°C.
9LOW ‐ Below ‐4°C and above 260°C.
- 22 -
Process Condition
o Temperature
Field measurements of CR of
CS under insulation, similar to
that of a closed system‐
oxygen saturated
CUI与封闭系统中的外部腐
蚀类型类似，原因：溶解氧
的水溶液，在温度范围内的
腐蚀速率变化。
Effect of temperature on steel corrosion in water
- 23 -
Source: NACE RP 0198
Process Condition
o Insulation Installation 保温材料的安装（也包括设计）
- 24 -
Source: ABU CUI Inspection Guidance
Process Condition
o Operating condition 操作条件
Intermittent or variable (cyclic service) operation
of equipment; 间歇操作
Temperature variations along the height or length
of the equipment;
Temperature at which attachments to equipment
operate; and
Idle or mothballed conditions 闲置设备
- 25 -
Equipment (Piping) Material / Design
o Carbon Steel / low alloy:
Locations which allow for water ingress are mostly those
With protrusions extending through the insulation;
Water intrusion areas;
Far away from water ingress points, may also suffer badly
from CUI, because of water migrating through the
system;
Water accumulated locations;
Bad thermal capacity of the piping or equipment
设备上有穿过保温的突出连接件的;水入侵区域及非入
侵区域；积水位置；(材料的) 导热能力差的设备
- 26 -
Equipment (Piping) Material /Design‐‐Protrusions
- 27 -
Source: NACE RP 0198
The presence of insulation is not a requirement.
Thermal insulation primarily provides a medium to hold and transport
the water with its chlorides to the metal surface.
Coating can prevent CUI effectively.
Equipment (Piping) Material
o Stainless Steel 对不锈钢而言，有无保温，保温是何材料，腐蚀
发生机理多为外部氯化物应力腐蚀开裂，良好的有效的涂层可防止这
种外腐蚀发生：氯化物侵入，应力集中，温度条件
For S/S the term CUI refers to Chloride External Stress
Corrosion Cracking (Cl‐ESCC).
Chlorides in the permeated water can, depending on the
temperatures, cause CL‐ESCC in AISI Type 300 series austenitic
stainless steel: typically found in stressed areas (such as welds),
where chloride ions dissolved in water are in contact with type
300 stainless steel at temperatures above 50°C.
- 28 -
Coating
o The main barrier between the steel surface and its
environment.
o The condition of the coating is crucial. Coatings
degrade with age.
o A poorly applied coating system can be worse than no
coating, since it can accelerate corrosion by
concentrating the corrosive effect on areas of coating
breakdown.
涂层：设备防腐的主要方式之一，金属表面和外部环
境之间的重要屏障。涂层质量和维修尤为重要。
- 29 -
Source: NACE 0198 S4 T1 for S/S, T1 for C/S
- 30 -
Source: Above Ground Pipe External Condition Examination Competent Person Training –L48
Insulation Material
Water‐leachable salt content in insulation, such as
chloride, sulfate, and acidic materials in fire retardants, that
may contribute to corrosion; 盐分及防火材料中的酸性物
质
Water retention, permeability, and wet ability of the
insulation; and 保水力，渗透性
Foams containing residual compounds that react with
water to form hydrochloric or other acids. 泡沫中的残余
物质与水形成盐酸等其他酸
- 31 -
Insulation Material
Foam glass vs. Mineral wool Benefits
• Reduced risk of water ingress and CUI
• Considerably lower maintenance costs
• Easier to remove in connection with inspection
• No danger of cutting fingers
• Wetting does not change insulation properties
• Temperature range ‐260C to +430C
- 32 -
Source: Data from CUI material of NSBU
Thinking Map Screening CUI issues
for Detailed Review
The factors
list here as
mentioned
before…
Just for
Reference
- 33 -
Source: EFC CUI guideline / UK
• The main factors below acted and towards to CUI
Moisture湿润环境
CUI
Triangle
Susceptible Temperature
Material
温度条件
敏感材料
- 34 -
Source: CUI material of NSBU
CONTENT
• CUI in Peng Lai Oil Field蓬莱油田CUI现状
- 35 -
CUI in Peng Lai Oil Field
K1-13P-GAA-Q-PRD-0008086
- 36 -
PL Insulation Materials
WHPA
WHPC
WHPE
Peng Bo
- 37 -
Insulation Damage ‐‐ Water Ingression
WHPA WHPC
The
insulation
status of
WHPA
vessel (Jul,
2012)
- 38 -
The latest CUI

records of
WHPA Piping WHPA 2” gas
Coating line (Sep, 2012)
Breakdown
- 39 -
Piping CUI
WHPA：12” crude pipe to pipe line.

