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From Trauma to Transcendence: CUI and Coatings of Choice
Dr. Mike O’Donoghue – AkzoNobel Vijay Datta, MS – AkzoNobel SSPC Webinar, October 25th , 2016
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Agenda Introduction Causes of CUI and Mitigation of CUI
CUI Coating Solutions Coating Testing Unless otherwise agreed in writing by AkzoNobel, all products supplied together with all technical service, information, advice and recommendations given are subject to our standard terms and conditions of sale which are available on request. Any information given here is for guidance only and is provided without any representation or warranty of any kind, express or otherwise. Further, AkzoNobel accepts no control or liability for the appropriateness of any product or the surface, structure or design to which our products are applied or the application process itself. You should seek independent expert advice as to the appropriateness of a particular design or structure for use of our products. We also strongly recommend that independent testing and/or assessment is carried out prior to the application of any product to determine suitability for use. Protective Coatings
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Corrosion Cost Comparison
Annual Global Cost of Corrosion: > US$ 2.5 Trillion (3.4% of a country’s GDP) Annual Cost of US Natural Disasters : > $19 Billion Corrosion costs the US Economy > 50 times as much as all the natural disasters Vijay – read and cite Pierre Crevolin (what was G2 MT Vijay?) Vijay – Impact Study States “ By using currently available corrosion control practices, it is commonly estimated that savings of between 15 and 35% could be realized…. Courtesy: NACE International IMPACT Study, 2016 G2MT Laboratories 2014 Pierre Crevolin, NACE Western Regional Conference 2005
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Corrosion Under Insulation (CUI) – Costs Billions
Corrosion rates of carbon steel can be significant if operating at high temperatures and subject to temperature cycling, particularly when thermally insulated “… approximately 35% of incidences of corrosion failures, or near failures were caused as a result of corrosion under insulation …” (This statement follows a 2 year survey of plant failures at a major US petrochemical complex)
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Corrosion Related Accidents
Motiva Delaware City started when sparks from welding on a catwalk fell onto, and then into, a severely corroded sulfuric acid tank, that then ignited and exploded.
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Corrosion Under Insulation
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Overview of CUI Corrosion of steel under thermal insulation due to the presence of moisture, oxygen, and other corrodents Known since 1950’s High interest since 1983 NACE SP & EFC 55 Carbon Steel C to 175C Stainless Steel 50C to 175C
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CUI Corrosion under ‘wet’ thermal insulation - aggressive
CUI is up to 20x faster than atmospheric corrosion (1.5 – 3.0 mm/year) Insulated high temperature steelwork requires protection against CUI which is a threat during construction, shutdown and intermittent use of equipment
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Why is there is a problem?
No insulation is 100% waterproof The corrosion rate under wet insulation can be up to 20 times greater than the rate at ambient operating conditions Corrosion is hidden Nothing runs above 212oF forever Equipment temperatures cycle Inspection can be limited and costly Reluctance to shut down unit Budgetary concerns
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Implications of CUI Critical Steel Temperature Ranges for corrosion:
C-Steel 25F → 302F (Greatest Risk of Corrosion) S-Steel 122F→ 302F (Greatest Risk of E.S.C.C. ) The highest corrosion rates are normally experienced in operational conditions between 140F to 250F Moisture ingress into broken or compromised insulation can occur from 32F to 302F E.S.C.C. = External Stress Corrosion Cracking Stress corrosion cracking (SCC) is the growth of cracks in a corrosive environment. It can lead to unexpected sudden failure of normally ductile metals subjected to a tensile stress, especially at elevated temperature in the case of metals. SCC is highly chemically specific in that certain alloys are likely to undergo SCC only when exposed to a small number of chemical environments. The chemical environment that causes SCC for a given alloy is often one which is only mildly corrosive to the metal otherwise.
