Corrosion Under Insulation

STUDENT INTERNSHIP PROJECT 2018
(11st Sept 2017 – 19TH APRIL 2018)
Muhammad Naqib Bin Nordin (21431)

Mechanical Engineering
21431
© 2015 PETROLIAM NASIONAL BERHAD (PETRONAS)
All rights reserved. No part of this document may be

reproduced, stored in a retrieval system or transmitted in any
form or by any means (electronic, mechanical, photocopying,
Presentation Title (acronym) ; recording or otherwise) without the permission of the copyright
Division – Name/OPU/HCU/BU (acronym) ; owner.
Name of Presenter ©Petroliam Nasional Berhad (PETRONAS) 2014 1
Internal
INTERNSHIP BACKGROUND
Host Company : Petronas Carigali Sdn Bhd(PCSB-PMA)
University Supervisor : Universiti Teknologi Petronas (UTP)

HC Supervisor : Puan Reena Amirah Binti Ruslan
UTP Supervisor : Dr Mohamad Zaki Bin Abdullah

Presenter : Muhammad Naqib Bin Nordin
SIP Title : Development of Corrosion under Insulation
(CUI) Campaign at Duyong CPP Glycol
Regeneration C
Presentation Title (acronym) ;

Division – Name/OPU/HCU/BU (acronym) ;
Internal
AGENDA
Development of corrosion under insulation (cui)

Campaign at duyong cpp glycol regeneration ‘c’
PROJECT BACKGROUND
PROBLEM STATEMENT
PROJECT OBJECTIVE
METHODOLOGY AND RESULT
CONCLUSION AND RECOMMENDATION

Internal
 Project Background
What is CUI?
• Formation of corrosion
(galvanic, chloride, acidic or
alkaline) occur on surface
metal under insulations
Metal Element contribute to CUI

1. Metal
2. Oxygen
3. Presence of water
4. Cyclic thermal operation
Carbon steel Stainless steel

- 15°C to 175°C 50°C to 150°C
Internal
4. Corrosion occurred
on metal surface under
1. Jacketing insulation
3. Coating
2. Insulation
Internal
Source of water
1. Damaged Jacketing
Jacketing due to mechanical
impact / improper
Installation
2. Insulation Collecting
moisture
Insulation
3. Diffusion of water
Coating underneath paint/
coating
4. Continuous hidden Metal

corrosion process
under insulation (CUI)
Internal
 Problem Statement
1. Duyong CPP Glycol Regeneration ’C’ Glycol Flash Separator V-1370
Design / Construction Data

1. Operating Temperature : 200°C - 210°C
2. Vessel Material Spec : Carbon Steel (SA 106)
3. Initial Insulation Status : Rock Wool
4. External Environment : Expose to weather

Internal
 Problem Statement
Susceptibility to CUI
CUI Risk Operating Temperature
Extreme Cycling or dual process temperature between -20°C and 320°C
High Process temperature between 50°C and 120°C

Medium Process temperature between -5°C and 50°C
Medium Process temperature between 120°C and 175°C
Low All temperature >175°C
Low All temperature <-5°C

(Source: PTS 30.46.00.31)

Internal
 Project Objective
1. Prevention of Loss of Product and Containment (LOPC)

incidents.

Internal
 Project Objective
1. Person 2. Environment 3. Asset 4.Reputation

• Injury • Contaminate the • Explosion • Show that
• Death marine ecosystem • Damage of company has
equipment bad HSE
procedure

Internal
 Rectification Method
1. External Visual Inspection
• To identify any points that could have lead to water

entry and possible CUI
Corrosion

Internal
2. Insulation Removal
• To identify any points that could have lead to water

entry and possible CUI

Internal
3. Non-Destructive Test (NDT)
 Ultrasonic Test Inspection
Radiography Test Inspection  .

