Selection of Coating Systems for CUI Service

Christian Zupicich, Technical Service, christianz@hitempcoatings.com

Michael F. MeLampy, Vice President, mmelampy@hitempcoatings.com
Hi-Temp Coatings Technology, Inc., P. O. Box 2347, Acton, MA, 01720, USA

ABSTRACT
This paper will discuss issues related to corrosion protection of high temperature
carbon steel substrates which are insulated to preserve energy, provide process control
and to keep workers safe from burn injuries. Corrosion under insulation (CUI) is a
serious problem for many owners who have insulated service, where severe corrosion
often occurs which can cause plant or process shutdowns, environmental damages and
potential injuries to workers.
A review of past and current technologies for preventing CUI will be presented.
The initial and long term costs, performance characteristics, expected service life as
well as ease of application and repair of coatings used under insulation will be
discussed. Field and laboratory performance experience obtained from users, thirdparty laboratories, and vendors of the various coating systems are used for this
comparison.
It is this long term cost which determines the true value to the user of any CUI coating
system. Local and overall risks associated with perforations are also of major concern. The two
along with several other factors are important in coating selection process.

INTRODUCTION
Corrosion Under Insulation (CUI) is a problem for those involved in power, refining,
petrochemical and other thermal processing industries. CUI is corrosion that occurs at the
substrate beneath an insulating material which can develop and progress quickly dependent on
the availability moisture, contaminants and temperatures. All of this happens where it is hidden
from view and is often overlooked.
A specification manager of a major oil and gas multi-national, stated:
The REASON the steel was not adequately protected in the first place is
because when our plants were built, industry did not understand that the
environment under insulation was going to be almost like immersion conditions
(or worse) so the correct type of coating was not used. As a result, almost
NONE of the surfaces under insulation, in facilities older than 15 years, are
adequately protected from CUI. CUI is a phenomenon because of our
ignorance.
Insulation is applied on pipes and vessels which contain and/or transfer hot materials to
provide heat retention or energy savings, to improve process control, and/or to protect workers
who access the equipment with protection from burns. Refining, petrochemical processing,
power generation and other process generally involve heating or hot fluids and gases

transmission to produce to create intermediate products or end products. Power plants often
use steam and high pressure steam to create electricity.
Cladding, typically galvanized steel, aluminum, stainless, or plastic based is attached
over the insulation to protect it from damages and to help keep the insulation materials dry.
These cladding systems can deteriorate over time and can fall into a state of disrepair
Additionally improper construction may allow water leakage into the insulation layer and to the
substrate. Often this water contains electrolytes. Potential microenvironments can be created
within the insulated jacket and as a result corrosion can begin, in places more concentrated,
resulting in accelerated corrosion leading to potential mechanical failures such as leakage or
worse.

COATING SYSTEM SELECTION

NACE Publication 6H189, from 1986 A State of the Art Report of Protective Coatings for
Carbon Steel and Austenitic Stainless Steel Surfaces Under Thermal Insulation and
Cementitious Fireproofing (1), states the following:
No particular corrosion problems were considered or anticipated with carbon
steel under thermal insulation when the plant construction boom began in the
1960s. Prior to that time, insulation was applied over bare steel, or in some
cases, over one coat of oil-base primer that had been applied over mill scale.
When serious corrosion was later noted, many engineers concluded that better
surface preparation and a better primer, or better maintenance of the insulation
waterproofing, would mitigate the formation of corrosion.
After finding extensive corrosion hidden in these insulated environments, the addition of
coating systems for use under insulation became more common. However, coating system
selection has been a learning process. Coating types included; inorganic zinc, elevated
temperature coal tar epoxies, phenolic and novolac epoxy tank linings, thin film silicones, and
thermal spray aluminum. A great deal has been learned as a result of these systems coming
into disrepair, and newer technologies have been developed to allow engineers with greater
options for application methods and service life resulting in new first and life cycle cost
considerations for selecting coating systems to work in these harsh environments.
Currently there are no universally accepted test methods for use in CUI coating
selection. Several manufacturers have developed test procedures, which should be evaluated
by the specifier and end user for relevance to their operations. With no accepted test methods
the specifier and owner should evaluate the look to the properties of the coating, including the
temperature resistance, ability to resist thermal shock, thermal cycling, and boiling water, as
well as constructability and user friendliness, to develop an understanding of the applied
products lifecycle and cost to determine which will be best for the CUI service. All CUI service
requirements may be different resulting from different environments, insulation and cladding
systems, maintenance efforts of the facility and of course actual operating environments
including the possible need to steam clean, or purge pipelines and vessels as part of an
operating units regular maintenances.
As there are limited accepted test methods some owners have developed their own
testing mechanisms and suppliers are also pushing forward accelerated testing mechanisms to
help predict the life of CUI coatings. New technologies for testing and coatings formulation are
beginning to show promise in determining the best way forward.