WHPE flow line
Insulation stripped, no corrosion signs
of the bottom elbow. (operating temp:
30‐60°C)
- 40 -
Vessel CUI – Coating Breakdown
Scattered rust stain found at Penbo T2 SSC
- 41 -
WHPA Process Piping CUI Survey – Sept 2012
• WHPA Flow line
• MAWT: 4.93mm
• Alarm thickness for straight/elbow:
5.87mm
Data support see next page as
verification of the mean thickness of
pipe material.
Piping A9: Typical CUI from external CVI
photos
The external surface condition has been
reported and sent to Maint. for spare
parts preparation & coating/insulation
repair.
- 42 -
A9 UT/T Report – Mar, 2012 A9 UT/T Report – Sep, 2012
Nominal wall thickness: 7.62mm, corrosion Average thickness from UT/T in Mar: 7.28mm
allowance 1.6mm, average thickness from UT/T
in Mar: 7.52mm
- 43 -
A9 UT/T Report – Mar, 2012 (Annual
PM)
For all CMLs
Nominal wall thickness: 7.62mm,
corrosion allowance 1.6mm, average
thickness from UT/T in Mar: 7.52mm
A9 UT/T Report – Sep, 2012
(Monitor per 6 month)
For the CMLs with related lower
thickness readings
Average thickness from UT/T in Mar:
7.28mm
A9 Flow line UT Inspection ‐ Example
Conclusion: UT thickness data is acceptable, low possibility of CUI induced leak
结论：超声测厚值是可接受的，CUI导致泄露的风险较低
‐ 44 ‐
WHPA vent scrubber: valve corroded – corrosion under insulation blanket
WHPA CUI
Survey –
Sept, 2012
- 45 -
WHPA vent scrubber: external pipe work, especially valve, flange and bolts
corroded
WHPA CUI
Survey –
Sept, 2012
- 46 -
WHPC Test Separator, Jul, 2012
WHPC Multiphase
meter strainer, Jul,
2012
- 47 -
WHPC WI Pipe,
Sep, 2012
6”-WI-1109-9SV1S01
3”WI-1224-9SV1S01
- 48 -
WHPM Multiphase
meter strainer &
drain vessel, fair
insulation condition
CUI
Free/Slight
to new
facility…
WHPM production
pipe, fair insulation
condition
- 49 -
WHPC, Dec, 2012
4”‐FG‐1557‐6CB2S81:
2010/12/15: Average thickness: 7.87mm
2012/12/12: Average thickness: 7.63mm
External rust stain increased especially on the piping connection
area
- 50 -
CONTENT
• How we manage CUI issue我们如何管理CUI
- 51 -
CUI Issue Gaps
No documented CUI Management Program.
No CUI Inspection/Survey PMs.
Weak Coating Repair Program.
Lack of CUI Awareness.
MORE EFFORTS IN 2013!
CUI Management Development Plan
Short Term Actions
Annual insulation repairs – Completed.
Onsite coating Survey to include piping CUI issue – Gary Zhang
– Completed.
Update A&OI Inspection Report to include a section for CUI
Inspection/Photograph. – Dec 2012 – Completed.
CUI Awareness Basic Introduction to Offshore Personnel. ‐
Dec 2012 – Jan‐Mar 2013 ‐‐ Ongoing
CUI Management Development Plan
Medium / Long Term Actions
Implementing now and to update the progress till CUI
management program build up completion in 2013.
- 54 -
CONTENT
• Early Signs of CUI CUI 的早期迹象
- 55 -
Early Signs of CUI
Visual inspection is the main method for routine
observation
To purposively check the piping / equipment with
insulation on, rather than insulation stripping off.
