NACE Jubail Meeting March 31 st 2009

1. NACE Jubail Meeting March 31st 2009

2. Simple approach toCorrosion Under Insulationprevention .“IMMP” coating technology

3. Corrosion under insulation - consequences

4. Corrosion Under Insulation • Insulation used extensively since mid-70’s oil shock to save on plants energy costs • 60% of leaks are from piping systems. • Highest corrosion rate: 60-70ºc temperature range • Most CUI problems within 15-20+ years service life

5. Corrosion Under Insulation • ExxonMobil total annual maintenance cost= $350million • 10% is CUI related = $35 million on CUI alone • Saudi Aramco Fathi Al Qadeeb, Engg. Specialist, Inspection Support Services Div :2008 survey: CUI #1 challenge in 17 out of 30 facilities.

6. Corrosion Under Insulation (CUI) • Most high temp. equipment & piping under thick layer insulation & lagging • Protect against injury • Save energy costs. • In the 70s & 80s no threat of corrosion was anticipated, and corrosion protection used was: • Thin layer high temperature resistant coatings • Shopprimers • Sacrificial zinc rich coatings • Damaged cladding joints too often left untouched

7. Corrosion Under Insulation (CUI) • In recent years there has been much focus on • Accidents • System failures • Shutdowns • The costs of which are substantial

8. CUI – typical inspection findings after insulation removal Valve corrosion Pipe corrosion

9. Typical Corrosion Under Insulation Inorganic zinc silicate

10. CUI - The Simple Approach • A complex problem needs a simple approach • Understand your problem • What are the constituents of the moisture under the insulation • Are there chlorides in the insulating material? • Is there a cyclic temperature effect? • How long between maintenance? • How often is it desired to inspect?

11. What are the constituents of the moisture? • Does the moisture contain: • Chlorides • Acids • Alkalis • Other chemicals that together with water form ‘attacking’ species Important! a good coating resistant to alkalis may not resist acids

12. Are there chlorides in the insulating material? • If the insulating material naturally contains chlorides, with moisture this will increase the risk of corrosion • A good anticorrosive system is needed • Beware when using Sacrificial Zinc systems: accelerated sacrificing may occur

13. Is there a cyclic temperature effect? Cyclic Temperatures • Increase corrosion rates • Reduce lifetime of most coatings • Can create condensation • Small amounts of moisture are forced out of the atmosphere by condensation when the substrate is at the lowest temperature.

14. How long maintenance intervals? • Design depends upon lifetime expectations • How much maintenance is expected at each interval? • If shut down - what are these costs vs initial cost of a coating system? • Normal design rules apply, with increased atmospheric severity

15. How often is it desired to inspect? • Regular inspection • Implies easy access/repair • Some coatings can be applied during operation • Relatively cheap • Spreads cost whilst the structure is earning money! • Infrequent Inspection • Implies difficult access/repair • Costly repair • Requires shutdown at high cost • Play safe – over specify • Small extra cost compared to expensive repair shutdown

16. Anything Else? • Budget • What can you afford? Money spent now saves later • Substrate • Sa 2½? • St 2? • Non ferrous? • Etc…. • Over Specifying according to normal rules, is often your only chance!

17. Inert Multipolymer Matrix Paint

18. What is IMMP? • A thick-film, non-sacrificial proven CUI protective system: - Surface tolerant - Hot application up to 260°C - Dry temperature resistance to 650°C, peak 750°C - Dry/wet/dry cycling -185 to 540°C - Resistance to boiling water - Single pack - Tested, approved and used by Oil Majors

19. Where use IMMP? • High / low temperature applications • Carbon or stainless steel • Cyclic Conditions, even whith Thermal Shock • Specially well suited to CUI • Suited for atmospheric exposures too • Outstanding at very high temp. (>500 °C) • Excellent for cryogenic service

20. Cyclic Service • All heated process equipment is in cyclic service, the only variable is the frequency of the cycles. • The more frequent and wide the process temperature cycles, the more critical the need is • Where the cycles go above 190°C, only IMPP technology provides a thick-film, non-sacrificial proven CUI protective system.

21. Steam Interface Occurs when the temperature of the insulated surface Increases and passes 100°C The most stressful Temperature range for any CUI protective coating system IMPP technlogy exceptionally resistant to steam interface

22. Inert Multipolymer Matrix Paint IDEAL FOR MAINTENANCE • Surface Tolerant • Application up to 260°C • Temperature resistance 650°C (750°C intermittent) • No special equipment required • No special preparation required • No shut down required for painting • Single pack = no pot life issues, economy.

23. Surface Tolerant • Hand and Power tool - St2 • Blast cleaned surfaces increases lifetime • High Pressure Water Jetted • Simply clean, dry and free from loose material / rust • Old paint should be removed • Remaining paint limits the max temperature and lifetime IMMP, similar size to HC resins

24. Application Substrate Temperature Apply up to 260°C • Ideal for application to units which have been stripped and are being re-insulated as part of a process upgrade • Simplifying maintenance by avoiding or reducing shutdown period

25. How does IMMP compare with other technology? • Based on a blend of Inorganic Binders that tolerate different temperature ranges • Binder is modified: includes an Organic component to help adhesion and corrosion resistance performance • Other technologies often blend polymers for the same reason…

26. Long lasting thick barrier providing a reliable coverage of a rough steel surface Combination of Organic modified Inorganic resins IMPP provides proven protection at extreme temperatures IMPP IMPP

27. High Build protection at high temperatures • IMPP provides a thick barrier • Moisture penetrates at temperatures below 100°C • i.e. shut down periods or construction/erection period

28. High Build protection at high temperatures • As temperature increases the moisture is driven out • Rejuvenating the coating • When temperatures are normally below 200°C we recommend standard coating systems: Phenolic novolac epoxy, etc..