Introduction to Protective

coating and Insulation

 Please put the microphone
in the off position

 Do not hesitate to stop the show

and ask about any part
 Training Contents
 Corrosion
 Protective coating
Insulation
 Corrosion
 Definition of Corrosion
Corrosion is the deterioration
of a material, usually a metal,
or its properties because
of a reaction with its
environment .
 Organizations Involved in Corrosion
 NACE International
 American Gas Association
 American National Standards Institute
 American Petroleum Institute
 American Society of Mechanical Engineers
 American Society for Testing and Materials
 ASM International
 Materials Technology Institute
 SSPC-The Society for Protective Coatings
 Steel Tank Institute
 Costs of corrosion
Direct costs
 Excessive Maintenance, Repair, and Replacement
 Lost Production and Downtime
 Product Contamination
 Loss of Product
 Loss of Efficiency: Oversizing and Excess Energy Costs
 Increased Capital Costs
 Accidents
 Costs of corrosion
Indirect Consequences

 Safety Risks .
 Structural Collapse
 Leaks
 Product Contamination
 Consumer Confidence
 Loss of Redundancy
 Appearance
 Increased Regulation
 Changes in Engineering
Practice
 Costs of corrosion

Structural Collapse, a Fatal Highway Parking Garage Collapse Due to

Bridge Collapse into the Ohio River Deicing Salt-Accelerated Corrosion of
Reinforcing Steel3
 Costs of corrosion

Ruptured Pipeline Internal Surface of Corroded

Resulting in 12 Fatalities Pipeline
Corrosion
 Corrosion cell

Anode

Electrolyte Oxygen

Cathode
Water drop on metal
 Corrosion
 Other corrosion mechanisms
 See section 4 of Block 5 Part 1
 Pitting corrosion (doesn’t require 2
dissimilar metals – usually a scratch in a
protective surface)
 Galvanic series
 Rank of metal and alloys according to its corrosion
resistance “Nobility”

 Nobility is a prosperity of metals expresses the

tendency of metals to enter into chemical reactions
Forms of corrosion

General Corrosion
Forms of corrosion

lkGalvanic corrosion
Forms of corrosion

Pitting corrosion
Forms of corrosion

Crevice corrosion
Forms of corrosion

Stress corrosion cracking

 Forms of corrosion

Selective corrosion
 Corrosion prevention
 Metal Type
 Protective Coating
 Cathodic protection
 Environmental Measures
 Corrosion Inhibitors
 Design Modification
 Protective coating
 Global Paints & Coatings Industry Outlook 2020-2025: $179.4
Billion
 Protective coatings are a simple way to reduce corrosion, by
limiting the exposure of the metal to a corrosive environment.
 Paint is a very common protective coating, but tar, pitch,
bitumen and plastics are also used.
 An important consideration for protective coatings is to ensure
the coating is well adhered to the metal, and that it remains
intact or is regularly repaired/recoated.
 Surface preparation

Mechanical compilation
Objective

Surface cleanliness

Surface roughen
 Mechanical compilation
Grinding Smoothing Refilling

• Weld slag • Sharp edges • Under cut

• Weld spatter • Notches • Pitting >2 mm

• Lamination • Holes

• Flame cute edges • Beam tips

• Weld beads
 Rust grades
 Rust grade A: Steel surface largely covered with adherent mill
scale with little if any rust.
 Rust grade B: Steel surface, which has begun to rust and from
which the mill scale has begun to flake.
 Rust grade C: Steel surface on which the millscale has rusted
away or from which it can be scraped, but with slight pitting
visible under normal vision.
 Rust grade D: Steel surface on which the millscale has rusted
away and on which general pitting is visible under normal
vision
Rust grades
 Surface cleanliness
 Mill scale
 Rust
 Dust
 Oil
 Grease
 Contaminations
 Salts
 Dirt
 Moisture
 Surface roughen
 Roughness
 BS 40 < R <75 Micron
 NACE 40 < R <90 Micron
Surface preparation methods

Blast Cleaning

Tool cleaning

Chemical cleaning

Fire cleaning

Water Jetting
Blast cleaning
 Types of abrasives

Sand Aluminum silicate Chilled Iron

Garnet Steel shot Egg shell

 Abrasive cleaning grades
 Sa 1 Light blast cleaning. When viewed without magnification,
the surface shall be free from visible oil grease and dirt and
from poorly adhering mill scale, rust, paint coatings and
foreign matter.

