Technology

Coatings That Provide Corrosion Protection in Insulated Service

By Mr. Peter P. Bock and Mr. Michael F. MeLampy
ABSTRACT
This paper reviews the corrosion prevention options available for use in protecting insulated carbon and stainless steel process vessels and pipelines. A brief history of materials and older technology and their issues followed by industries various attempts at providing solutions will be discussed. Discussion of the importance of coatings for use under insulation, especially in cyclic service, and that all service is ultimately cyclic. The concept of a safety factor for coating materials in these very harsh environments will be provided along with potential failures when the sometimes limited safety factor is exceeded. A table of corrosion protective coating selection options will be presented and discussed. Additionally this table will present newer technologies that are offering easier application and better service. First costs and life cycle costs evaluations and a process for determining these will be provided. Actual field examples/cases will be discussed. Insulation systems can include, foam glass, aerogel, calcium silicate, expanded perlite, mineral wool, and fiberglass. These are typically applied via mechanical means onto unprotected, painted or otherwise corrosion protected substrate. These materials provide different levels of thermal protection and these different insulation systems require different thicknesses of materials to provide similar levels of thermal performance. These insulation materials are generally clad with sheet metal or other materials to stop the flow of water from entering into the insulation material. This water ion vapor or liquid form can include contaminants, such as salts and acid rain, and can have a detrimental effect the thermal performance of the insulation and can increase the opportunity for corrosion to occur. Insulation and protective coating materials need to be selected so ensure that no adverse effect of material selection which can result in shortened life of the process vessel. As an example some insulation materials can have the presence of chlorides which can cause adverse effects when coming into contact with austenitic stainless steels. In this example the combination may result in chloride induced stress corrosion cracking, which may result in structural failure of the substrate material leading to catastrophic failure of the vessel or pipeline. Determination of coating systems and materials for use under insulation has been an learning process. A NACE Report from 1986 states: No particular corrosion problems were considered or anticipated with carbon steel under thermal insulation when the plant construction boom began in the 1960s. Prior to that time, insulation was applied over bare steel, or in some cases, over one coat of oilbase primer that had been applied over mill scale. When serious corrosion was later noted, many engineers concluded that better surface preparation and a better primer, or better maintenance of the insulation waterproofing, would mitigate the formation of corrosion. [Note 1]
Visit our websites at www.safan.com / www.pm-pipeliner.safan.com

INTRODUCTION
Insulation is applied to hot surfaces, vessels, processing units, and piping systems in order to provide heat retention for process flow/control or to protect is used to provide protection for personnel that may come into contact with these hot surfaces (personnel protection). Additionally with the continued general increase in energy costs, many owners wish to retain heat and limit input of additional energy that might be saved with low level insulation. Refining and chemical processing are generally sophisticated cooking processes, where materials are heated under various conditions to produce higher-value mid-products or end products. Insulation can create microenvironments that can result in corrosion, and in some conditions accelerated corrosion, that can result in coating and mechanical failures.

18

JAN-MAR 2010

After discovering that corrosion can and does occur, addition of coatings and upgrades these coating systems used under insulation have included inorganic zinc, elevated temperature coal tar epoxies, phenolic and novolac epoxy tank linings, thin film silicones, and thermal spray aluminum. We as an industry have learned for the use of these materials. Now many are in disrepair, and a major problem exists not only in finding where these expired coatings systems are but then determining an appropriate repair and upgrade materials to maximize the life of the mechanical device. Some of these coating systems may be salvageable and others will need to be completely removed and have newer technology systems applied. And this is the good situations on the other end of the spectrum the vessel or pipeline will be considered a safety risk and need to be replaced. At the extreme the vessel or pipeline will fail before an evaluation takes place. One of the root causes of corrosion under insulation is leaky insulation, which has been examined resulting in improvements since the mid 1980s. However, less attention has been paid to developing a leak proof cladding system and non-absorbent insulation materials, than to improvements in CUI coating systems. It is important to know that eventually all cladding systems will leak. This allows corrosion to take place in even the least expected areas, given the lack of a properly working corrosion control coating system. Further studies are currently underway to determine the effect of various insulation materials on the microenvironments that exist in insulated service. Does the insulation material contribute to the corrosion environment by altering the pH or trapping more moisture at the surface? New insulation systems have been developed that are spray applied and may solve various under insulation systems. By being adherent to the properly corrosion protected substrate and by nature being monolithic, these systems may provide for a more consistent and observable microenvironment. Future incremental technologies will help to enable engineers and owners have practical solutions for this troublesome issue.

shutdown or as in many cases may cycle much more frequently. It has been found that excessive corrosion does occur when no or insufficient coating materials are used to provide corrosion protection. This situation left unchecked, can result in process fluid leaks, and in more unfortunate instances, these process fluid leaks can result in fires and explosions leading to extensive repair costs, process unit down time, personnel injury and even death.

