Corrosion Under Insulation

Inspection in Ammonia
Urea Plant

Work Preparation & Planning

Khandaker Asirul Hoque

Asirul.Hoque@outlook.com
Definition of CUI
“Corrosion of piping, pressure
vessels and structural
components resulting from water
or moisture trapped under
insulation or fireproofing.”

Ammonia jetty area pipeline CUI, 2009

Affected Materials:
Carbon steel, low alloy steels, 300
Series SS and duplex stainless
steels.
Corrosion Under Insulation (CUI)
As per Giel Notten, widely known corrosion expert
“Corrosion Under Insulation (CUI) is the number-1
problem in Chemical Process plant after 20 years of
operation”

The plant is getting older and the insulation cover

sheeting is deteriorating. Near lugs, attachments,
instrumentation nozzles and inlet & outlet lines, the
insulation cover sheeting is not properly installed.
Rainwater can penetrate into the insulation and
cause CUI.
Susceptible temperature range

As per API 510- 9th Edition susceptable temperature range

for CUI is

• 10°F (–12°C) and 350°F (175°C) for carbon

and low alloy steels

140ºF (60ºC) and 400ºF (205ºC) for austenitic

stainless steels.
CUI Mechanism
Corrosion Under Insulation caused by:

Ingress of water through-insulation

Water vapors condensation

Corrosion promoted by:

Trapping of water
Ammonia jetty area pipeline CUI, 2009

Elevated temperatures (around 100º C)

Temperature gradient

Temperature cycling (Intermediate Service)

Absence or poor condition of coating

Poor/broken insulation

Marine Environment (Chloride Deposition)
Influence of relative Humidity on Atmospheric
Corrosion of Carbon Steel
Susceptible Locations

Insulation support or stiffening rings

CO2 absorber
CUI near
bottom skirt,
2010

• Nozzles and man-ways

Susceptible Locations

Other penetrations, e.g. Ladder clips, pipe supports

Damaged insulation areas

Susceptible Locations

Un-insulated Lifting Lugs

Near Bottom Drain Lines

Saddle Support of
Horizontal Heat Exchangers
Morphology of CUI

After insulation is removed from carbon
and low alloy steels, CUI damage often
appears as loose, flaky scale covering the
corroded component.

In some localized cases, the corrosion can

appear to be carbuncle type pitting

Austenitic SS often shows Cl-SCC

Damage Mechanisms

CUI

Carbon Stainless
Steel Steel

Uniform Localized pitting Stress Corrosion

Corrosion &
(below painting) Cracking
uniform wall loss
CUI Inspection: Work Organization
Manager
Inspection

Production Inspection Workshop Maintenance Civil

Supervisor from Insulation Removal
Maintenance Civil Supervisor
Production for Visual Inspectors & Re-insulation
Support For re-painting
permit and process From Inspection work
supervisor job
related support Section supervisor
(To be nominated (To be
(To be nominated (To be nominated)
from each plant) nominated)
for each plant)

Mechanical
Insulation Technician for
Operator from
NH3/ Urea &
Technician for scaffolding, Civil contactor
Insulation surface for repainting
Utility Plant
removal preparation for
NDT
Work Organization (cont.)

CUI inspection is a multi disciplinary work. Good
communication & understanding is required between group
members.

Best time to execute such inspection is during plant shut
down period and dry season.

Insulation is hazardous material so proper safety
supervision is also important.
 Work Schedule

Date April 2013 May 2013 June 2013

Job Tasks Week 1 Week 2 Week 3 Week 4 Week 1 Week 2 Week 3 Week 4 Week 1 Week 2
Study CUI as per API 510, 571 & RBI
recommendation
Preparation of CUI Job volume
Assessment of material and Job by
maintenance
Inspection Checklist preparation

CUI inspection work of Ammonia Plant

Repainting and reinsulation job in Ammonia
Plant
CUI inspection work of Utility Plant
Repainting and reinsulation job in Utility
Plant
CUI inspection work of Urea Plant
Repainting and reinsulation job in Urea
Plant
Report Preparation
Update information into RBI Software
Inspection Type
Carbon Steel

Ultrasonic Thickness
Uniform Oxidation & Thinning Measurement (UT)

Localized Metal Loss Pit Depth Measurement

Stainless Steel

Cl stress Corrosion Cracking Dye Penetration Testing (DPT)