 Sa 2: Thorough blast cleaning. When viewed without

magnification,the surface shall be free from visible oil grease
and dirt and most of the millscale, rust, paint coatings and
foreign matter. Any residual contamination shall be firmly
adhering.
 Abrasive cleaning grades
 Sa 21/2: Very thorough blast cleaning. When viewed without
magnification, the surface shall be free from visible oil grease
anddirt and from mill scale, rust, paint coatings and foreign
matter.Any remaining traces of contamination shall show only as
slight stains in the form of spots or stripes.

 Sa 3: Blast cleaning to visually clean steel. When viewed

without magnification the surface shall be free from visible oil
grease and dirt and shall be free from mill scale, rust, paint
coatings and foreign matter. It shall have a uniform metallic
colour.
Tools
 Tool cleaning

Hand brush

Hand tools
Scrubber
Tool
cleaning Power brush

Power tools
Needle gun
 Fire cleaning
• Rust :
consists of hydrated
iron(III) oxides
Fe2OnH2O and
iron(III) oxide-
hydroxide (FeO (OH),
Fe(OH)3).

• Fire cleaning is unsafe

in cleaning of high steel
thickness
 Chemical Cleaning
Suitable for cleaning of internal side of low size piping

Degreasing

Pickling by HCL 10% Or H2 SO 45% to remove the mill scale & rust

Neutralizing by soda ash 2%

Passivation by Zinc phosphate or Zinc chromate

 Water jetting
Advantage Disadvantage
 Environmental Friendly  No roughness
 High Productivity  Produce bad surface
 No salts in the surface appearance
 low cost of water  Used in maintenance project
 High fixed cost
 Need inhibitors
 Need special painting types
Painting application
 Application methods

Brush Roller

Air spay Air less spray

 Brush
Advantage Disadvantage
 Good penetration  Bad appearance
 Good for stripe coat  Low productivity
 Low paint consumption  Problems with thick paint
 Easy for use  Poor distribution for
thickness
 Roller
Advantage Disadvantage
 Low paint consumption  Fair appearance
 Easy for use  Low productivity
 Problems with thick paint
 Low thickness per coat
 Poor distribution for
thickness
 Bad penetration
Brushes Rollers
Air spray
 Air spray
Advantage Disadvantage
 Good penetration  Paint contamination by air
 Excellent finishing  Over spray
 Good distribution for paint  Need repeating filling
 Relative high thickness per  Problems with thick paint
coat  Need trained technician
 Need source of compressed
air
 Air less spray
 Most popular method in painting application
 Airless spray
Advantage Disadvantage
 Good penetration  Over spray
 Excellent finishing  Need trained technician
 Good distribution for paint  Need source of compressed
 high thickness per coat air
 Very good productivity  Machine needs
 Suitable for thick paint
maintenance regularly
 Other methods of application
 Galvanization
 Other methods of application
 Electrostatic coating
 Other methods of application
 Metalizing
Painting Technology
Painting system
 Painting constituents

Binder

Additives Painting Solvents

Pigment
 Binder
 Solid or high viscous liquids
 The most important part in paint
 Responsible for film formation
 Give adhesive & cohesive prosperities
 Responsible for the mechanical & physical properties
 Types as Epoxy, Alkyd ,Polyurethane
 Pigment
 physically powder and give the paints color & opacity
 Types :
 Color Pigments
 Catholically Pigments
 Rust inhibitive Pigments
 Laminar Pigments
 Biocides
 Additives
 Microns of materials add to the painting during
manufacturing to improve prosperities
 Types :
Driers
 Anti Settling agents
thixotropic agents
Leveling agents
Stabilizers
Plasticizers
 Antifoaming
 Safety and control
 Hazards associated with blasting and painting
processes
 Duties for painting supervisor
 PPEs for blasting and painting
 Recovery for blasters and painters
 Waste control
Insulation
 Insulation types

Hot insulation

Thermal Cold insulation

insulation
Insulation Personal
protection
Acoustic
insulation
o

Insulation used in industry to prevent excessive heat

loss or to maintain the temperature at low level .