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Thermal Cycling – The vehicle for CUI
Moisture movement Insulation Coating HEATING COOLING Steel Coating must provide excellent corrosion protection to insulated steelwork which experiences thermal cycling conditions
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Corrosion at Elevated Temperatures
For corrosion to occur three key elements MUST be present Water is not present in equipment where continuous operating temperatures above 248F exist However, during shut down or cyclic temperature operations, rapid cooling can lead to condensation, & subsequent corrosion problems Repeated cycling increases both corrosion rates, and potential for failure of coating systems Air Steel Water Corrosion
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CUI Dynamics C U I Moisture Under Insulation Project Soluble Chlorides
Budget Soluble Chlorides C U I Inspection Cyclic Temperatures Maintenance Requirements
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CUI Coating Solutions - Balancing…
Anticorrosive Properties Thermal Resistance (Cartoon Figs Courtesy Hexion)
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Metallic, Organic and Inorganic Solutions to CUI?
Mike
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CUI Solutions - Thermal Spray Aluminum
Flame spray, arc spray, plasma spray techniques Aluminum Spray Alloy 1100 or 1350 SSPC-SP5/NACE 1/Sa3 (3-4 mils) Temp Resistance to ca 595C Life cycle costs are low Process slow, installation costs are relatively high vs coating spray application, DFT issues, needs to form oxides Galvanic protection – sacrificial system Susceptible to corrosion by wet salts above 80C Porosity Seal coat or no-sealer coat? Wire Compressed Atomising Air Oxygen Fuel Gas Mixture Coating Spray stream of molten atomised particles Substrate Nozzle Air Cap A long and accomplished history of success Offshore platforms and bridges For CUI – the jury is out – TSA can deteriorate under wet insulation Sacrificial system International Standards for application and composition High degree of Surface prep Porous, some interconnectivity of voids, open structure We studied sealing: porosity reduced, see Ole Knudsen
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CUI Solutions – Transcendence Road
Temperature Higher bond strengths of Inorganic Si-O bond (452 KJ mol-1) vs Organic C-C bond (350 KJ mol-1 ) confers thermal stability Inorganic - Inorganic copolymer, TMIC 650C Inorganic – Conventional Thin Film Silicones, TSA 600C 400C Inorganic - Zinc Silicates vijay Organic - Phenolic/ Novolac Epoxy 220C Organic – Epoxy 125C Technology Protective Coatings
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The Zinc Silicate Question (photo courtesy Peter Bock)
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NACE SP SP Typical Protective Coating Systems for Carbon Steels Under Thermal Insulation and Fireproofing – Courtesy Art MacKinnon, PPG Hi-Temp Coatings System Number Temperature Range (A)(B) Surface Preparation Surface Profile, µm (mil) (c) Prime Coat, µm (mil) (D) Finish Coat, µm (mil) (D) CS-1, CS-2, CS-3 Epoxy, Fusion Bonded Epoxy, Epoxy Phenolic minus 110° to 302°F [minus 45° to 150°C] CS-4 -45° to 205°C (-50 to 400°F) NACE No. 2 / SSPC-SP 10 50-75 (2-3) Epoxy novolac or silicone hybrid, (4-8) Epoxy novolac or silicone hybrid, (4-8) CS-5 -45° to 595°C (-50 to 1100°F) NACE No. 1 / SSPC-SP 515 (2-4) TSA, (10-15) with minimum of 99% aluminum Optional: Sealer with either a thinned epoxy-based or silicone coating (depending on maximum service temperature) at approximately 40 (1.5) thickness CS-6 -45° to 650°C (-50 to 1200°F) 40-65 ( ) Inorganic coplymer or coatings with an inert multipolymeric matrix, (4-6) CS-7 Petroleum wax primer; ambient to 140°F [60°C] CS-8 Shop primers and topcoats for inorganic zinc (IOZ) minus 110° to 750°F [minus 45° to 400°C] Novolac, phenolic, inorganic copolymer and inert polymeric matrix
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Coatings for CUI Mitigation
Epoxy Phenolic Silicone Acrylic TMIC Silicone IMMP Binder: High Temperature Silicone Acrylic Heat Resistant Cold Spray Aluminum High Temperature Silicone Temperature Ranges: Ambient up to 392F; intermittent surges up to 446F 500F -321F up to 1200F 1004F -321F up to 1202F Typical Systems: 2-coats x 4-6 mils DFT 2-coats x 1.6 mils DFT 2-coats x 4 mils DFT 3-coats x 1 mil DFT 1-coat x 1.6 mils DFT over IOZ 500F over OZ 300F 1-coat x 8 mils DFT 2-coats x mils DFT over IOZ Under Insulation: Yes No Substrate: Carbon Stainless 302F = 150C 392F = 200C 446F = 230C 500F = 260C 300F = 150C -321F = C 752F = 400C -265F = -165C 1050F = C 1004F = 540C 1202F = 650C IMMP = Inert Multipolymeric Matrix Paint TMIC = Titanium Modified Inorganic Copolymer
