How to mitigate the risk of CUI? ProRox PS 960/970 mandrel wound pipe sections with. WR-Tech

Transcription

1 Hw t mitigate the risk f CUI? PrRx PS 960/970 mandrel wund pipe sectins with WR-Tech

2 Cntents 1 What is CUI and why is it a prblem? Crrsin statistics and imprtance f insulatin Cmmn preventative measures t cmbat CUI The challenge and slutin Cmpetitive material cmparisn Cnclusins 7 FAQs 8 ROCKWOOL Technical Supprt 9 Where t find mre infrmatin

3 What is CUI and why is it a prblem?

4 What is CUI? Crrsin Under Insulatin (CUI) is the result f an electr chemical reactin between an unprtected metal, water and xygen, ccurring under the insulatin CUI is a prduct f wet metal expsure, frm trapped misture buildup under the insulatin (unable t evaprate) Accelerated by temperature and the presence f chlrides and/r sulphates in the water Water/misture (frming int an electrlyte) can cme frm a variety f surces, bth external and internal: Rain Salt water mist Cndensatin Cycling f the system Wash-dwn water Leaks r spills in the prcess Unprtected Metal Oxygen CUI Water

5 Temperature accelerate CUI Carbn/mild steel risk f crrsin Stainless steel risk f ESCC Reference: Shell DEP Gen. September % f CUI incidents ccur n pipes (Exxn study) CUI can be accelerated in an envirnment in high salt (seaside & castal areas) & humid cnditins and / r installatins with intermittent and cycling temperature ranges.

6 Why is CUI a prblem? CUI is a SYSTEM challenge! Surrunding envirnment Plant peratin Equipment/system design Chice and installatin f: Cating Insulatin Jacketing/cladding Inspectin and maintenance Undetected crrsin Leaks Shut dwns Repairs $$$ CUI is a significant part (up t 40%) f the maintenance cst n pipes Cstly prblem due t mre frequent repairs, shutdwns, verhauls, and verall reductin f plant service life Even wrse, CUI increases the risk f spills, leaks, and disastrus accidents

7 Crrsin statistics and imprtance f insulatin

8 Crrsin statistics and imprtance f insulatin Damaged insulatin jacketing/cladding ften allws water t penetrate int the insulatin, which can cause crrsin Csts due t crrsin, dwntime, and additinal unanticipated energy lsses are substantial Annual Cst f Crrsin Heat lsses frm damaged insulatin can be up t 8x greater

9 Cmmn preventative measures t cmbat CUI

10 Cmmn preventative measures t cmbat CUI There are several (different) practices that can emplyed t reduce r pssibly eliminate the ptential fr CUI prblems Basic material rules t help reduce CUI: Prperly designed and installed jacketing/cladding system Use f a suitable cating system fr pipe surface prtectin Chsing an insulatin material with imprtant crrsin reductin characteristics

11 Insulatin selectin NACE SP (2.1.2): CUI f carbn steel is pssible under all types f insulatin. The insulatin type may nly be a cntributing factr. The insulatin characteristics with the mst influence n CUI are: Water-leachable salt cntent in insulatin, such as chlride, sulphate and acidic materials that may cntribute t crrsin; Water retentin, permeability, and wettability f the insulatin; and Fams cntaining residual cmpunds that react with water t frm hydrchlric r ther acids. Because CUI is a prduct f wet metal expsure duratin, the insulatin system that hlds the least amunt f water and dries mst quickly shuld result in the least amunt f crrsin damage t equipment. Crrsin can be reduced by careful selectin f insulatin materials.

12 The challenge and slutin

13 The challenge Keeping water ut is nt that simple! Water ingress cannt be avided and will ccur under every type f insulatin Chse an insulatin t cunter the harmful effects f CUI with: The lwest water absrptin The fastest misture dissipatin Durable perfrmance ver the entire CUI temp. range Lw amunt f leachable chlrides

14 The slutin ROCKWOOL Technical Insulatin has develped the next generatin f stne wl pipe sectins with a unique binder technlgy t mitigate the risk f CUI: ROCKWOOL PrRx PS 960 / 970 mandrel wund pipe sectins with WR-Tech ( WR-Tech Water Repellency Technlgy)

15 The slutin What is WR-Tech? WR-Tech incrprates a revlutinary cating-friendly binder technlgy (inrganic hydrphbic resin) that cats the fibers f ur stne wl pipe sectins during the prductin prcess. What is the advantage f WR-Tech? PrRx mandrel wund pipe sectins with WR-Tech has a 5 X lwer water absrptin than the standard available EN classified stne wl. This reduced water absrptin cntributes t a mitigatin f the risk f CUI. Hw d PrRx mandrel wund pipe sectins with WR-Tech mitigate the risk f CUI? NO SILICONE OIL The 5 X lwer water absrptin increases water repellency f the stne wl, making it difficult fr water t penetrate the wl. At the same time, the wl remains pen fr water vapur diffusin, allwing any water inside the system t egress. Lwer amunt f water at the pipe surface = Reduced risk f CUI

16 The slutin Prduct features:

17 The slutin Water ingress Metal jacketing/cladding is sensitive t mechanical damage and imprper installatin. As a result, water ingress can ccur int the system. 1 - Highest water repellency PrRx Pipe sectins with WR-Tech are 5X mre water repellent than the best available stne wl prducts.

