SUCCESSFUL METHODS FOR MITIGATION OF CORROSION UNDER INSULATION (C.U.I.) AND OTHER CREVICE CORROSION USING SURFACE CONVERSION TECHNOLOGY

Transcription

1 SUCCESSFUL METHODS FOR MITIGATION OF CORROSION UNDER INSULATION (C.U.I.) AND OTHER CREVICE CORROSION USING SURFACE CONVERSION TECHNOLOGY Patrick J, Dunn Sr. Vice President Mechanical Products Division Polyguard Products, Inc. P.O. Box 755 Ennis, Texas

2

3 Corrosion Under Insulation (CUI) CUI has been recognized as a problem in many industries Insulation is a necessary component of the system and is designed to: Save energy Control process temperatures Protect workers from high temperatures NACE Standard RP is a good source of information, but electrolytes will eventually find their way into even the best system

4 Corrosion Under Insulation

5 Selecting the Correct Coating System Performance Operating Temperatures Moisture Resistance Anti-Corrosion Properties Application Surface Prep Dry/Cure Time Labor & Equipment Requirements Total Cost Product Application Ease of Maintenance Comparison of TOTAL installed cost is recommended

6 Anti-Corrosion Gel Performance Operating Temperatures up to 350 Moisture Resistance Hydrophobic Anti-Corrosion Properties Mineralization & Buffering Technology Application Surface Prep SP-2 or better Dry/Cure Time - None Labor & Equipment Requirements - Minimal Cost Installed cost is typically lower than other systems

7 Technology The technology works in three basic ways Barrier system The specially formulated products have great adhesion characteristics and are hydrophobic to help keep moisture away from the substrate. Mineralization - Growing an engineered surface, or surface conversion creating a surface which resists corrosion even if moisture gets to it. Buffering system If moisture migrates through the gel, it is buffered to a high ph which is alkaline enough not to corrode metal.

8 Basic Science Surface conversion technology, also known as mineralization, is the ability to grow very thin minerals on metal surfaces. The mineral forms when reactants are delivered to the surface of a metal or metal containing article. Substrates contribute ions that form a thin layer of mineral, which chemically bonds to the surface of the metal and has been measured to be angstroms thick. Lattice-forming oxides anchor to this surface layer and polymerize into a three-dimensional inorganic framework until the final surface is formed. Patents and patent applications cover unique formulations as well as the mineralized layer that is formed. METAL METAL METAL METAL Metal surface: Oxides Metal carbonates Metal hydroxides Metal surface Polymerized metal silicate lattice Protected surface Extended surface Mineral formation

9 Surface Formation Untreated steel surface Mineralized steel surface 10 um 10 um The presence of the mineralized layer can be confirmed by conventional analytical surface methods such as x-ray Photoelectron Spectroscopy (XPS) or Atomic Force Microscope (AFM)

10 History of the Technology Automotive Technology has been used in automotive applications for approximately 30 years. Crevice Corrosion on Brake Cables Industrial Applications First industrial application was with the US Navy. Solved their #1 and #2 corrosion maintenance problem. Watertight Door Latching Mechanisms Deck Edge Elevator Wire Ropes

11 2 Year Salt Water Immersion Test Samples were prepared with fiberglass pipe insulation, surface conversion gel technology and placed in a 5% aerated salt bath. 11

12 2 Year Salt Water Immersion Test 10 DAYS 365 DAYS 81 DAYS 138 DAYS Samples were removed at timed intervals to determine protection of substrate

13 2 Year Salt Water Immersion Test TWO YEAR IMMERSION 55mil PER YEAR CORROSION RATE 13

14 2 Year Salt Water Immersion Test One uninsulated pipe in the test proved that the Gel does not undercut 14

15 Undercutting Test 2000 hrs ASTM B117 Salt Spray Gel Protected Steel Panel 2000 hrs ASTM B117 Salt Spray Gel Removed One unique property of gel surface conversion technology is that the gel will not undercut like a hardening barrier coating will.

16 Isothermal Testing 16

17 Weight Loss Testing 17

18 Corrosion Under Insulation (CUI)

19 Corrosion Under Insulation (CUI) Ammonia Piping Remediation

20 CUI - North Slope 2003

21 CUI - North Slope 2010 Inspection

22 CUI Bundled Pipe Corrosion Remediation of Bundled Pipe System (BIR)

23 CUI Bundled Pipe (BIR) X-Ray Inspection Through Insulation

24 CUI Bundled Pipe (BIR) Remove Metal Jacket Remove Insulation

25 CUI Bundled Pipe (BIR) Removal of Aged Mastic

26 CUI Bundled Pipe (BIR) Physical Inspection of Pipes Removal of Rust Scale with wire brush and pot scrubber

27 CUI Bundled Pipe (BIR) Install of Corrosion Gel Uniform Thickness Trowel

28 CUI Bundled Pipe (BIR) Install Stand-offs and Insulation Install Metal Jacketing

29 DOWNHOLE CORROSION PROTECTION

30 Benefits of the Technology: Practical products and applications Multiple delivery systems Ease of application Insensitive to surface preparation and application conditions (SP-2 Hand Tool Cleaning or better) Superior anti-corrosion performance Environmentally benign Easy to inspect

31 Companies With Product Installations Budweiser General Mills Nestle Green Giant British Petroleum Best Brands Foods Philadelphia Gas Fred Meyer Foods Unocal AK Oil Platforms Dot Foods ExxonMobil -Sakhalin Island Steam Lines Phase I Phase II -Downhole Wells Alaska Alta-Dena Dairy Conagra Tyson Foods Tyson Chicken Tyson Fresh Meats Kroger US Cold Storage Publix Grocers Tombstone Pizza OxyChem Equistar Union Carbide Cytec Phillips MODOT-Missouri Dept of Transportaton Nicor Tesoro Refinery Monarch Foods Safeway U.S. Navy Kraft Foods Dow Chemical Schepps Dairy ConocoPhillips - downhole Coors Brewing Canada Hydro Indiana University Chiller Pipe Southgate Foods Wal-Mart Scotia Bank Toronto (CHW) Shepps Dairy Chevron The entities listed above have used and/or specified surface conversion technology on one or more projects, however, the naming of these entities do not imply advertisement or public endorsement of the product.