Where to start in finding and repairing CUI:

One major multinational oil and gas refining company spent over two years using Risk
Based Identification models and utilizing many testing methods to help determine where to start
planning and begin to repair equipment with CUI. A ten year program was then begun to repair,
recoat, and reinsulate equipment, vessels and pipelines so that they can continue to operate for
many more years. and is currently doing maintenance and repair as a part of a ten year
program. Other owners are following this course of action and many more will need to moving
forward. If not the operating units who prefer to ignore the mounting evidence will do so at their
own peril and risk.

INSULATION and CLADDING

Improvements in insulation and cladding technology have been made steadily since the
mid 1980s. It is important to know that eventually most if not all cladding systems will leak.
This leakage allows water and contaminants (electrolytes) to enter the clad insulation system,
where it can then become trapped, and with moisture evaporation these contaminants can
concentrate. The configuration of the insulation and cladding system over vessels and related
piping can allow this moisture and moisture vapor to travel quite far, resulting in corrosion in
unexpected places.
Insulation systems can include, foam glass, calcium silicate, expanded perlite, mineral
wool, and fiberglass. Newer insulating materials include aerogels and spray applied ceramic
loaded acrylic coatings systems.
Insulation systems are typically attached using mechanical means, while some spray
applied insulations are adherent to the surface. Mechanically fastened insulation materials are
then generally clad with sheet metal to protect the insulation from damage and to stop the flow
of water from entering into the insulation material, while the spray applied materials may need to
be top or seal coated. The mechanical attachment of the insulation is appropriate in higher
traffic areas, however these mechanical attachments lead to breaks in the insulation, resulting in
heat loss, potential formation of crevice corrosion where the insulation is compressed tightly
against the substrate, and other issues.

CORROSION CONTROL
The following could be thought of a as a basic definition for a good elevated temperature
or CUI coating. A coating for elevated temperature and/or CUI service must be easy to use in
both new construction and maintenance and repair situations, survive elevated temperature,
thermal shock and thermal cycling, boiling water, intermittent immersion, and still be able to
provide long term corrosion protection when a corrosion cell develops.
Corrosion control coatings are not always used under insulation. Even though many processes
are thought to be isothermal or continuous, all processes are cyclic - over time. Use of
protective coatings is good decision for the life of the project especially when repair and
maintenance can be so expensive in the future. Without a well thought out plan with
appropriately selected corrosion control coatings, and when left unchecked, this corrosion can
result in process fluid leaks through perforations. These perforations can result in unplanned
shutdowns, and when hydrocarbons are involved, can result in fires and explosions leading to

extensive down time, repair costs, environmental remediation, process unit down time,
personnel injury and even death.
Owners desire cost-effective long life protective coating systems. Each unit and process
is unique and needs specific coating system solutions that result in the best applied and
lifecycle project costs. The economics of repair and maintenance are driven mostly by the cost
of down time during which repairs and equipment replacement can be made, other costs include
labor, access, and materials.
Outages are scheduled in advance and often include coating replacement projects, with
many painting workers on the site. Of course the huge cost of a shut down even just the lost
profit from operations can be quite large and as a result outage time frames are minimized.

CONSTRUCTION ISSUES
The size and scope of maintenance efforts, plant expansions, and upgrades continues to
grow. For new construction the coating system must survive transportation to the final site,
installation, and assembly. Touch up in the field is expected and must be quick and easy to
accomplish.
Maintenance and upgrades in existing units have many constraints and limiting factors
involved when trying to do proper coating application. Most plant turnarounds have become too
brief, intense and crowded. Inaccessible areas are also a big concern. Additionally, these
projects involve health safety & environmental issues.
Shutting down a facility for maintenance, results in lost revenue and related profit which
cannot be made up or replaced as many of these operations are continuous in nature. Just lost
profit can amount to a large sum of money every day, and is one of the largest costs
encountered by an operating facility. As such maximum cost effectiveness maybe achieved by
performing as much maintenance as possible while the facilities are in operation, allowing the
owner to continue revenue and profit generation. Several years ago a managing director of a
venture in China asked (paraphrased) the following question:
Why can I only do coating maintenance work during an outage? I have a 1000
guys running around here changing valves, motors and pumps, and then I have
to have another 1000 trying to paint everything. Surface preparation and coating
work is not realistic to do when performing maintenance on all the mechanical
equipment, and it can only extend the outage!
This manager understands the true cost of outages and why they can be so costly. Not only do
you lose revenue and related profits, each day of outage work is very costly especially with
coatings work. With larger than normal crews, quality of application may become suspect.