以目测的方式,在不拆保温的情况下,通过对可疑部位的
识别和观测, 寻找CUI的早期迹象。
HOW TO IDENTIFY THE EARLY SIGNS OF CUI?
- 56 -
Suspect Areas of CUI ‐ NACE
- 57 -
Source: NACE SP 0198
Suspect Areas of CUI – UK CUI Paper
Locations susceptive to CUI:
以下部位主要位于管线上（可见示意图）：
•Valves, fittings, etc. with irregular insulation •Improperly lapped jacketing (e.g.
surfaces;阀门,管件等非常规的保温表面； seams on top); 不适当安装的保温
• Pipe hangers, supports and shoes;管吊架，夹克
支撑、管鞋
• Insulation support rings; 保温支
• Holes for inspection; 检验孔
• Insulated flanges; 保温的法兰撑环
• Insulation junctions and terminations; 保温 • Stiffener rings; 环状加强筋
连接处及终端 • Sagging areas of piping (e.g .
• Damaged or missing jacketing; 破损或丢失 elbows) and other low points. 管
的外部保温夹克线下垂部位及其他低点
- 58 -
Suspect Areas of CUI – Piping
阴影区域即积水/CUI
可能存在部位
- 59 -
Source: External Corrosion Guideline / COP Cooperate
管线CUI可疑位置补充：
水平位置的管线，顶部夹克密封处
竖直管线终端的保温终止处
大管径主管线与小管径支管连接处
及
人员行走可触及的保温管线
- 60 -
Source: API RP 583 Corrosion Under Insulation and Fireproofing E1
以下部位主要位于压力容器上
• Stiffener rings;环状加强筋
• Insulation support rings;保温支撑环
• Skirt fireproofing (“rain hat”);雨帽
• Brackets (platform, ladder, pipe, etc.);支架（容器上的平台，扶梯，管
路等）
• Lifting lugs;吊耳
• Dead legs (vents, drains, etc.); 死管段（通风排水系统等）
- 61 -
Source: API RP 583 Corrosion Under Insulation and Fireproofing E1
Suspect Areas of CUI – Vessel / Tank
- 62 -
Source: NACE SP 0198
Pressure Vessel / Tank
- 63 -
Source: API RP 583 Corrosion Under Insulation and Fireproofing
E1
Pressure Vessel / Tank 压力容器/储罐CUI可疑位置位置补充（或见示意图）：
- 64 -
Source: API RP 583 Corrosion Under Insulation and Fireproofing
CUI Defect Checklist (1)
- 65 -
CUI Defect Checklist (2)
- 66 -
Samples from ABU – Piping CUI
- 67 -
Samples from ABU – Piping CUI
- 68 -
Samples of Pressure Vessel CUI
- 69 -
Samples of Pressure Vessel CUI
- 70 -
What I Can Do for CUI Prevention
All personnel on offshore ( Employee & Contractor)
make sense of:
o CUI Typical Patterns
o Suspect Locations
AND….
1. CONSULT A&OI OFFSHORE INTEGRITY INSPECTOR / ONSHORE
INSPECTION TEAM;
2. REPORT TO THE SUPERVISOR FOR RECORDING / MORE AD HOC
INSPECTION !
The simple CUI checklist is provided by A&OI and suggest offshore
carry the checklist for walk along observation at convenient
opportunities.
- 71 -
QUIZ
What is the main factors resulting in CUI
& when does that need to consider CUI?
What the temperature range deemed as
high likelihood of CUI for insulated
equipment?
What can you do when find CUI issue?
- 72 -
Any CUI findings please contact with A&OI offshore Inspector (@5954) or onshore Integrity Inspection Team
- 73 -

Corrosion Under Insulaton Awareness Basic Training 2013

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Corrosion Under Insulation (CUI)

North Sea Australia

The latest CUI

WHPA：12” crude pipe to pipe line.

WHPC Test Separator, Jul, 2012

HOW TO IDENTIFY THE EARLY SIGNS OF CUI?

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