Ammonia Plant Equipment
Sl Equipment Equipment Name Shell Material Probable
Number CUI Locations
1 1-S-202 PROCESS CONDENSATE Carbon Steel Bottom Skirt,
SEPARATOR Manhole, Lifting
Lug
2 1-S-302 MIST SEPARATOR Carbon Steel Bottom Skirt,
Manhole, Lugs
3 1-S-304 HOT CONDENSATE Carbon Steel Bottom Skirt,
SEPARATOR Manhole, Lugs

4 1-S-412 INTER SEPARATOR FOR 1-K- Carbon Steel Bottom Skirt,

401 Ladder Supports,
Lugs
5 1-S-502 Let Down Vessel Carbon Steel Ladder, Manhole
cover support
6 1-S-503 Flash Vessel Carbon Steel Ladder, Level
Gauge, Lugs
7 1-V-102 Blow Down Vessel Carbon Steel Lugs, Manhole,
Ladder supports
Ammonia Plant Equipment
Ammonia Plant Equipment
Sometimes insulation is used at locations where only
personal protection (PP) is required. This increases the
risk for CUI considerably. When installing personal
protection instead of insulation, the structural integrity
will be improved.

1-E-421 1st intercooler (air) no insulation required, only personal
protection

1-E-504 NH3 water cooler no insulation required on inlet line
(only PP).

1-E-510A/B NH3 condensers no insulation required, only
personal protection

1-V-601 A/B Adsorber A & B
Utility Plant Equipment
Sl Equipment Equipment Name Shell Material Probable CUI
Number Locations
1 3-V-201 Continuous Blow Down Carbon Steel Near bottom support,
Flash Tank flange connection
2 3-V-203 Drain Flash Tank Carbon Steel Near bottom support,
flange connection
3 3-V-901 A Adsorber A Carbon Steel Around Insulation Support
Ring, Lugs
4 3-V-901B Adsorber B Carbon Steel Around Insulation Support
Ring, Lugs
5 3-S-901 MOISTURE SEPARATOR Carbon Steel Around Insulation Support
Ring, nameplate
6 3-E-701 Mixing Station Heat Carbon Steel Insulation support ring,
Exchanger nameplate, base
7 3-E-901 Air Cooler Carbon Steel Near nameplate & base
8 3-E-903 Regenaration Gas Heater Carbon Steel Near nameplate & base
Utility Plant Equipment
Urea Plant Equipment
Sl Equipment Equipment Name Shell Material Probable CUI
Number Locations
1 2-V-903 Boiler Feed water Carbon Steel Lifting lug- 2 nos & Ladder
Collecting Drum support
2 2-V-905 HP STEAM SATURATOR Carbon Steel Support- 2 nos & Level gauge
support
3 2-E-303 LP CARBAMATE Stainless Steel Lifting lug- 2 nos., Bottom
CONDENSER insulated part
4 2-E-202 HPCC Carbon Steel Saddle Support & inlet from
2-E-201
5 2-X-901 Steam Vent Stack Carbon Steel Bottom Insulated part where
damage occurred
6 2-E-803 A/B Hydrolizer Heat Exchanger Stainless Steel Partially remove insulation
near saddle support and
perform thickness monitoring

7 2-E-802 Desorber Heat Exchanger Stainless Steel Thickness check near saddle
support and perform
thickness monitoring
Urea Plant Equipment
RBI Approach of Pipeline CUI Inspection
Critical Areas for Pipeline CUI
Common Locations of pipeline CUI
1. Pipes those are in intermittent service
2. Steam tracing pipe lines
(sometimes in Urea plant SS pipe is steam traced by CS tracing
line- Introduce risk of external Cl-SCC)
3. Termination of insulation in a vertical pipe.
4. Bulges or staining of the insulation or jacketing system or
missing bands.
5. Low points in piping systems that have a known breach in
the insulation system
Pipeline CUI
Vertical run pipeline partially
insulated are very prone for
CUI at the lower portion of
the pipe.

Several Pipelines in Boil Off Gas

and Ammonia Loading pump
area were found continually
wet and cold insulation
lifetime exhausted. Immediate
insulation replacement is
recommended
Pipeline CUI

4”-LA-60007-A2-C55

4”-LA-60020-A2-C55

12”-GA-60009-A2-C55
To 6-K-201 B inlet line
Conclusion

Atmospheric corrosion is a serious threat to the safe
operation of older, petro-chemical process plant.

CUI detection is a challenging job; it is highly
unpredictable

Reduce use of insulation as much as possible

Avoid insulation where it is not a process requirements

Design modification, apply suitable coating, surface
preparation, use suitable aluminum cover sheet etc.

Prepare painting surface and apply coating as per
internationally acceptable codes & standard.
Q&A Session