Pre-Construction Inspection Issues

An important requirement in planning coating work for insulated service, in or out of
service, is to determine the actual peak surface temperature of operating equipment. Knowing
the design operating temperature is important but it is the peak temperature that may damage
the applied coating material. Many operators may use high pressure steam to de-sludge
operating vessels and related pipelines raising the temperatures of the substrate higher than
design temperature. Often this unplanned peak temperature may be detrimental to a coating

system that was selected based just on operating temperature. It is wise to discuss these
issues with unit operators as they are typically most familiar with the operating process. They
understand the temperatures experienced by the process during normal operations as well as
those related to maintenance efforts and also temperature excursion related to upsets.

CUI ISSUES
The ideal CUI coating system must survive:

Actual operating, design and peak temperatures at the substrate surface

including thermal shock and cycling.
Lengths of time under 212F and when water is present.
Electrolytes from environmental water, which can concentrate.
Boiling water and steam interface.
Intermittent immersion service and damp surface exposure whenever the
surface is below 212F.

For insulated equipment there is a CUI cycle of corrosion which can lead to corrosion.
Assuming that nothing stays hot forever, there will be times when the substrate surface
temperature is under 212F (100C).

Water and electrolytes from the weather or other plant conditions such cooling
towers can enter the insulation system at breaks in the insulation which can
result from poor workmanship and damage.
The water is heated boils and evaporates leaving the electrolytes behind.
The stem either escapes from the cladding or condensates on the inside of the
cladding resulting in rewetting of the insulation (possibly in a different location).
As such the water under the cladding is never entirely expelled.
Additional water is brought into the insulation system when possible.
Electrolytes included with water often concentrate under the insulation.
Eventually the insulation may become saturated and in many cases the
insulation material never dries.

Chloride Induced Stress Corrosion Cracking of Austenitic Stainless Steel

A coating system should be used to protect austenitic stainless steel vessels and
equipment from chloride induced stress corrosion cracking. The coating system should provide
a barrier to protect sulfide, chloride, and other halides from coming into contact with the
substrate. Chlorides are available in the atmosphere, from the production process and even
from the insulation material placed in contact with the stainless. Any coating used for this
application should be formulated to eliminate or minimize chlorides, sulfide and halides while
providing good barrier protection, and must be able to survive the thermal shock and cycling as
well as peak temperature required of this service so the coating can provide the protection as
required.

CUI COATING SYSTEMS

Coating systems are available for insulated service for both new construction and
maintenance. Newer coating technologies offer greater thermal shock and cyclic tolerance,
longer service life, ease of application with less stringent surface preparation requirements and
application to hot operating equipment. Applying coatings to operating equipment for
maintenance has proven to be very economical as lost revenues due to down time can be
avoided. One and two pack systems are available offering thicker film builds.
Many coatings used to prevent CUI require pristine surface preparation while other are
found to be more forgiving. The coating manufacture should be consulted to verify surface
preparation, mixing (one, two or more component), pot and induction time, application, wet film
thickness and recoat window. Some coatings allow for application to operating equipment up to
300C.

TYPICAL CUI COATING SYSTEMS

Thin Film Silicones
Thin film silicones were the standard coating for service above 750F. However, thin film
silicones provide little protection at ambient temperatures. Thin film silicones applied direct to
metal provide for little corrosion protection below 212F. Thin film silicones are still encountered
as a topcoat over inorganic zinc in CUI environments. Poor performance in CUI service,
especially cyclic service makes their use less than desirable. As more learn that better
performance is available, many begin to move away from specifying silicones.
Inorganic Zinc
Inorganic zinc systems have an advantage as the coating system can provide sacrificial
corrosion protection with peak temperature up to 750F (product data sheet review). In dry CUI
situations where the insulation does not leak water, inorganic zinc can survive intact for a
considerable time.
However the 1983 NACE ASTM Symposium on Corrosion of Metals Under Thermal
Insulation (2) presented a list of premature failures of zinc in CUI situations. Reversal of
polarity, failure of the binder in wet heat conditions, rapid sacrifice of the zinc in immersion-like
conditions and presence of chemicals which produced water soluble salts were all listed as
contributors to failure. The bottom line was that insulation leaks water, the water contains
electrolytes, and the anodic zinc coating sacrifices.
Thermal Spray Aluminum
Included in the list of CUI protective coating systems is thermal spray aluminum which is
now becoming specified more often. Thermal spray aluminum is the application of elemental
aluminum to the surface. It requires near white abrasive blast cleaned surface with an angular
profile. If these and other conditions are not met thermal spray aluminum often fails to adhere
to the surface. This metal material is applied with oxy-fuel or electric spray arc equipment.
Thermal spray aluminum is becoming less expensive and more common. Typically, application
equipment does not allow for difficult to reach areas and require direct line of site application.
Properly applying a thermal spray aluminum coating on a bolted flange can be quite the
challenge.

