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The Risks of CUI at Various Temperatures and Levels of Operation

CS CONTRACT SERVICES LTD CS CONTRACT SERVICES LTD ENVIRONMENTAL POWERTHERM www.powertherm.co.uk The Risks of CUI at Various Temperatures and Levels of Operation The complication of CUI on process plant and pipework is connected mainly with steel components. Failures have occurred, with loss of containment, due to localised corrosion progressing undetected beneath insulation. Steel corrodes when it is in contact with water and has a free supply of oxygen. When plant and pipework are insulated, there is usually a space in which water can collect on the metal surface with access to air. The ingress of water into the insulation is often caused by one or more of the following: poorly designed and/or installed protective finish or cladding; cladding joint sealant breakdown; mechanical damage to the protective finish; or cladding removed and not properly replaced (common around valve boxes). When water penetrates the insulation, it tends to collect at low-lying sections of plant and pipework and around discontinuities, eg- the base of vessels; pipework supports; the intersection between nozzles and vessels; the underside of elbows and horizontal pipe runs; and drain legs. OPERATING TEMPERATURE Experience indicates that many factors influence the risk of CUI including whether trace heating is installed (a high-risk factor). Operating temperature greatly affects the risk of CUI. The following table indicates the likely risk of CUI for carbon steel pipework, without trace heating, under various operating regimes: Operating Risk Of CUI Temperature Painted Pipework Painted Pipework Painted/Unpainted Pipework <10 Years Old <10 Years Old >10 Years Old Intermittent Continuous Intermittent or Operation Operation Continuous Operation <-30 OC Low - Medium Low Medium -30 OC to 30 0C Medium Low - Medium High 30 OC to 120 OC High High High >120 OC Medium Low Medium CUI is generally, but not exclusively, a high risk in the temperature range of -4'C - +175°C (25 F to 347 F). However, the highest corrosion rates are more commonly experienced in operational conditions between 60 C – 120°C (140°F to 248°F). Under these conditions, corrosion rates between 1.5 – 3.0mm per year have been reported, and the potential for corrosion doubles for every 15°C – 20°C increases in temperature between O – 100°C (32 – 212'F). - - - HIGH RISK TEMPERATURE RANGE FOR CUI 60°C – 120°C CONSEQUENCES OF THE EFFECTS OF CUI? Corrosion under insulation poses a significant operational, safety, and economic challenge for a variety of industries. As it cannot be seen, CUI has become a critical safety hazard, with numerous cases causing severe, life-threatening outcomes. If left unchecked, CUI can result in leakage from pipes and equipment. If such equipment operates under high pressure and located where workforce is present, this has the potential for catastrophic consequences. Significant complications include: Major equipment outages, leading to lost production Unexpected maintenance costs Health and safety of personnel Environmental issues Reputation damage PIPE FAILURES CAUSED BY CUI 60% THE SPACE-RING SYSTEM (SRS) SRS reduces damage to the cladding surface, whilst providing airflow and drainage from within, keeping pipes dry and safe from the threat of CUI. SRS uses support rings to transfer the weight load onto the pipe itself, which is considerably stronger than cladding. Strengthening the insulation system prevents seams from buckling and moisture entering the system. POWERTHERM SPACE-RING SYSTEM In addition, the air space introduced allows free flowing air and the internal surface of the cladding acts as a gutter to keep the pipe and surrounding insulation dry. EXTERNAL CLADDING SPACE-RING PIPE INSULATION AIR SPACE DRAINAGE HOLES For more details on how the SRS helps to prevent CUI please visit: https://youtu.be/QVWc6lItGyO RES POWERTHERM nga. •ebu nqa. CONTRACT SERVICES LTD ISO 9001 ISO 14001 ISO 45001 QUALITY MANAGEMENT HEALTH & SAFETY MANAGEMENT MANAGEMENT +44 (0) 114 288 9119 [email protected] www.powertherm.co.uk Francis House, Orgreave Drive, Handsworth, Sheffield, S13 9NR \\

The Risks of CUI at Various Temperatures and Levels of Operation

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The complication of CUI on process plant and pipework is connected mainly with steel components. Failures have occurred, with loss of containment, due to localised corrosion progressing undetected ben...

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