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Epoxy Phenolic and Novolacs (CS-4; - 45C to 205C, -50F to 400F)
Barrier Protection - Epoxy Phenolic coatings perform well in high temperature aggressive environments because of their very densely cross linked nature Epoxy Polyamine + Crosslink Typical Cross-linked Epoxy Epoxy Phenolic Polyamine + Crosslink VJ explains Densely Cross-linked Epoxy Phenolic
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Barrier Protection Playing Field (CS-6; - 45C to 650C, - 50F to 1200F) Examples:
Carboline Thermaline 4001 Dampney Thurmalox 225HD Hempel Versiline 56990 International Interbond UPC 1202 Jotun Jotatemp 650 PPG Hi-Temp 1027 Sherwin Williams Heat-Flex Hi –Temp 1200
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MIO Pigmented IMMP for CUI Mitigation
SEM Image after 4000C 200X Magnification MIO Platelets Barrier Protection
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Aluminum Flake Pigmented TMIC for CUI Mitigation
SEM Image after 4000C 1000X Magnification Interlacing aluminum platelets, intact Barrier Protection
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CUI Coatings - More Balancing
Damage own to metal Harder Coating “Bruising” effect only Softer Coating Vijay explains This is TMIC – Titanium Modified Inorganic Copolymer Q. VJ to M: How does real life experience of this technology compare with the laboratory tests, is there any correlation? You have done lots of independent lab testing on this technology, tell us about that? Marine & Protective Coatings
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International Paints Cyclic Pipe Tests Courtesy O’Donoghue and Datta, International Paint
CCCPT CUI Cyclic Corrosion Pipe Test
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Courtesy O’Donoghue and Datta, International Paint`
CUI Cyclic Pipe Tests Courtesy O’Donoghue and Datta, International Paint` 100C Diameter = 6 cm Length = 60 cm 1 litre 1% NaCl twice/day Temperature °C Time 600C 8 hours Heated to 600C Naturally cooled 16 hours Repeated x 30 600C cyclic temperatures to mimic end user processes
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Monitoring / Verifying the Coating Temperature
CCCPT procedure run with temperature probes to measure temperatures across the pipe
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TSA and IMMP & TMIC Coatings on Carbon Steel
VJ explains IMMP TSA
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Coatings on Carbon Steel up to 560C
70C-100C 100C-165C 165C-215C 215C-300C 300C-450C 450C-560C IMMP TMIC
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PPG CUI Chamber Test (2008-Present) Courtesy Dik Betzig PPG Hi-Temp Coatings
Testing method approved: Shell Oil 2008, Aramco 2010 Method B 350F (177C) 5% NaCl Temperature Control Ambient to 250C Method B 5% NaCl solution
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CUI Chamber Test Cell Courtesy Dik Betzig PPG Hi-Temp Coatings
Before Test After 6 Weeks Front View After 6 Weeks Bottom View
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Track Record Cyclic Service Conditions: 260C to 40C
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Case History France
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Case History France
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Case History Texas
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Case History Texas
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Publications “When Undercover Agents are Tested to the Limit: Coatings in Action (CIA) and Corrosion Under Insulation” JPCL, May 2014 SSPC Presidential Lecture Series Award in 2013 “When Undercover Agents Can’t Stand the Heat: Coatings in Action (CIA) and the Netherworld of Corrosion Under Insulation” JPCL, February 2012 Outstanding Publication of the Year Award in 2013 “From Trauma to Transcendence: Corrosion Under Insulation” NACE, Northern Area Western Conference, 2010
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Vijay Datta, MS vijay.datta@akzonobel.com Dr. Mike O'Donoghue
Thank You - Questions? Vijay Datta, MS Dr. Mike O'Donoghue
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