18 The slutin Water remval frm surface CUI can happen under all types f insulatin. It is paramunt t remve water when it des get t the pipe surface. 2 - Fastest water dissipatin The pen structure ensures that water can evaprate freely frm the pipe surface thrugh the insulatin material. The lwest water absrptin within the mineral wl categry ensures the fastest dry-ut time.

19 The slutin Thermal expsure The CUI range cvers temperatures up t 250 C. Ideally, insulatin material perfrmance in relatin t CUI related prperties shuld nt be affected ver this whle range. 3 N reductin f repellency Maintains water repellency perfrmance ver the whle CUI temperature range. Thus, making it the mst durable, water repellent stne wl prduct.

20 The slutin Speed f crrsin prcess Specific leachable substances in the insulatin material can accelerate the CUI prcess. Lw leachable substances < 10 ppm chlride Cmplies with strict industry standards ASTM C795 and EN Pipe surface prtectin Catings are an imprtant line f defense t prevent CUI. Prper cating prtectin ver the whle surface is critical. Cating friendly Silicne il free: n fish-eyes r negative influence n adhesin Cmplies with VW test Des nt mechanically and/r chemically damage catings Thermal/mechanical expsure Mechanical lads + thermal cycles can increase the brittleness f insulatin materials and cause cracking; enabling water t easily reach the pipe surface Durable prduct tughness PrRx PS with WR-Tech des nt becme brittle ver time r after expsure t high temperatures N cracking reduce ptential water ingress t the pipe surface

21 Cmpetitive material cmparisn

22 Cmpetitive material cmparisn Water absrptin ROCKWOOL cnducted water absrptin testing using 2 different standards: Standard Title Descriptin Details EN Thermal insulating prducts fr building equipment and industrial installatins - Determinatin f shrt term water absrptin by partial immersin f prefrmed pipe insulatin Simulates the water absrptin caused by expsure t rain during prduct installatin 24 hr test Measures water absrbed (kg/m 2 ) ASTM C1763 Standard Test Methd fr Water Absrptin by Immersin f Thermal Insulatin Materials Measuring the water absrptin f flat specimens* under isthermal cnditins, as a result f direct immersin in liquid water 2 hr & 48 hr immersin under 1 head f water Measures water retained (% vl.) and recvered (% vl.) Heat treated and nn-heat treated * ASTM C1763 is typically fr flat specimens, but ROCKWOOL adpted the test fr pipe sectins

23 Cmpetitive material cmparisn Water absrptin Summary f EN test: EN Rain (ne side immersin) 24 hrs ROCKWOOL PS 960/970 with WR-Tech Pipe sectin A Pipe sectin B Pipe sectin C Water absrbed (kg/m 2 ): Nn-heat treated 0.1 (declared < 0.2) 0.1 (declared < 1) 0.5 (declared < 1) 1.4 (declared < 1) Water absrbed (kg/m 2 ): Heat 250 C fr 24 hurs 0.1 (declared < 0.2) 62.5 (n declaratin) 30.1 (n declaratin) 43.8 (n declaratin) Pipe sectins A, B and C are cmmercially available mineral wl based pipe sectins in Eurpe, with Ws declaratins f < 1 kg/m 2

24 Cmpetitive material cmparisn Water absrptin Summary f ASTM C1763 test: ASTM C1763 Frced full immersin 48 hrs, n heat aging Standard PrRx PS 960 with WR-Tech Pipe sectin X Pipe sectin Y Pipe sectin Z Water absrbed (vlume %) ASTM C1763 full immersin Recvery Water absrbed (vlume %) - 48hrs recvery (drying) MiW prducts X, Y and Z are cmmercially available mineral wl based insulatin fr piping (industrial) in Nrth America

25 Cmpetitive material cmparisn Water absrptin heat aged samples Summary f ASTM C1763 test: ASTM C1763 Frced full immersin 48 hrs after heat aging, C Standard PrRx PS 960 with WR-Tech Pipe insulatin X Pipe insulatin Y Pipe insulatin Z Water absrbed (vlume %) ASTM C1763 full immersin Recvery Water absrbed (vlume %) - 48hrs recvery (drying) MiW prducts X, Y and Z are cmmercially available mineral wl based insulatin fr piping (industrial) in Nrth America

