Overview of how some manage corrosion under insulation

1. Introduction to
Augustus2015
Seminar/ Webinar
Series
Moderator =
Ed Merrick – TVA, APTECH
Panelists =
Peter Hunt – Engen, Shell,
Sunoco, Dupont
Frank Simpton – Amoco,
Saudi Aramco, Hovensa,
Acuren, Jacobs

2. THE AUGUSTUS GROUP, LLC
(AUGUSTUS) – WHO ARE WE?
 Founded in Houston Texas in 2004
 Privately Owned Small Business Registered in SAM
Program
 Engineering and Consulting Services to Refining and
Chemicals and Aerospace Industry for >10 Years
 Focus is on Materials Technology, Asset Integrity Problem
Solving, and Risk Management On and Off Shore
 Collective Experience in……
 Bolting Technology and Leak Management
 Materials Technology, Failure Analysis, Non-
Destructive Examination, Suitability for Service
 Fitness for Service and Risk Based Inspection
 Aerospace, Petroleum and Chemical, Fossil/Nuclear
Power Consulting Upstream and Downstream

3.  Wrote Chemical Manufacturer’s Association’s
Mechanical Integrity Supplement used to Train
Over 300 Member Companies
 >20 RBI Implementations Since 1995,
 First Known Refinery Program at BHP Hawaii,
 NASA Johnson and Stennis AFB
 Developed APTECH’s (Now Intertek) RBI
Program and Software
 Experience with Most Major Software Packages
& Programs – Tichuk, Meridium, PCMS, The
Welding Institute, Capstone, Reliasoft
 Full Scope RBI Implementations
 Using Capstone and PCMS Software
 Management Systems, Procedures, Audits, Training
EXPERIENCE - MECHANICAL
INTEGRITY AND RBI

4. Areas of Specialty Operating Company Former
Employee
Jim Towers Pipelines, Litigation Exxon, Conoco
Peter Hunt Refinery Management, MI/QAQC Shell
Bob Blackstone Stress Analysis, Fracture Mechanics, Welding,
Fatigue, Design
ABS
Gene Rak Corrosion, MI Exxon
Scott Miller NDE Saudi Aramco
Edwin Merrick RBI, Materials Technology, Welding, Bolting, Leak
Management
TVA, Aptech
Scott Merrick Education, Training City of Nashville
Dick Jones Corrosion, PSM, MI, Chemical Plant Management US Steel/ Aristech
Joel Olener PSM
Les Loushin MI, Materials Technology Arco Chemical, Sunoco
Gene Silverman AST Integrity, Eagle System INTANK
Alan Judkins Business Development US Steel/ Aristech
David Sanders Inspection Program Management & Site
Implementation
Petrochem/TEAM
Marvin Mehler Corrosion Engineering NCRA
James Waldrop TA Planning Citgo
Paul Rose NDE, Data Analysis (EVA, etc.)
Mike Fox Maintenance, MI Implementation, Safety Program
Management
Honeywell
Jesse Meisterling Bolting Technology, Leak Management Raymond Engineering
Dave Holthaus NDE Jacobs Engineering
Frank Simpton Inspection Program Management & Implementation,
Corrosion, Damage Management, On-stream
Inspections
Acuren, Hovensa, Saudi Aramco
ENGINEERING CONSULTANTS

5. AUGUSTUS APPLIES TECHNOLOGY
Manufacturing Excellence
Life Cycle
Management
Process
Safety Management
and
Mechanical Integrity
Incident Investigation
Failure Analysis
Acceptability for
Continued Operation
Insurance
Arbitration
Support
and
Litigation

6.  2/19 - Improving your Turnaround
Performance by Managing for Leak Free
Startup – Webinar
 2/26 11am CST, Use Risk Based Inspection
Tools for Optimizing Performance – Webinar
 3/5, 11am CST, Managing Your On-Stream
Inspection Program and External Versus
Internal Inspections - Webinar
 3/12, 11am CST, Managing Corrosion Under
Insulation - Webinar
 3/17 & 3/18 – MI for PSM Compliance
SEMINAR
 MORE TO BE SCHEDULED, CHECK
WWW.THEAUGUSTUSGROUP.NET
WEBINAR/SEMINAR SERIES – HELPING OUR
CUSTOMERS ALIGN WITH BUSINESS OBJECTIVES

7. Managing Corrosion Under
Insulation
Moderator = Ed Merrick – TVA, APTECH
Panelists = Peter Hunt – Engen, Shell, Sunoco, Dupont
Frank Simpton – Amoco, Saudi Aramco, Hovensa,
Acuren, Jacobs

