From Trauma to Transcendence: CUI and Coatings of Choice

1. From Trauma to Transcendence:CUI and Coatings of Choice Dr. Mike O’Donoghue – AkzoNobel Vijay Datta, MS – AkzoNobel SSPC Webinar, October 25th , 2016

2. Agenda • Introduction • Causes of CUI and Mitigation of CUI • CUI Coating Solutions • Coating Testing Unless otherwise agreed in writing by AkzoNobel, all products supplied together with all technical service, information, advice and recommendations given are subject to our standard terms and conditions of sale which are available on request. Any information given here is for guidance only and is provided without any representation or warranty of any kind, express or otherwise. Further, AkzoNobel accepts no control or liability for the appropriateness of any product or the surface, structure or design to which our products are applied or the application process itself. You should seek independent expert advice as to the appropriateness of a particular design or structure for use of our products. We also strongly recommend that independent testing and/or assessment is carried out prior to the application of any product to determine suitability for use. Protective Coatings

3. Corrosion Cost Comparison Annual Global Cost of Corrosion: > US$ 2.5 Trillion (3.4% of a country’s GDP) Annual Cost of US Natural Disasters : > $19 Billion Corrosion costs the US Economy > 50 times as much as all the natural disasters Courtesy: NACE International IMPACT Study, 2016 • G2MT Laboratories 2014 • Pierre Crevolin, NACE Western Regional Conference 2005

4. Corrosion Under Insulation (CUI) – Costs Billions Corrosion rates of carbon steel can be significant if operating at high temperatures and subject to temperature cycling, particularly when thermally insulated “… approximately 35% of incidences of corrosion failures, or near failures were caused as a result of corrosion under insulation …” (This statement follows a 2 year survey of plant failures at a major US petrochemical complex)

5. Corrosion Related Accidents

6. Corrosion Under Insulation

7. Overview of CUI • Corrosion of steel under thermal insulation due to the presence of moisture, oxygen, and other corrodents • Known since 1950’s • High interest since 1983 • NACE SP0198 - 2010 & EFC 55 • Carbon Steel - 4C to 175C • Stainless Steel 50C to 175C

8. CUI • Corrosion under ‘wet’ thermal insulation - aggressive • CUI is up to 20x faster than atmospheric corrosion(1.5 – 3.0 mm/year) • Insulated high temperature steelwork requires protection against CUI which is a threat during construction, shutdown and intermittent use of equipment

9. Why is there is a problem? • No insulation is 100% waterproof • The corrosion rate under wet insulation can be up to 20 times greater • than the rate at ambient operating conditions • Corrosion is hidden • Nothing runs above 212oF forever • Equipment temperatures cycle • Inspection can be limited and costly • Reluctance to shut down unit • Budgetary concerns

10. Implications of CUI • Critical Steel Temperature Ranges for corrosion: • C-Steel 25F → 302F (Greatest Risk of Corrosion) • S-Steel 122F→ 302F (Greatest Risk of E.S.C.C. ) • The highest corrosion rates are normally experienced in operational conditions • between 140F to 250F • Moisture ingress into broken or compromised insulation can occur from • 32F to 302F

11. Thermal Cycling – The vehicle for CUI Moisture movement Insulation Coating COOLING HEATING Steel Coating must provide excellent corrosion protection to insulated steelwork which experiences thermal cycling conditions

12. Air Corrosion Water Steel Corrosion at Elevated Temperatures • For corrosion to occur three key elements MUST be present • Water is not present in equipment where continuous operating temperatures above 248F exist • However, during shut down or cyclic temperature operations, rapid cooling can lead to condensation, & subsequent corrosion problems • Repeated cycling increases both corrosion rates, and potential for failure of coating systems

13. CUI Dynamics Moisture Under Insulation Soluble Chlorides Project Budget C U I Inspection Cyclic Temperatures Maintenance Requirements

14. CUI Coating Solutions - Balancing… Anticorrosive Properties Thermal Resistance (Cartoon Figs Courtesy Hexion)

15. Metallic, Organic and Inorganic Solutions to CUI?

16. Coating Compressed Atomising Air Air Cap Nozzle Wire Oxygen Fuel Gas Mixture Spray stream of molten atomised particles Substrate CUI Solutions - Thermal Spray Aluminum • Flame spray, arc spray, plasma spray techniques • Aluminum Spray Alloy 1100 or 1350 • SSPC-SP5/NACE 1/Sa3 (3-4 mils) • Temp Resistance to ca 595C • Life cycle costs are low • Process slow, installation costs are relatively high vs coating spray application, DFT issues, needs to form oxides • Galvanic protection – sacrificial system • Susceptible to corrosion by wet salts above 80C • Porosity • Seal coat or no-sealer coat?