Internal
 Methodology
Corrosion
on surface
of metal Nozzle 2
Manhole
and Stud
bolt
Nozzle 5

Internal
 Methodology
• Depressurization &
Draining
• Zero Hazard Chemical
Internal Welding Blasting and Reinstatement

Painting of new
cleaning Work Insulation

Internal
 Methodology
Internal Cleaning
Before Internal Cleaning After Internal Cleaning

Internal
 Methodology

Painting of new
• Nozzle Replacement
by performing
Welding Activity
Internal
 Methodology
Hot work/ Welding Activity
Nozzle Replacement for Nozzle Replacement for

Nozzle 2 (N2) Nozzle 5 (N5)
Internal
 Methodology
• Blasting to remove corrode area

• Paint coating system No 5A1, 3 Coat
system

Painting of new

Internal
 Methodology
Blasting and Coating
Completed Blasting activity Completed Painting activity

Internal
 Methodology

Painting of new
• Installing new
Insulation Microporous
Silica (MPS)
Internal
 Result
Installation of new Insulation
Installation new insulation Completed Installation of new

Microporous Silica (MPS) Insulation with stainless steel
cladding
Internal
 Conclusion and Recommendation
• The units V-1370 Glycol Flash Separator is safe to operate

and the condition is satisfy after repair work completed
• Prevent unplanned shutdown and failure of LOPC

Internal
 Conclusion and Recommendation
Develop training course on understanding and management

on CUI.
Revisit inspection interval to extend life time of units and

prevent CUI failure

Internal
PRESENTATION OUTLINE
Q&A SESSION
THANK YOU !
Internal

Corrosion Under Insulation

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STUDENT INTERNSHIP PROJECT 2018

(11st Sept 2017 – 19TH APRIL 2018)

Muhammad Naqib Bin Nordin (21431)

© 2015 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be

Host Company : Petronas Carigali Sdn Bhd(PCSB-PMA)

University Supervisor : Universiti Teknologi Petronas (UTP)

UTP Supervisor : Dr Mohamad Zaki Bin Abdullah

Presentation Title (acronym) ;

Development of corrosion under insulation (cui)

METHODOLOGY AND RESULT

CONCLUSION AND RECOMMENDATION

Metal Element contribute to CUI

Carbon steel Stainless steel

4. Continuous hidden Metal

1. Duyong CPP Glycol Regeneration ’C’ Glycol Flash Separator V-1370

Design / Construction Data

Presentation Title (acronym) ;

High Process temperature between 50°C and 120°C

Medium Process temperature between 120°C and 175°C

Low All temperature >175°C

Low All temperature <-5°C

Presentation Title (acronym) ;

1. Prevention of Loss of Product and Containment (LOPC)

Presentation Title (acronym) ;

1. Person 2. Environment 3. Asset 4.Reputation

Presentation Title (acronym) ;

1. External Visual Inspection

• To identify any points that could have lead to water

Presentation Title (acronym) ;

• To identify any points that could have lead to water

Presentation Title (acronym) ;

3. Non-Destructive Test (NDT)

 Ultrasonic Test Inspection

Radiography Test Inspection  .

Presentation Title (acronym) ;

Internal Welding Blasting and Reinstatement

Presentation Title (acronym) ;

Before Internal Cleaning After Internal Cleaning

Internal Welding Blasting and Reinstatement

Hot work/ Welding Activity

Nozzle Replacement for Nozzle Replacement for

• Blasting to remove corrode area

Internal Welding Blasting and Reinstatement

Presentation Title (acronym) ;

Blasting and Coating

Completed Blasting activity Completed Painting activity

Presentation Title (acronym) ;

Internal Welding Blasting and Reinstatement

Installation of new Insulation

Installation new insulation Completed Installation of new

• The units V-1370 Glycol Flash Separator is safe to operate

• Prevent unplanned shutdown and failure of LOPC

Presentation Title (acronym) ;

Develop training course on understanding and management

Revisit inspection interval to extend life time of units and

Presentation Title (acronym) ;

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