Properly applied thermal spray aluminum is thought to provide a barrier coating if applied
at thicknesses over 14 to 20+ mils. Lesser thicknesses may leave porosity and allow for
premature deterioration. Users of thermal spray aluminum should also remember that
aluminum is anodic to carbon steel, and a thermal spray aluminum coated system in a mild acid
environment is simply one anode. However when applied at heavier thicknesses barrier coating
properties can be achieved. Once corrosion begins, any portion of the thermal spray aluminum
can be sacrificed. Many use a thin film silicone applied seal coat on thermal spray aluminum to
help seal the porosity which can be developed as part of the application process, however this
can mask the presence of thin film applications which may result in flash rusting, even before
the equipment is put into service.
As with almost every product, aluminum wire used in thermal spray applications can be
purchased at various costs based on grade of aluminum and other quality aspects. The owner
should be careful to select the correct material along with the correct surface preparation
requirements. Further the overall plant chemical process should be reviewed to determine if
any product might have deleterious effect on aluminum.
Phenolic & Novolac Epoxies
A shortcoming of various types of epoxies under insulation is peak temperature
tolerance. There is a maximum peak for these products. Based on product data sheets. These
peak temperatures often are referred to as dry heat resistance, and as already discussed, the
CUI environment rarely stays dry. These peak temperatures are misleading. Organic
components in the formulation can begin to break down at temperatures from 330F to 350F.
As many unit operators are increasing process temperatures, the thermal safety margin for
these types of epoxies is limited. Additionally the dry film thickness requirements and the limited
recoat interval between coats, can also be an issue. Thinner than specified DFTs can result in
less of a barrier coating, while above the recommended can crack and delaminate at operating
temperatures.
Newer CUI Coatings
Inert multi-polymeric matrix, inorganic silicone co-polymer based coatings & high build
silicone-based coatings are typical generic names for some of the proprietary newer
technologies. These technologies, allow for simple application of coating materials using typical
spray equipment, and even brush and roller application. This class of ambient and/or hot
application coatings allows larger flexibility for hot surface application. Maximum recoat
intervals may be an issue depending on manufacture. Typical total DFTs are heavier than other
coatings and depending on manufacture can range from 8-18 mils in 1 3 coats depending on
requirements. Most CUI applications range from 10 to 12 mils in 2 coats.
Depending on manufacture a maximum recoat window may not exist allowing for better
scheduling, ease of touchup, and longer term maintenance planning. Depending on product
selection, allowable application surface temperatures can range up to 600F with most about
300-350F, and as such, nearly all process equipment can be coated while in operation and
making money for the owner. As always, safety precautions are of primary importance, and
facility owners should review safety practices to ensure proper practices are used including
grounding of equipment, good ventilation, removal of all sources of ignition and good personnel
protection is in place. Product data sheets and the manufacture should be consulted for
additional information.

CONCLUSIONS
The specifying engineer or owner needs to revisit their standard specification to update it
with appropriated products needed for project specific requirements, adding newer technologies
as may be desired. They should determine if some of the addition features of newer coating
and technologies are appropriate for use in their facilities. The owner must evaluate many
issues for updating and upgrading specifications, leading to improved first and life cycle costs
(and their appropriate trade off costs), service life, reduced downtime, and maximization of profit
for petrochemical, power and other heating processes that typically operate 24 hours a day and
7 days a week.
Manufactures and suppliers should be questioned to seek as much information as
possible so proper specifications that are advantageous to the owner and provide value over the
lifecycle of the installation can be created and used. Project costs especially first costs may lead
to better life cycle costs, or may lead to continuous maintenance efforts. With newer
technologies available new methodologies are now becoming common place and allow for
smarter designing and smarter maintenance.
References:
1
C. Steely, W. Pollock, A State of the Art Report of Protective Coatings for Carbon Steel
and Austenitic Stainless Steel Surfaces Under Thermal Insulation and Cementitious
Fireproofing. NACE Publication 6H189, 1986.
2
E.G. Haney, The Zinc-Steel Potential Reversal in Cathodic Protection, NACE Paper
No. 216, 1981, Pg. 4.