1. Corrosion under insulation (CUI)
The Solution for
Corrosion under insulation (CUI)

2. Corrosion Under Insulation (CUI)
CUI has been recognized as a problem in many industries
Insulation is a necessary component of the system and is designed to:
Save energy
Control process temperatures
Protect workers from high temperatures
NACE Standard SP is a good source of information, but electrolytes will eventually find their way into even the best system

3. Anti-Corrosion Gel Performance
Operating Temperatures – over 350° F/177 ° C
Moisture Resistance – Hydrophobic
Anti-Corrosion Properties – Mineralization, Inhibitors & Buffering Technology
Application
Surface Prep – no sandblasting, free of oils/greases
Cure Time – None, visual inspection easy and non-destructive
Equipment – Brush, PVC glove or spray
Environmentally benign
Cost
Total application cost is typically lower than other systems
Line shutdown not required

4. Technology
Barrier system – The specially formulated products have great adhesion characteristics (requiring minimal surface prep) and are hydrophobic to help keep moisture away from the substrate. Never cures thus microscopic air pockets don’t form.
Mineralization - Growing an engineered surface, or surface conversion – creating a surface which resists corrosion even if moisture gets to it. Undercutting cannot occur.
Buffering system – If moisture migrates through the gel through vapor drive, it is buffered to a high pH which is alkaline enough not to corrode metal. Gel also contains a number of corrosion inhibitors.

5. How the reactive gel corrosion treatment works:
When the ferrous (steel) surface (1) is covered with a layer of reactive gel (2), the metal surface reacts with components in the gel to form a mineral layer (3). This thin glasslike layer (3) acts as a barrier between chlorides and the metal surface, thus providing corrosion resistance.
The mineral layer (3) has a thickness of angstroms, only 0.01% as thick as a piece of paper.

6. Although the thin mineral layer can be damaged by mechanical abuse, there is extra protection built into the system, i.e.:
• If the mineral surface is scratched or damaged, and there is residual gel in contact with the area, the mineral layer will be regenerated by the gel ingredients.
• The gel contains a buffering agent, which raises the pH of water at the surface of the steel to 10 or above, a level unfavorable for corrosion of ferrous substrates. (Another formulation for aluminum adjusts the pH to 6-8).

7. Untreated steel surface Mineralized steel surface
Surface Formation
10 um
10 um
Untreated steel surface
Mineralized steel surface

8. History of the Technology
Automotive
Technology has been used in automotive applications for >
30 years. Originates before Second World War.
Crevice Corrosion on Brake Cables
Industrial Applications
First industrial application was with the US Navy. Solved their #1 and #2 corrosion maintenance problem.
Watertight Door Latching Mechanisms
Deck Edge Elevator Wire Ropes
Other specific areas

9. 2 Year Salt Water Immersion Test
Samples in Aerated 5% salt solution

10. 2 Year Salt Water Immersion Test
Samples in Aerated 5% salt solution

11. 2 Year Salt Water Immersion Test
Non-Bead Blasted Pipe
Bead Blasted Pipe

12. Stress Crack Corrosion on SS
Control Sample Typical Stress Cracking
with in 100 hours of exposure
Per ASTM C 692
EDC 2400 Treated Sample
No Cracking after 100 Hours
Exposure Per ASTM C 692
Gel Treated Sample
No Cracking After 100 Hours
Exposure Per ASTM C-692

13. Anti-Seize

14. Ammonia Lines
Ammonia Test Site
Flange Remediation

15. North Slope

16. AMMONIA SYSTEM INSTALLATION EXAMPLE ON OPERATING SYSTEM USING:

17. PICTORAL INSTALLATION
REMOVING METAL JACKET

18. PRIMER ON INSULATION
CORROSION ON PIPE

19. REMAINING PRIMER EASILY REMOVED

20. Pipe temperature thickens the RG-2400 LT quickly
Pipe temperature thickens the RG-2400 LT quickly. After 3 passes over an area it gets difficult to spread and achieve adhesion.
The slight frost on the pipe left some voids, however fresh “warm” material could be put over these areas and achieve ahesion.
INSTALLING RG-2400 LT

21. A WELL COATED PIPE READY FOR INSULATION

23. CONCLUSIONS
COATING A 24° PIPE IN OPERATION IS POSSIBLE IN SMALL SECTIONS.
RG-2400 MUST BE WARM TO IMPROVE COVERAGE AND EASE OF APPLICATION
INSULATION MUST BE INSTALLED IMMEDIATELY UPON ACHIEVING COVERAGE TO PREVENT CONDENSATION FROM FORMING ON THE RG-2400
INSULRAP OR FABWRAP VAPOR BARRIER SHOULD BE USED TO KEEP OUT MOISTURE
TESTING WILL CONTINUE ON -15° F LINES IN OPERATION AND -50° F LINES IN OPERATION. RESULTS WILL BE ADDED TO THIS PPT PRESENTATION.
GLYCOL WILL BE TESTED TO REMOVE FROST ON THE COLDER LINES.

24. Product Application - Tank
The tank was completely sprayed in approximately one hour

25. Tank Chime Application – Texas City, Texas

26. Conoco/Phillips Well Casing
WELLS WERE FIRST FLUSHED WITH 55 BARRELS OF 120° F CLEAN WATER TO REMOVE SLUDGE, WATER WAS PUMPED OUT AT END OF FLUSH CYCLE.

27. Companies With Product Installations/specifications
Anheuser Busch
General Mills
Jolly Green Giant
British Petroleum
Best Brands Foods
Philadelphia Gas
Fred Meyer Foods
Unocal
Dot Foods
Exxon Mobil
CODELCO
Tuborg
Efes Pilsen
GlaxoSmithKline
Shell
OxyChem
Ernst & Gallo
Equistar
Union Carbide
Cytec
Phillips
MODOT
Nicor
Monarch Foods
US Navy
Kraft Foods
ConocoPhillips
Coors Brewing
Canada Hydro
Indiana University

28. Benefits of the Technology:
Practical application – simple non-curing gel
Multiple delivery systems (spray, glove, brush)
Insensitive to surface preparation and application conditions
Demonstrated superior anti-corrosion performance
Environmentally benign
Easy to inspect