8. CORROSION UNDER INSULATION (CUI)
 Well known phenomena
 Cost wise is the worst type of corrosion
 Gulf coast represents over 70% of
corrosion issues, elsewhere averages
between 40-60% of piping costs
 Corrosion can be galvanic, chloride,
acidic or alkaline
 Potential for a major Process Safety
Incident

9. CUI – THE RESULT

10. CUI – HISTORY
 If you insulate metal, you have a potential for CUI
 ASTM STP 880 “Corrosion of Metals Under Thermal Insulation” in
1985
 Recommended use of multiple NDE techniques
 NACE RP 0198-98 “The Control of Corrosion Under
Thermal Insulation and Fireproofing Materials - A
Systems Approach”
 Recommended use of protective coatings
 Experience in 2003
 Trying a number of techniques
 Indicated 100% stripping of insulation only certain method
 Better techniques and processes now used

11. CUI - CAUSES
 Temperature Range – +25F to 300F, but can
occur at higher temperatures, worse in cyclic
conditions
 Coating – breakdown of the coating barrier
Average Coating life is 5-12 years
 Insulation – wicks and retains moisture
Worst insulations are Mineral wool and CalSil
 Lagging – penetrations and poor maintenance
Choice between AL or SS

12. CUI – TYPES
 Galvanic - wet insulation with an electrolyte
present which allows a current to flow between
metals of different corrosion potential
 Chloride - a combination of insulation
containing leachable chlorides with the 300
series austenitic stainless steel surfaces
 Acidic/Alkaline - either an alkali or an acid are
present in certain fibrous or granular
insulations, which is inadvertently mixed with
moisture in the environment

13.  No method has proven 100% effective
 A combination of methodologies should be
used
 Risk based where and how likely CUI may
occur (more on this later)
 Age of coating
 Type of Coating
 Type of insulation used
 Operator practice
 Maintenance practices
CUI - DETECTION

14.  Appropriate Methods
 Can use the strip all method to allow a visual inspection
 Various NDE Techniques
 RT - (Conventional, Real Time, or Low Intensity) but cannot be
used for all situations
 Pulsed eddy current – screening method
 Guided Wave UT – Excellent for inspection of supports,
dependent on skill of inspector and is a screening technique
 UT Thickness – accurate but not detect pitting type corrosion
 Thermography – only if moisture is present
CUI – DETECTION, CONTINUED

15. CUI - PREVENTION
 Prevent moisture or electrolytes from coming in contact
with bare metal
 Repair or replace protective coating before it breaks
down
 Use Aluminum foil wrapping for SS
 Use a superior protective coating such as TSA
 TSA coatings have a life of 30 to 40 years.
 In the petrochemical industry, TSA is:
 Recognized as Best-In-Class for CUI prevention by EFC, and
 Included in industry standards such as NACE SP 0198-2010, CINI
7.4.04, EFC Publication #55, and NORSK M501.

16. CUI - PREVENTION,CONTINUED
 Use a non wicking insulation such as Pearlite
 Install lagging properly and ensure it is sealed
correctly
 Train operators and maintenance to treat
insulated pipe with care
 Ensure on a risk based process that there is a
well though out inspection plan
 Where possible, do not insulate, use a wire
"standoff" cage
 NB: Inspection is not a prevention method

17. CUI – INFORMATION SOURCES
 API – 510/570
 API RP 583, Corrosion Under
Insulation and Fireproofing
 NACE SP0198-2010, Control of
Corrosion Under Thermal Insulation
and Fireproofing Materials – A
Systems Approach

18. WHERE TO INSPECT
 Highest priority to equipment and
piping where:
 Water can be trapped
 Equipment operates near cooling
towers, sea breeze or steam
condensate
 Surface condensation is a factor
 Previous history of
weatherproofing deterioration

19. VESSEL INSPECTIONS
 Typical areas most vulnerable
include:
 Top platform supports
 Ladder supports
 Exposed stiffing or support
rings
 Small gusset supports
 Nozzles and manways

20. SUSCEPTIBLE AREAS - VESSEL

21. TANK INSPECTIONS
 Typical areas most vulnerable
include:
 Roof nozzles
 Stairway supports
 Insulation support rings
 Gussetted connections
 Wall to base junction

22. SUSCEPTIBLE AREAS - TANKS

23. PIPING INSPECTION
 Typical areas most vulnerable
include:
 Pipe supports and gussets
 Flanges/valves
 Low points in line

24. SUSCEPTIBLE AREAS - PIPING

25. EVALUATION OF CUI CORROSION
 Baseline CUI Inspections to Find
and Mitigate Problems in Piping and
Fixed Equipment
 RBI or Classification of Piping to
Prioritize Work
 VT Inspection of Insulated Piping with
IR Inspection of Insulated Piping to
Complement VT

26. 26
CORROSION CIRCUITS IDENTIFICATION
 Corrosion Under Insulation: (CUI) are to be
set up as separate piping circuits within the
piping system where they are installed.