A coating for elevated temperature and /or CUI service must survive the elevated temperature, thermal shock and thermal cycling, and still be intact to provide corrosion protection when temperatures fall below 100C.
The major difficulty associated with CUI is the word under. Corrosion which can become extensive is not visible and can be very localized and severe. Routine inspection of exposed (non-insulated) service can lead to detection of areas having excessive corrosion, allowing repair procedures to be scheduled. Inspection of insulated service environments involves the removal of insulation and is typically expensive. Due to less than a 100% full inspection, unidentified areas of corrosion may remain hidden.

AGING INFRASTRUCTURE, IMPROVING QUALITY AND EFFICENCY

There has been gaining interest in high temperature coating systems to control CUI. Many older refineries and chemical plants upgrade for higher quality products or for improved efficiency, or simply expand. Typically these improvements expansions and upgrades require higher temperature processes and a need for improved coating materials. Existing coating materials with maximum temperatures limits may be exceeded and any safety factor becomes smaller. Leaks resulting from corrosion have led to unexpected outages, injury and death, and to extensive downtime, with its associated to extensive remediation costs. Many refineries and chemical plants have undertaken far-reaching CUI integrity surveys to determine the extent of corrosion under the insulation and then put a plan together for repair strategies on these long-neglected vessels, pipes and processes. Equipment owners desire cost-effective long life protective coating systems, which will survive ever-higher operating temperatures. Each process has unique needs, which need addressed through innovative coating solutions at reasonable, though not inexpensive, applied cost. Primarily

CORROSION CONTROL
Corrosion control systems have not always been used on hot surfaces or under insulation, especially in older installations. It had been thought that corrosion does not occur above 100C, and therefore corrosion protection was not needed. Unfortunately, even though many processes are thought to be continuous, it seems all processes are cyclic over different periods of time. This may mean that a process only cycles down to below 100C during a yearly

20

JAN-MAR 2010

Visit our websites at www.safan.com / www.pm-pipeliner.safan.com

the economics of repair and maintenance are mainly driven by the cost of the labor and the down time during which repairs will be made. These repairs can include replacement of the vessel, substrate, and or the coating, insulation and cladding. The costs can be huge when down time is included in the costs. Maximum cost effectiveness may be to do as much of this work as possible while the facilities are in operation. In some cases this may mean reducing the surface temperatures of equipment being prepared and coated to a level compatible with the maximum hot-surface application limit of the coating materials to be used. The choice of coating materials and application methodologies are very important if owners are to increase the amount of work completed based on limited budgets. Some work will require complete operation unit shut down, and the costs associated with this, while other work, with proper planning, material selection, and application methods will allow coating work to be performed during unit up time. Many petrochemical companies specifications list the maximum temperature for CUI service in the 175C to 205C range. Many do not require any sort of coating under insulation for equipment operating continuously above these temperatures, claiming that the minimal amount of corrosion occurring on such equipment is compensated for by additional wall thickness allowance. However all equipment thermally cycles. Some units may have a one year cycle, where they are heated to operating temperature and stay hot until the next scheduled turnaround in three years, but they still cycle. In other cases, thermal cycles may go from highest to lowest several times daily. Similarly, additional wall thickness is a good measure against corrosion on flat surfaces, but it offers little protection against pitting on corners, gussets, and so on. Considering the small additional price of surface preparation and application of a CUI coating versus the cost of taking a unit out of service, stripping the insulation, weld repairing corrosion pitting corrosions, repairing the CUI coating and then replacing the insulation. Based on current experiential knowledge an owner/specifier should always consider using a cui coatng material on carbon and austenitic stainless steel substrates. Real operating and peak temperatures can be elusive. Specifications may have been based on temperature breakpoints to coincide with temperature limits of available and purportedly effective coating systems the last time the specification was revised. The 176C to 205C may be the actual operating temperature for a lot of refinery processes, but it is also the maximum temperature for coal tar,

phenolic, and novolac epoxies. Some dispute whether epoxies are suitable for temperatures over 149C due to the amines used in these coatings. And while the maximum process temperature is stated to be 176C to 204C, there will be inevitable thermal over-run from process upsets, and other operations such as - during turnarounds, equipment is typically flushed with high pressure steam, which may go well above 218C on some surfaces. In recent years there has also been a tendency to increase process temperature to improve efficiency and allow for manufacture of higher quality products.