Thermal insulation functions are :

Safety “Personal protection

Hot and cold conservation

Operation costs
 Hot insulation
 The insulation that will retard the transfer of heat
energy from the insulated surface when the
temperature in the system is higher than ambient
temperature.

 Hot insulation used to maintain the temperature of the

product high enough for the product to flow, or flow
at a higher rate than it would at ambient temperature
for protection cost reasons .
 Hot insulation materials
Calcium silicate < 1000 c
 Hot insulation materials
Mineral wool < 850 c
 Hot insulation materials
Foam glass < 430 c
 Hot insulation materials
Polyisocyanorate < 140 c
 Hot insulation materials
Pearlite < 1200 c
 TABLE “E”
INSULATION THICKNESSES FOR HEAT CONSERVATION
NPS
(INCHES) OPERATING TEMPERATURES °C
PERLITE MINERAL FIBRE
60 67 94 122 150 177 205 233 261 288 316 344 372 400 428 455
to to to to to to to to to to to to to to to to
66 93 121 149 176 204 232 260 287 315 343 371 399 427 454 483
0.5 40 40 40 40 40 40 40 40 40 40 50 50 50 50 65 75
0.75 40 40 40 40 40 40 40 40 40 40 50 50 50 65 75 75
1.0 40 40 40 40 40 40 40 40 40 40 50 50 65 65 75 90
1.5 40 40 40 40 40 40 40 40 40 50 65 65 65 65 90 100
2.0 40 40 40 40 40 40 40 40 50 65 65 75 75 90 100 100
2.5 40 40 40 40 40 40 40 50 50 65 75 90 90 100 100 115
3.0 40 40 40 40 40 40 40 50 65 75 75 90 100 100 115 115
4.0 40 40 40 40 40 40 50 65 65 75 90 90 100 115 115 125
6.0 40 40 40 40 40 50 65 65 75 75 90 100 115 115 125 125
8.0 40 40 40 40 50 50 65 75 75 75 100 100 115 125 125 125
10.0 40 40 40 50 50 65 65 75 75 90 100 115 125 125 125 140
12.0 40 40 50 50 65 65 75 75 90 90 115 115 125 125 140 150
14.0 40 50 50 65 65 65 75 75 90 90 115 115 125 140 150 150
16.0 50 50 65 65 65 65 75 90 90 90 115 125 140 150 150 150
18.0 50 50 65 65 65 65 90 90 90 90 125 125 140 150 150 165
20.0 50 50 65 65 65 75 90 90 90 100 125 140 150 150 165 165
24.0 50 50 65 65 65 75 90 90 100 100 140 140 150 150 165 165
30.0 50 50 65 65 65 75 90 100 100 115 140 150 150 165 165 175
36.0 50 65 65 65 75 75 90 100 115 115 140 150 150 165 165 175
FLAT 65 65 75 75 75 90 100 115 125 125 150 150 150 165 165 175
 Cold insulation
 The insulation that will retard the transfer of heat energy from
the insulated surface when the temperature in the system is
Lower than ambient temperature.

 Hot insulation used to maintain the temperature of the product

low enough for the product to flow, or flow at a higher rate
than it would at ambient temperature for protection cost
reasons .
 Cold insulation materials
Cellular “Foam “ glass > -270 c
 Cold insulation materials
Polyisocyanorate > -145 c
 Cold insulation materials
Polyurethane foam > -100 c
 Acoustic Insulation
 Acoustic insulation applied to piping which gases , fluids or
particle solids are transported at high velocities .
 The use of high density mineral wool is commom practice to
reduce the noise level .
 Lead vinyl sheets may used over the mineral wool and then
protected by metal jacket
 Other types of acoustic insulation includes perforated metal or
plastic sheets may be used .
 Acoustic insulation materials

Lead vinyl sheets -50 c -100 c

 Safety and control

 Hazards associated with Insulation .

 Duties for insulation supervisor
 PPEs for insulation activities
 Waste control