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Generally, plants located in areas with high annual rainfall or warmer, marine
locations are more prone to CUI than plants located in cooler, drier, mid-continent
locations. External inspection of insulated systems should include a review of the
integrity of the insulation system for conditions that could lead to CUI and for signs of
ongoing CUI (i.e. rust stains or bulging). However, external indicators of CUI are not
always present. Mitigation of CUI is accomplished through good insulation practices
and the use of appropriate coatings.
Special attention should be given to insulate stainless steel equipment and piping, as
insulation can cause chloride stress corrosion cracking of these alloys. Insulation can
be a source of chlorides or can cause the retention of water and concentrating of
chlorides under the insulation.
2.0 Definitions
API American Petroleum Institute
IR Infrared
UT Ultrasonic Testing
3.0 References
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3) NACE Standard RP0198-98, The Control of Corrosion Under Thermal
Insulation, and Fireproofing A Systems Approach, NACE International, TX,
1998.
4) W.I. Pollock and C.N. Steely, Corrosion Under Wet Thermal Insulation,
NACE International, TX, 1990.
Yes
No
Is Material Insulated?
Yes
Is Operating temperature No
below 150 Deg. Celsius?
Yes
No
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4.0 Time Dependency of the Damage Mechanism
Therefore, the inspection plan effectiveness level should be evaluated using the
Control Plan 03 Control for Localized External Thinning (CUI).
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Appendix A
Carbon steel, low alloy steels, 300 Series and duplex SS.
b) Poor design and or installations that allow water to become trapped will
increase CUI.
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l) Environments that provide airborne contaminants such as chlorides
(marine environments, cooling tower drift) or SO 2 (stack emissions) can
accelerate corrosion.
a) Carbon and low alloy steels are subject to pitting and loss in thickness.
b) 300 Series, 400 Series and duplex SS steels are subject to pitting and
localized corrosion.
c) 300 Series SS are also subject to chloride stress corrosion cracking (Cl -
SCC), especially in older calcium silicate insulation known to contain
chlorides. Duplex SS is less susceptible.
e) Design Issues:
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Piping or equipment with damaged/leaking steam tracing.
Localized damage at paint/coating systems.
Locations where moisture/water will naturally collect (gravity
drainage) before evaporating (insulation support rings on vertical
equipment).
The first few feet of a horizontal pipe run adjacent to the bottom of
a vertical run is a typical a CUI location.
a) After insulation is removed from carbon and low alloy steels, CUI damage
often appears as loose flaky scale covering the corroded component.
Damage may be highly localized.
c) For 300 Series SS, specifically in older calcium silicate insulation (known
to contain chlorides), localized pitting and chloride stress corrosion
cracking can occur.
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e) Mitigation of ClSCC under insulation is best accomplished by preventing
chloride accumulation on the stainless steel surface. This is best
accomplished by first maintaining the integrity of the insulation. Second,
by preventing chloride ions from contacting the stainless steel surface
with a protective coating.
Insulation can be a source of chlorides and/or cause the retention of water and
chloride concentrating under the insulation. The spray from seawater and cooling
water towers carried by the prevailing winds can cause Cl - SCC. The spray soaks
the insulation over the austenitic stainless steel equipment/piping, the chloride
concentrates by evaporation, and cracking occurs in the areas with residual stresses
(e.g. weld and bends). Other cases of cracking under insulation have resulted from
water dripping on insulated pipe and leaching chlorides from insulation.
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Operating Environment
Temperature
(C) Marine / Cooling
Temperate Arid / Dry
Tower Drift Area
Table 1: Estimated Corrosion Rates for Carbon and Low Alloy Steel Under Wet
Insulation in Various Environments
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