HOW HOT IS IT - - REALLY?

The first step in planning high temperature coating work with equipment in or out of service is to determine the actual maximum surface temperatures of piping and equipment to be prepared and coated. Knowing the operating temperature is important but it is the maximum temperature that may damage applied coating material. Drawings and prints are useful only for determining locations but may not help much when used as a guide to operating temperature. Upsets and cleaning systems with high pressure steam can lead to higher temperatures. In most cases unit operators are familiar with how hot the process runs. They also know what can be throttled back without affecting the overall process, what needs to run as is, when temperature cycles occur in each unit, and how wide and how long they are. Operators may also know of events where temperatures may spike much higher, such as cleaning routines, turnarounds and other unusual activities. Any coating system selected obviously needs to be designed to survive these temperatures with an appropriate safety factor. In most other engineering disciplines in refineries and chemical processing units, a relatively large safety factor is required. The owner should give careful consideration about an appropriate safety factor design for coating used on elevated temperature project.

CONSTRUCTION ISSUES
As the size and scope of plant expansions and upgrades continues to grow, there is a relentless pressure to simplify construction processes and to squeeze the budget. Traditional coating systems are considered too slow, too cumbersome and too expensive. The design engineer demands one- or two-coat systems with extremely fast dry characteristics which allow both coats to be applied at the fabricators yard. The applied system must survive transportation to the final site, installation, and assembly. Touch up in the field is expected and must be quick and easy to accomplish.

JAN-MAR 2010

21

Maintenance painting in refineries and chemical plants shares with new construction the reality of ever-shrinking budgets, both financial and in time. Many additional limiting factors involved in trying to do meaningful surface preparation and quality coating application in the cramped surroundings of an operating refinery or chemical plant. The key word here is operating. Most plant turnarounds have become too brief, too intense and too crowded. Inaccessible areas are also a big concern. Additionally, these projects involve Health Safety & Environmental as much as painting and insulation. They typically involve work areas which are fully enclosed and surrounded by equipment operating at temperatures in the 149C range or higher. The first consideration has to be worker safety. Insulators, blasters and painters may be working in an environment with considerable heat, and as such, care has to be taken to assure that workers do not suffer from heat stress, and also that they are able to do the application in accordance with good painting practice and specification requirements.

frame. Proper access surface preparation equipment and materials are not typically available, and constraints are critical if the unit has been shut down. If the unit has not been shut down, time is less significant, but all operations must take place at the working surface temperature of the operating vessel or pipe. The cost of removing all the cladding, insulation and CUI coating on a vessel or pipe run is so high that most owners prefer to postpone the process, indefinitely if possible. And when the inevitable arrives, there is still the unanswered question of what coating system to put under the insulation.

SURFACE PREPARATION AND INSPECTION

Surface preparation is one of the most important and costly part of the coating system. In most cases the choice of coating systems will dictate the surface preparation requirements. New technology CUI coating systems may not require the typical white metal clean surface preparation efforts, and can work well in a less then optimum application environment. Several surface preparation techniques are appropriate from hand tool cleaning up to abrasive blast cleaning to white metal including high pressure water cleaning. This paper is not to discuss these options, but to keep in mind that each option has an implied cost associated with it along with an expected lifecycle benefit. Associated costs such as scaffolding, tenting, disposal and equipment charges need to be considered. Other costs include cost of operations within the facility and requirements such as training, hot work permits, and access to the specific area should be considered. Of course the largest cost is typically the cost of shutting the process down for this work, if required by the coating system selected.