27. AUGUSTUS CORROSION UNDER
INSULATION (CUI) DAMAGE
MANAGEMENT

28. QUALITY REVIEW/AUDIT OF INSPECTION
DOCUMENTATION
 ? Are You Actively Managing CUI
 ? Do You Have a Risk Based Approach
 Typical Augustus Review/Audit
 Assess Quality Of VT and UT Inspection
Documentation and Data
 Procedures
 Qualifications Of Inspectors
 Results
 Interviews with Management Engineers and
Inspectors
 Identifies Opportunities For
 External Vs Internal Inspections
 Input To RBI Program

29. WHY DO WE DO IT?
 Planning For
 On-stream
Inspections
 Optimization Of
Outage or
Turnaround Scope
 Focusing Inspections,
e.g. CUI
Hazard
Screen
Risk
Benchmark
Inspection
Plans
Non-
Intrusive
Inspections
Opportunity
Inspections
Turnaround
Plan
Evergreen
Risk
Analysis
Turnaround
Inspections

30. THE BEAUTY OF RISK BASED DECISION
MAKING
 100% of Susceptible Locations in the High Risk
Items
 Use Stratified Statistical Sampling of
Representative Areas in:
 50% of Susceptible Locations in Medium High and
Medium Risk Items
 10% to 50% of Susceptible Locations in Low Risk
Items
 Sampling & Repairs etc. to be Expanded as
Problems are Found

31. QUALITATIVE RB CUI MANAGEMENT
 Relies On Expert Judgment and Weighting
of Qualitative Factors
 Group Meeting To Review Procedures And
Agree On Scope, Approach, And Details Of
Review
 Maintenance
 Inspection
 Engineering
 Operations
 Contractors?
 We Recommend Integration with PHA

32. WHAT DOES THE QRA LOOK LIKE
 Qualitative Risk Analysis &
Prioritization
 Gut Level Sensibility Calibration for
 RBI Analysis of Items
 Inspection Data
 Add Financial Implications Aligned with
Business Case

33. USE METALLURGICAL AND CORROSION
ANALYSIS
 Using the PHA Software or Access Tools as
Appropriate
 Align PHA Nodes with Process Segmentation to
Establish
 Qualitative Probability of Failure
 Validate Metallurgical and Corrosion Analysis
 Identify Any New Damage Mechanisms or Concerns
 Qualitative Consequence of Failure
 Compare COF from QRA and RBI (if Available)
 Document Business Interruption COF

34. PROCESS HAZARDS CHANCE OF OCCURRING,
INTERNAL MECHANISMS

35. CHANCE OF OCCURRING, EXTERNAL
MECHANISMS

36. FAILURE MODE

37. CHANCE OF OCCURRING X FAILURE MODE =
QUALITATIVE LIKELIHOOD OF FAILURE
CHANCE OF OCCURRING X FAILURE MODE
LIKELIHOOD

38. QUALITATIVE CONSEQUENCE OF FAILURE

39. TYPICAL 5X5 MATRIX FOR USE IN
INSPECTION PLANNING
Consequence Ranking
ABCDE
HIGH
MED HIGH
MEDIUM
LOW
1
2
3
4
5
ProbabilityRanking
Consequence
A-Catastrophic
B-Very Serious
C-Serious
D-Significant
E-Minor
Probability
1-Very High
2-High
3-Moderate
4-Low
5-Very Low

40. RISK DISCOVERY FOR EVALUATION

41. TO SEMI-QUANTITATIVE ANALYSIS AS
NEEDED

42. AN AFFORDABLE TOOL MEETING API
580 AND 581 REQUIREMENTS

43. SUMMARY
 Wet insulation is primary cause
of CUI
 Good design is a necessity
 Proper repairs of damaged
weatherproofing
 Good inspection program
concentrated or areas of
vulnerability

44. Sometimes you have to
deliver an Unpopular
Answer
But it is All about
Making the Right
Decisions and Taking the
Right Action
OPERATIONS
SAFETY
INSPECTION
MAINTENANCE
SUPERVISOR
ENGINEERING
PLANT
MANAGER’S
OFFICE
ENGINEERING MANAGER’s – Daily
Challenges

45. RISK MANAGEMENT – Consider
Augustus’ MI Seminar in March