1. Elevated Temperature Service and Insulative Coatings
Coatings for CUI
Elevated Temperature Service and Insulative Coatings

2. Corrosion Under Insulation
Can’t see it
Don’t know how bad it is
But you know it is occurring somewhere!

3. CUI Environment For many years engineers ignored CUI … why?
The substrate will always be hot and dry
Insulation/cladding will not leak
If this is true – no corrosion!
This is an ideal, but unrealistic condition
Any/all of the following:
Thermal cycling
Ambient up to 1000°F
Wet/dry cycling
Constantly wet
The worst corrosion happens in the °F range

4. NACE SP0198-2010 Control of Corrosion Under Thermal Insulation and
Fireproofing Materials—A Systems Approach

5. History of CUI Practices
NACE Publication 6H189 – (1989)
Recognized CUI as a big problem!
Recognized IOZ as problematic
Agreed that the most corrosive temperature range ( °F)
Promoted epoxy-phenolics or glass-flake, amine-cured coal tar epoxies
NACE RP0198 (2004)
Recommended Practice (no testing criteria)
NACE SP0198 (2010)
Standard Practice identified several technologies
Still no “test” or performance criteria
Currently a task group to come up with a testing criteria for evaluation

6. Standard Practice NACE - SP0198 (2010)
Substrates
Stainless steels
Carbon steel
Temperature Ranges
Up to 140°F
Up to 300°F
Up to 400°F
Up to 1000°F
Up to 1200°F
Temperature range where most corrosion occurs

7. NACE SP0198 System Generic Temperature Limit Features Carbowrap Tape
Petrolatum tape
Up to 140°F/60°c
Easy installation
Minimal surface prep
Low temperature application
Carboguard 890
Epoxy
Versatile epoxy
Carboguard 690
Up to 300°F/149°c
Low temperature cure
Moisture tolerant
Carbomastic 15
Up to 300°F/149°C
Surface tolerant (SSPC-SP3)
Thermaline 450 EP
Epoxy-phenolic
Up to 400°F/204°c
Most commonly specified
Thermaline 450
Epoxy-novolac
Up to 425°F/218°c
Outstanding chemical resistance
Glass-flake reinforced
20 year history
Thermaline 4001
Inorganic copolymer
Up to 1200°F/ °C
Inorganic polymer
Aluminum and MiO reinforced
Single package

8. Carboline Products For CUI
Thermaline Series

9. Thermaline 450 EP Epoxy-phenolic chemistry Temperature limit: 400°F
Two coats (4-8 mils/ct)
Temperature limit: 400°F
Excellent chemical resistance
Immersion-grade epoxy
Excellent thermal shock resistance

10. Thermaline 450 Novolac Epoxy-novolac chemistry Flake-glass reinforced
Temperature limit: 450°F
Outstanding chemical resistance
Oustanding thermal shock resistance
Adhesive strength higher than cohesive
1 or 2 coat application (12 to 15 mils)
20 years of history

11. Thermaline 4001 Inorganic copolymer Flake reinforced
Aluminum
Micaceous iron oxide
Temperature resistant (-321°F to 1000°F)
Boiling water resistant
Two coats at 3½-5 mils/coat

12. Thermaline 450 – Case Histories
Owner
Application
Shell Offshore (GOM)
Compressor modules
Denbury Resources (New Ineria, LA)
Line heater
Chevron Refinery (Salt Lake City, UT)
Insulated pipe
NORCO (Baton Rouge, LA)
Valero (Sunray, TX)
Insulated ductwork
Valero (Memphis, TN)
Chevron (Big Foot)
Crews quarters

13. Thermaline 450 – Case Histories
Owner
Application
BASF (Freeport, TX)
Insulated tank
Brazos Pipe and Steel (TX)
Steel, piping and vessels
Formosa Plastics (TX)
Insulated piping
Bayer Chemical (Freeport, TX)
BP (Texas City, TX)
Structural steel
Dow Chemical (Freeport, TX)
Gulf Coast Waste Authority
Insulated piping/vessels

14. Thermal Barrier Durable Insulative Coating Energy Savings
Carbotherm® 551
Thermal Barrier
Durable Insulative Coating
Energy Savings

15. Carbotherm 551
An insulative, liquid-applied, water-based epoxy coating that provides the following:
Protective thermal protection for workers
Resistance to solar (thermal) radiation
Insulation for heat efficiency
Durable insulative coating for industrial uses
Minimizes corrosion under insulation (CUI)
Eliminates condensation from cold surfaces

16. Epoxy versus Acrylic Increased durability Greater adhesion
Hardness
Strength
Greater adhesion
Increased chemical resistance
Comparable thermal conductivity (insulation value)
Higher film build with faster recoat times

17. Epoxy versus Acrylic “General Properties”
Property
Carbotherm 551
Insulative Acrylics*
Solids by Volume
82%
74-80%
Thermal Conductivity
0.055 BTU/hr-ft-°F
BTU/hr-ft-°F
Temperature Resistance
350°F
Topcoating
Optional
Recommended
Chemical Resistance
Excellent
Poor - Fair
*Average range for four commercially available products

18. Epoxy versus Acrylic “Application Differences”
Property
Carbotherm
551
Standard Insulative Acrylics
High Build Insulative Acrylics
Film Build/Coat
40 mils
(1 mm)
20 mils
(0.5 mm)
45 mils
(1.1 mm)
Recoat
5 hours
4 hours
16 hours
# Coats to Apply
160 mils (4 mm)
4 coats
8 coats
3 coats
Time to Apply
2 days
4 days
3 days

19. Epoxy versus Acrylic “Physical Property Differences”
Carbotherm
551
Insulative Acrylics*
Adhesion
1000 psi (cohesive)
250 psi (cohesive)
Tensile Strength
800 psi
40 psi
Hardness
55 Shore D
34 Shore D
Pencil Hardness B 6B
*Values are typical

20. Worker Protection Thickness?
The hotter the surface, the thicker the material needed to protect workers.
# Coats
Thickness
Temperature 1
20 mils (0.5 mm)
Up to 65°C (150°F)
40 mils (1.0 mm)
Up to 93°C (200°F)
Up to 121°C (250°F) 2
60 mils (1.5 mm)
Up to 149°C (300°F)
80 mils (2.0 mm)
Up to 177°C (350°F)

21. Outstanding Thermal Radiation Reflectivity and Resistance
84.7% solar reflectivity
Can reduce the thermal increase caused by solar radiation by up to degrees Fahrenheit
Just a single coat of 40 mils (1 mm) provides protection from solar radiation

22. Thickness vs Heat Efficiency
Carbotherm 551
Thickness/# Coats
Heat Efficiency
@ Process Temperature
250°F
350°F
120 mils/3 coats
30%
33%
160 mils/4 coats
36%
40%
200 mils/5 coats
42%
46%
Data in chart assumes horizontal tank with ambient temperature of 75°F (24°C) and no wind.

23. Sweating Surfaces
Insulates cold substrates from warm moist ambient air
Condensers
Cold vessels
LP tanks
Prevents “drips”
Minimizes slippery surfaces
Reduces corrosion

24. Questions?