PRE CONSTRUCTION INSPECTION ISSUES

The usually bright metal cladding applied over the insulation and corrosion actually gives a false sense of security, even after mechanical damage and water incursion, it maintains a pristine appearance. Until rust is running out the bottom of an insulation termination, looks good is the usual evaluation of the CUI coating system underneath. Inspection of CUI coating systems is difficult and expensive as the coated substrates are almost entirely hidden by insulation and cladding, so that observation of corrosion as it occurs is impossible. Observation ports are typically discouraged; for fear that they will leak and allow water penetration. Where observation ports are included, they are small compared to the overall CUI surface, and are invariably placed for ease of access, as opposed to where areas most likely to suffer degradation of the CUI coating system. The cost of removing and replacing even a small portion of the insulation and cladding is costly. It is only rarely done by concerned owners and engineers who want to observe how the CUI coating system is holding up. In many instances the severity of corrosion under insulation becomes apparent only when there is a perforation or loss of wall thickness in a vessel or pipeline. Spot repair of CUI coating systems can be problematic. As an example - the insulation was usually removed for a different purpose such as to change out a valve. Removal of additional insulation is outside the scope of work or time

THE CUI CYCLE

For insulated vessels, equipment and piping which cycle frequently in terms of time, and which cycle extensively in terms of minimum and maximum temperature, there is a CUI cycle of corrosion which affects the substrate. Assuming that nothing stays hot forever, there will be times when the substrate is under 100C. Water under the cladding is never entirely expelled; additional water is drawn in whenever available. Electrolytes in the water concentrate and may be strengthened or neutralized by chemicals released from wet insulation. Eventually the insulation may become saturated. In any case, the substrate corrodes if not properly protected. Most insulated equipment in refineries and chemical processing facilities is outdoors and not roofed over. These are usually humid environments regardless their actual

22

JAN-MAR 2010

Visit our websites at www.safan.com / www.pm-pipeliner.safan.com

geographic location: a typical facility has stacks, steam leaks, and cooling towers, and many facilities are located near the shore or a river. These plant environments are rarely pH neutral, and even in the most environmentallyfriendly refineries there is usually mildly acidic environment evident every time effluents combine with dew, mist, drizzle or man-made moisture. Combine this acidic electrolyte with poorly protected carbon steel or stainless surfaces and corrosion is likely. As the plant operates, the CUI cycle is repeated endlessly, every time the pipe or vessel cycles between hot and cold temperatures. Assuming that nothing stays hot forever, there will be times when the substrate is under 100C. Water under the cladding is never entirely expelled; additional water is drawn in whenever available. Electrolytes in the water concentrate and may be strengthened or neutralized by chemicals released from wet insulation. Eventually the insulation may become saturated. In any case, the substrate corrodes if not properly protected. The ideal CUI coating system must:

maintenance situations, many of these new-generation coating systems can be applied while units are in service.

REPLACEMENT CUI COATING SYSTEM

Selecting a CUI system for repair or over coatings of an installed system requires evaluation of existing coatings that remain on the substrate, and whether it is more cost effective to save some of the old system, or to remove it completely. Washing and spot surface preparation versus a full abrasive blast can save time and labor costs, but only if the remaining portions of the existing coating system are stable enough that they will survive a long time and/or overcoating them can provide a significantly extended service life. Otherwise full removal is the only choice. The coating systems below are those commonly encountered in CUI systems in the field today. Some of these systems have long windows for field repair and overcoating; others do not and would require full removal and replacement. When the decision is made to do limited preparation over existing aged CUI coating systems, cross-compatibility becomes a significant issue. The new overcoating system must be compatible with what is left on the substrate, whether it is old coating or residual corrosion products. Only one class of the new CUI coatings is truly surface tolerant, the inert multipolymeric matrix coating systems. These can be applied over salt-free but rusted surfaces, over new or aged but tightly adhering inorganic zinc, over tightly adhering and otherwise clean residues of thin-film silicones, and of course over aged films of itself. The new high build silicone primers can also be used to overcoat clean, aged inorganic zinc, but surface preparation for this class of products is a bit more rigorous, limiting application over aged rusted steel, or over steel which has turned after washing or wet abrasive blast preparation. Areas of bare rusty steel where aged, failing thermal spray aluminum in CUI service has anodically sacrificed, can be spot repaired with inert multipolymeric matrix coating systems or with new technology high build silicone primers, once appropriate surface preparation has been done. There is continuing disagreement whether the entire thermal spray aluminum surface and areas of bare steel should be overcoated, or whether repair coating should be applied only to areas where the aluminum has been completely depleted. Thermal spray aluminum is normally overcoated only with thin-film silicone or thin epoxy seal coats. Past research

Survive to and past actual operating temperatures at the

substrate surface.

Survive unexpected excessive temperature spikes well Survive immersion for lengths of time under 100C and
when water is present. beyond stated operating temperatures.

Survive immersion in chemicals from environmental

water and from the insulation itself.

Survive damp surface exposure whenever the surface

is under 100C.

Survive the steam interface every time the substrate rises

above 100C.

Survive cyclic service including all of the above.