26 Cmpetitive material cmparisn EN Rain Test Water absrptin cnclusins frm tests Withut heat aging, there was up t 14 times difference in the amunt f water absrbed in CE-marked pipe sectins frm Eurpe, with the new PrRx PS ( WR-Tech) being best in class. Even after heat aging at 250 C fr 24 hrs, the new PrRx PS with WR-Tech still had superir water repellency at < 0.2 kg/m 2 Cmpetitive mineral wl based pipe sectins frm Eurpe absrbed frm 30 t 60 kg/m 2 after heat treatment ASTM C1763 Immersin Tests The new PrRx PS with WR-Tech had superir perfrmance Cmpetitr mineral wl prducts absrbed substantially mre water than PrRx PS with WR-Tech. After all materials were preheated: The water absrptin fr ther, cmpetitr mineral wl prducts went up by ver 10X, where as PrRx PS with WR-Tech nly went up nly abut 4X. Even after preheating, the WR-Tech material still had lwer water absrptin values than even the unheated samples f ther, cmpetitr mineral wl prducts Dryut perfrmance after water immersin was superir fr PrRx (WR-Tech), bth with and withut heat aging.

27 Cmpetitive material cmparisn Water absrptin Cnclusins frm tests ROCKWOOL s PrRx PS mandrel wund pipe sectins with WR-Tech: Excellent water absrptin perfrmance vs. all ther materials PrRx PS with WR-Tech is the best-in-class because f: Superir water repellency Fastest water dissipatin

28 Cnclusins

29 Cnclusins CUI is a system challenge and ccurs under all types f insulatin Water ingress cannt be avided! Water retentin at the pipe surface has a large influence n the rate f CUI Prducts with higher cncentratins f leached chlrides increases CUI rates Chse an insulatin material with imprtant characteristics that cunter the harmful effects f CUI PrRx PS with WR-Tech is by far the superir hydrphbic, pen-cell insulatin n the market 5X better water repellency than leading mineral wl materials when tested t the stringent EN standard (n declaratins) Labratry test results have prven that PrRx PS with WR-Tech has superir water absrptin perfrmance cmpared t cmpetitive materials. Quick release Durable perfrmance Lwest water absrptin ROCKWOOL PrRx PS with WR-Tech

30 Cnclusins NACE Natinal Assciatin f Crrsin Engineers NACE SP (2.1.2) PrRx PS 960/970 mandrel wund pipe sectins with WR-Tech Because CUI is a prduct f wet metal expsure duratin, the insulatin system that hlds the least amunt f water and dries mst quickly shuld result in the least amunt f crrsin damage t equipment. Crrsin can be reduced by careful selectin f insulatin materials

31 FAQ

32 Frequently Asked Questins (FAQs) Have yu changed the name f the PrRx pipe sectins with WR-Tech? We will cntinue t sell PrRx pipe sectins under the glbal nmenclature - PrRx PS 960 and PrRx PS 970. Is there an impact n thermal perfrmance f PrRx pipe sectins with WR-Tech? N, the thermal perfrmance f the prducts is nt impacted by the new Water Repellency Technlgy. Have ther technical r perfrmance prperties been changed? N ther technical prperties (e.g. leachable chlrides) f the stne wl have been changed r are being influenced by the new WR-Tech binder technlgy. The prduct appearance and physical prperties will be the same and will cntinue t be prduced t the highest quality that yu expect frm ROCKWOOL. When will PrRx pipe sectins with WR-Tech be available? Effective 1 st Octber, ur factries in Rermnd and Bhumin will cmmence prductin f PrRx pipe sectins with WR-Tech. We will als maintain the same item number and pieces per bx/pallets. Mre infrmatin abut Dahej will fllw sn. T indicate which prduct have the new WR-Tech innvatin, the WR-Tech lg will be placed n the label. Is WR-Tech a surface treatment f the finished prducts? WR-Tech is nt a surface treatment. This new technlgy cats the individual stne wl fibres in the insulatin prduct and prvides imprved water repellency. Can PrRx pipe sectins with WR-Tech be used in paint shps? Yes. PrRx with WR-Tech is silicne il free and the technlgy will nt affect cating applicatins. There is n risk f fish eyes, pinhles, r ther paint defects in paint shps. Als nt when the pipes are recated fr maintenance.

33 ROCKWOOL Technical Supprt

34 ROCKWOOL Technical Supprt Calculatins Design Supprt Insulatin thickness using ROCKASSIST - N installatin required - Certified VDI 2055 calculatin - EN ISO calculatin - Extensive calculatin ptins - Wide range f prducts - Dynamic prduct prpsals - Plausibily checks - Tablet & smartphne friendly Engineering input and technical guidelines (extensive prduct literature available) Specificatin reviews Interpretatin f cdes and standards Seminars n CUI, insulatin science, prduct cmparisns, etc. Dcumentatin f prduct cmpliance ROCKWOOL Technical Insulatin takes the lead in prviding cst effective and energy efficient insulatin slutins, prtecting bth the envirnment and yur investment.

35 Where t find mre infrmatin?

36 Where t find mre infrmatin? Check the website in rder t find mre infrmatin abut WR-Tech r ask yu sales representative