17. CUI Solutions – Transcendence Road Temperature Higher bond strengths of Inorganic Si-O bond (452 KJ mol-1) vs Organic C-C bond (350 KJ mol-1 ) confers thermal stability Inorganic - Inorganic copolymer, TMIC 650C Inorganic – Conventional Thin Film Silicones, TSA 600C Inorganic - Zinc Silicates 400C Organic - Phenolic/ Novolac Epoxy 220C Organic – Epoxy 125C Technology

18. The Zinc Silicate Question (photo courtesy Peter Bock)

19. NACE SP 0198-2010

20. Coatings for CUI Mitigation IMMP = Inert Multipolymeric Matrix Paint TMIC = Titanium Modified Inorganic Copolymer

21. Epoxy Phenolic and Novolacs (CS-4; - 45C to 205C, -50F to 400F) • Barrier Protection - Epoxy Phenolic coatings perform well in high temperature aggressive environments because of their very densely cross linked nature Epoxy Polyamine Crosslink + Typical Cross-linked Epoxy Epoxy Phenolic Polyamine Crosslink + Densely Cross-linked Epoxy Phenolic

22. Barrier Protection Playing Field (CS-6; - 45C to 650C, - 50F to 1200F) Examples: • Carboline Thermaline 4001 • Dampney Thurmalox 225HD • Hempel Versiline 56990 • International Interbond UPC 1202 • Jotun Jotatemp 650 • PPG Hi-Temp 1027 • Sherwin Williams Heat-Flex Hi –Temp 1200

23. MIO Pigmented IMMP for CUI Mitigation • SEM Image after 4000C • 200X Magnification • MIO Platelets • Barrier Protection

24. Aluminum Flake Pigmented TMIC for CUI Mitigation • SEM Image after 4000C • 1000X Magnification • Interlacing aluminum platelets, intact • Barrier Protection

25. CUI Coatings - More Balancing Damage own to metal Harder Coating “Bruising” effect only Softer Coating Marine & Protective Coatings

26. International Paints Cyclic Pipe TestsCourtesy O’Donoghue and Datta, International Paint CCCPT CUI Cyclic Corrosion Pipe Test

27. 8 hours Heated to 600C Naturally cooled 16 hours 600C Repeated x 30 Temperature °C Time Courtesy O’Donoghue and Datta, International Paint` CUI Cyclic Pipe Tests 100C Diameter = 6 cm Length = 60 cm 1 litre 1% NaCl twice/day 600C cyclic temperatures to mimic end user processes

28. Monitoring / Verifying the Coating Temperature CCCPT procedure run with temperature probes to measure temperatures across the pipe

29. TSA and IMMP & TMIC Coatings on Carbon Steel TMIC IMMP IMMP TSA

30. 70C-100C 450C-560C 100C-165C 165C-215C 215C-300C 300C-450C Coatings on Carbon Steel up to 560C IMMP TMIC

31. PPG CUI Chamber Test (2008-Present)Courtesy Dik Betzig PPG Hi-Temp Coatings Testing method approved: Shell Oil 2008, Aramco 2010 Method B 350F (177C) 5% NaCl Temperature Control Ambient to 250C Method B 5% NaCl solution

32. CUI Chamber Test Cell Courtesy Dik Betzig PPG Hi-Temp Coatings Before Test After 6 Weeks Front View After 6 Weeks Bottom View

33. Track Record Cyclic Service Conditions: 260C to 40C

34. Case History France

35. Case History France

36. Case History Texas

37. Case History Texas

38. Publications • “When Undercover Agents are Tested to the Limit: Coatings in Action (CIA) and Corrosion Under Insulation” • JPCL, May 2014 SSPC Presidential Lecture Series Award in 2013 • “When Undercover Agents Can’t Stand the Heat: Coatings in Action (CIA) and the Netherworld of Corrosion Under Insulation” • JPCL, February 2012 Outstanding Publication of the Year Award in 2013 • “From Trauma to Transcendence: Corrosion Under Insulation” • NACE, Northern Area Western Conference, 2010

39. Thank You - Questions? Vijay Datta, MS vijay.datta@akzonobel.com Dr. Mike O'Donoghue mike.odonoghue@akzonobel.com www.akzonobel.com/protective