NEW CUI COATING SYSTEMS

In recent years, coating systems suited for elevated surface temperature application have changed from a niche to an accepted part of doing business as many paint manufacturers have brought out new lines of products whose data sheets. New products now provide for application to elevated temperature substrates as well as for an elevated or cyclic peak operating temperature. High-temperature coating systems are now available for both new construction and maintenance. These coatings offer greater temperature and cyclic tolerance, longer service life and ease of application, without containing lead or chromium. These new coatings offer much higher DFT, less permeable films and a wider service temperature range than were ever available before in this category. In

JAN-MAR 2010

23

and industry practice discourage thick-film overcoats, since thermal spray aluminum under a thick coating film tends to suffer catastrophic failure due to cathodic dissolution of oxygen and anodic dissolution of the aluminum metal when the system is in a chloride-rich environment. [NOTE 2] Testing is ongoing whether this same mechanism exists for thermal spray aluminum overcoated with inert multipolymeric matrix coating systems or with high build silicone primers in a CUI environment. Most commonly used CUI coating systems, in particular thermal spray aluminum and inorganic zinc, require excellent abrasive blast surface preparation and are not at all tolerant of surface residues. They can be considered when thorough surface preparation of an existing CUI coating system is planned. Phenolic and novolac epoxies straddle the fence they overcoat clean, aged epoxy films well, as long as the aged epoxy has not been embrittled by heat stress. Epoxies are also suitable for overcoating clean aged inorganic zinc, but the composite systems maximum operating temperature is reduced from 399C to 204C. Phenolic and novolac epoxies are also the coating system of choice when process temperatures are never ever (ever) going to exceed the maximum service temperature of the epoxies. Thin film silicones are still encountered as a topcoat over inorganic zinc in CUI environments. Their poor performance makes them counterproductive. Although they can overcoat aged inorganic zinc, the performance of the overcoated system is only equal to that of the aged inorganic zinc without the overcoat, and of course only as good as thin film silicones where bare metal exists. Residues of aged thin film silicones are occasionally found in CUI service, usually as scattered smears of aluminum on an otherwise uniformly rusted substrate. What remains of such residues after high pressure washing and spot surface preparation may be left and coated over with inert multipolymeric matrix coating system.

100C cyclic service leads to quick failure. Thin film silicones are still encountered as a maintenance topcoat over inorganic zinc in CUI environments. Their poor performance makes them counterproductive. Although they can overcoat aged inorganic zinc, the performance of the overcoated system is only equal to that of the aged inorganic zinc without the overcoat, and of course only as good as thin film silicones where bare metal exists.

INORGANIC ZINC
Inorganic zinc has been the workhorse of many CUI programs because of the 399C stability of the ethyl silicate matrix and zinc dust filler. Additionally this zinc coated surface was one huge sacrificial anode; it was supposedly stable to 399C. However a 1983 Symposium on Corrosion of Metals Under Thermal Insulation, jointly hosted by NACE, ASTM and others presented a list of premature failures of zinc in CUI situations. Reversal of polarity, failure of the binder in wet heat conditions, rapid sacrifice of the zinc in immersion-like conditions and presence of chemicals which produced water soluble salts were all listed as contributors to failure. The bottom line was that insulation leaked water, the water contained electrolytes, and the anodic zinc coating sacrificed. [NOTE 3] On the other hand, in CUI situations where the insulation does not leak water, areas of inorganic zinc which stay dry can survive intact for a considerable time. There are large amounts of inorganic zinc under insulation in many refineries and chemical plants, and in many cases, dry portions of the zinc coating are in good shape. However, typically most are crosshatched by narrow lines of corrosion which coincide with joints in the block insulation. This pattern demonstrates where water leaked in at these joints and the zinc coating sacrificed, and eventually leads to pitting along these narrow lines. Repair of aged inorganic zinc in CUI situations can be a cost effective method. Instead of having to remove the remaining relatively intact zinc and corrosion by abrasive blast and then replacing the entire CUI coating system, it is practical to pressure wash the surface to remove zinc salts and other contaminants, spot prepare the areas of corrosion, and then overcoat the entire area with one of the newtechnology high build elevated temperature coating systems. These thick-film coatings seal the zinc. One system, the aluminum-containing system slows cathodic activity to a great degree. The other system, the non-metallic inert multipolymeric matrix system stops it entirely and both offer huge time and labor costs versus entirely removing the aged inorganic zinc system.

TYPICAL CUI COATING SYSTEMS

THIN FILM SILICONES
Until the development of the first generation of polysiloxane high build coatings for elevated temperatures in the mid 1990s, thin film silicones were the standard coating for service above 399C. However, thin film silicones provide little protection at ambient temperatures. The films are typically so permeable that even rain showers on exposed, normally dry surfaces were enough to rust through a three coat thin film silicone system within a short time at ambient temperatures. Any length of service below

24

JAN-MAR 2010

Visit our websites at www.safan.com / www.pm-pipeliner.safan.com

THERMAL SPRAY ALUMINUM

Included in the list of CUI protective coating systems is thermal spray aluminum which is non-liquid. This coating is applied with oxy-fuel or spray arc equipment. Thermal spray aluminum has a proven track record of more than several decades on sheet piling, bridge sections, dam gates and some applications under insulation. Thermal spray aluminum is becoming less expensive but still requires pristine surface preparation and skilled applicators. A white or near white metal or near white metal surface preparation is required. Application equipment does not allow for difficult to reach or inaccessible areas. Automated Thermal Spray Aluminum application on new equipment such as piping is becoming more economical. Typically these applications will use one of the new generation technology products to make field repair of installation related damages such as girth welds. Users of thermal spray aluminum should also remember that aluminum is anodic to carbon steel, and a thermal spray aluminum coated system in a mild acid environment (typical of older refineries) is simply one gigantic anode. Once any portion of the thermal spray aluminum is completely depleted, and when there is sufficient water present, the system becomes a huge electrolytic cell. Thermal spray aluminum cannot be spot repaired with itself, without the pristine surface preparation. There are limitations on recommended film thickness. Many use a liquid applied seal coats where the thermal spray aluminum may be subject to intermittent immersion to help seal the porosity which can be developed as part of the application process. One European user of thermal spray aluminum for CUI on offshore equipment currently recommends repair by spot preparation of failed areas with one of two approved thick-film new generation technology products. Short term independent lab testing done for this user has not shown problems with this repair method in these situations.

preparation, and are recommended for thin film application (two coats, 4 to 5 mils per coat). Flow characteristics are typically acceptable even with brush to airless spray application to surfaces in the 121C to 149C range. The epoxies spray well, flow out before setting, and form a pinhole-free film even on surfaces at 121C to 149C. Two critical points in the application of these high temperature phenolic epoxies are dry film thickness and recoat interval between the two coats. Dry film thickness is critical and must be kept in a relatively narrow range. DFT below the recommended leaves a porous film while above the recommended will crack and delaminate at normal operating temperatures. When applied to elevated temperature surfaces, the maximum recoat interval for these products is significantly shorter than with ambient surface temperatures and must be maintained to assure inter-coat adhesion. The shortcoming of phenolic epoxies under insulation is peak temperature tolerance. The maximum single peak for most of this category is 218C, based on product data sheets. Some think that these peak temperatures are misleading. Amines can begin to break down at temperatures from 165C to 175C When refiners are raising their process temperatures from 65C-149C to 65C-204C, the safe margin of phenolic epoxies for thermal spikes, cleanouts and even slight process variations is no longer viable and owner/specifier need to rethink the use of these products in these instances.

FIRST GENERATION THICK FILM POLOYSILOXANE

First generation polysiloxane-based products for elevated temperature service were introduced in the mid-1990s. Due to prevalence to micro-crack in cyclic service these product are no longer used and should be removed and replaced with an appropriate technology coating system.

COAL TAR EPOXY

Coal tar epoxy coatings are typically no longer manufactured or used because of inherent health hazards. It is typically more cost effective to remove these systems and replace it with a more user-friendly CUI coating whose performance characteristics meet the units requirements.

NEW GENERATION CUI COATINGS INERT MULTI-POLYMERIC MATRIX HIGH BUILD SILICONE-BASED PRIMERS
Newer technology products, the high build inert multipolymeric matrix and inorganic silicone co-polymer based coatings for elevated temperature service, allow for simple application of coating materials using typical spray equipment. This class of ambient or hot application coatings allows for far greater flexibility for hot surface application. Unlike epoxies, recommended DFT for these new technology products allows a much higher range. Maximum recoat intervals are much less critical. Typical DFTs are in the 5 to 6 mil DFT range per coat, assuring that permeability and porosity from typical low thickness coatings are not a

PHENOLIC & NOVOLAC EPOXIES

Phenolic epoxies typically have peak service temperatures in the 204C range and may be applied to surfaces at up to 149C, according to manufacturers data sheets. The high temperature phenolic epoxies require stringent surface

26

JAN-MAR 2010

Visit our websites at www.safan.com / www.pm-pipeliner.safan.com

problem, and in allowing a wider tolerance for DFTs above the recommended help to reduce application related defects. A wide latitude in maximum recoat interval also allows for better scheduling, ease of touchup, and longer term maintenance planning. Inert multipolymeric matrix coatings are formulated to have no chlorides, sulfides or halides to protect austenitic stainless steel surfaces from stress corrosion cracking. With allowable application surface temperature ranges up to 260C, nearly all process equipment can be coated with the inert multipolymeric matrix system while in operation and at higher temperatures. As always, safety precautions are of primary importance, and contractor and applicator personnel should consult the local safety authorities before undertaking any hot surface application work.

wastage at a job site. Maximum Dry Film Thickness per Coat of Material (in mils): Indicates how much paint film can be applied per coat. Item in parentheses indicates the normal number of coats applied. Although single-coat application seems better for speed and labor cost savings, a two coat application process is preferred since it greatly reduces holidays due to applicator error, and allows correction of under- or over application of DFT on the first coat. A CUI coating system must be thick enough to resist failure in immersion at temperatures under boiling, but must be thin and flexible enough to survive repeated expansion and contraction with the substrate without cracking, peeling or delamination. Flexible coating systems with a relatively high maximum DFT generally do better in long-term cyclic CUI service. Recoatable With Itself: Indicates that the coating material can be recoated with itself, for building of additional thickness, tie in, or future maintenance requirements. For specific recoat window opportunities the product data sheet or the manufacturer should be consulted. Some materials have an extremely long recoat window while others have a very limited recoat time frame. A coating system which cannot be recoated with itself causes immediate problems during new construction, and all but implies that full removal is required when any portion of the coated area fails after extended service life. A coating which can recoat itself, even after extended service (assuming the surface is clean and free of contaminants) and whose maximum recommended DFT allows the additional thickness of a refresher coat without worry of the total film cracking or failing due to excess DFT, is more user friendly and cost effective than a coating which can do only one or none of these things. Maximum Hot Apply Temperature: The ability to apply a CUI coating system to hot substrates can result in huge savings; equipment can continue to operate at full or limited capacity while insulation and CUI coating work are done. The higher the allowable substrate temperature, the less coating work will interfere with unit operation. All such work should be coordinated with local safety authorities and should be undertaken only by competent contractors. Special care should be taken to verify this temperature as some technical product data sheets have recently lowered this maximum number. AnodicMetal Content Sacrifices In Electrolyte: Reactive metal content in the dry film indicates that the coating is potentially subject to anodic sacrifice whenever an electrolyte is in contact. The depletion of the metal content may eventually lead to substrate corrosion. Coating systems

A CHART OF CUI COATING SYSTEMS

The following table summarizes generic high temperature coating materials commonly used for CUI service in new construction and field maintenance. Thermal spray aluminum is a part of this chart as it is an applicable technology for elevated temperature service even though it is not a liquid applied coating system. Coatings are listed by maximum operating temperature, decreasing left to right. Negative characteristics are indicated in lower case, favorable characteristics in UPPER CASE. Maximum Operating Temperature indicates the peak temperature the coating material can be subjected to per industry accepted standards or manufacturers data sheet. Repeated cycles to this temperature should not cause any deleterious effects on the existing coating. Surface Tolerant Minimum level of surface preparation acceptable. The quality of surface preparation affects the performance and service life of all coating systems. In many repair situations, even with full curtaining, dry abrasive blasting to SSPC SP10 is very expensive and very difficult to achieve. Systems which allow lesser dry abrasive preparation, wet preparation, or even power tool preparation are obviously more cost effective, even if a lower quality of preparation means somewhat shorter service life of the applied coating. In some cases, this characteristic may mean the difference between being able to do field applied, in-service preparation and coating, rather than having to replace the unit or pipe involved. User Friendly Mixing and Application: Products which are single component, do not require thinning, apply with readily available equipment, and spray and handle like ordinary industrial coatings are less likely to require specialized training and exotic application equipment and are less likely to cause problems, delays and material

JAN-MAR 2010

27

that do not rely on anodic metal protection but rely on barrier protection and other mechanisms to prevent corrosion are preferred for CUI service, since they do not become depleted with the passage of time. Survives Intermittent Immersion in Hot Salt Water: Mild chemical solutions can and do form beneath cladding and insulation from various sources, as detailed in the CUI Cycle above. Over time, chemical concentrations may increase due to the evaporation of the water from these solutions or from leaching of chemicals in the insulation. Immersion in hot salt water is a good baseline test of a coating systems ability to survive cyclic CUI service. An undocumented technology exchange presentation at NACE Corrosion 2007 [Note 4] showed relatively rapid failure of thermal spray aluminum coated panels immersed in hot salt water. Similar testing of phenolic and novolac epoxies and inert multipolymeric CUI coating systems shows no breakdown over extended periods of time. Stainless Steel Application: Indicates whether on not the coating material can be used on duplex and austenitic stainless steels in order to prevent stress corrosion cracking. Although this paper does not specifically deal with CUI on stainless steel, the more substrates a single CUI coating system can be used on, the more savings to the owner and contractor in that a single system can have multiple uses. Protects at Ambient: Almost all high temperature processes are cyclic, although some rarely repeat. As such, nearly every substrate will spend time at or well below 100C. A CUI coating system which dries at ambient temperatures, and can provide protection when the coated vessel or piping is damp, is a basic requirement. Similarly, the ability to protect against corrosion after application and before heating, and good UV resistance are advantages for new construction, where equipment may be painted and then sit exposed for months, sometimes years, before final installation, insulation, cladding, and heating of the substrate occur. Cryogenic Service: This attribute may be a requirement based on the intended service. As LNG units become more common, it is possible to have CUI service with extremes of low and high temperatures. A process knowledgeable expert should be consulted to determine the appropriateness of considering this attribute. Repairs Aged Inorganic Zinc: A large majority of identifiable aged coating under insulation in US refineries and chemical plants is inorganic zinc. Amazingly, many small areas of 18 to 22 year old zinc can be found intact under insulation, although the surface is usually criss-

crossed with lines of corrosion matching joints in the block insulation which allowed water ingress. Traditional repair of such surfaces involved blasting off all the old zinc and corrosion, and applying a new coat of inorganic zinc. A repair coating system which allows the intact zinc to remain and be overcoated after spot preparation of the areas of corrosion is a cost-saver. A system which allows the old zinc to be overcoated without degrading the maximum operating temperature of the CUI system (unlike epoxy systems, which reduce maximum operating temperature to the epoxys level of 204C from the zincs level of 399 C) is practical and a cost saver.

CONCLUSIONS
There is no single CUI coating system which is the answer for every environment and the solution to every problem. As such owners and specifiers should look into the different system options when selecting coating materials for high temperature service. There are trade offs in performance that may make the long term performance of a project a great success or a huge problem. And there is no one single CUI coating system which is the answer for every environment and the solution to every problem. Of course, one also needs to keep in mind that there are some high temperature services that will require other engineering means besides coatings. The owner and specifier should take into account all aspects of the application including shutting down the process, access, surface preparation requirement application ad insulation costs in addition to application to hot surfaces, and cure times, to name a few, before selecting the best product for an application. The costs of any CUI work, especially maintenance can be considerable, but a properly selected coating system including coating insulation and cladding applied to a proper level of surface preparation can minimize total cost, and can give the best cost expected service life.

REFERENCES
1 C. Steely, W. Pollock, A State of the Art Report of Protective Coatings for Carbon Steel and Austenitic Stainless Steel Surfaces Under Thermal Insulation and Cementitious Fireproofing. NACE Publication 6H189 1986 2 O. Knudsen, T. Rogne and T. Rossland. Rapid Degradation of Painted TSA, NACE Paper No. 04023, 2004, Page 6. 3 E.G. Haney, The Zinc-Steel Potential Reversal in Cathodic Protection, NACE Paper No. 216/1981, Page 4 4 H. Mitschke, Informal Technology Exchange presentation at NACE Corrosion 2007. No paper, 2007. PP

28

JAN-MAR 2010

Visit our websites at www.safan.com / www.pm-pipeliner.safan.com

PetroMin PipeLiner would like to show appreciation to Mr. Peter P. Bock, CUI Specialist and Mr. Michael F. MeLampy, Vice President Global Sales, Hi-Temp Coatings Technology, USA for this article which was presented at our NACE East Asian & Pacific Regional Conference & Exposition, held at Prince Hotel, Kuala Lumpur, Malaysia on 23rd to 25th November 2009.

30

JAN-MAR 2010

Visit our websites at www.safan.com / www.pm-pipeliner.safan.com