• Login
    • Join
  • FOLLOW:
  • Subscribe Free
    • Magazine
    • eNewsletter
    Checkout
    • Magazine
    • News
    • Research
    • Markets & Technologies
    • Raw Materials
    • Top Companies
    • Directories
    • Jobs
    • Events
    • Microsites
    • More
  • Magazine
  • News
  • Research
  • Markets & Technologies
  • Raw Materials
  • Top Companies
  • Directories
  • Jobs
  • Events
  • Microsites
  • Current / Back Issues
    Features
    Business Corner
    Editorial
    Digital Edition
    eNewsletter Archive
    Our Team
    Editorial Guidelines
    Subscribe Now
    Advertise Now
    World Reports
    eBook
    Top Features
    Fixr.com Announces 2021 Paint & Color Trends

    2021 CEO Forum

    Automotive OEM Coatings

    Mixing Equipment Directory

    The Wood Coatings Market
    Breaking News
    Online Exclusives
    Distributor News
    Financial News
    Paint & Coatings Manufacturer News
    People In the News
    Price Increases
    Product News
    Video Bites
    Raw Materials & Equipment
    Suppliers News
    Live From Shows
    Top News
    Barentz Expands Canadian CASE Team

    Shepherd Color Company Opens Sales Office in China

    Chromaflo Technologies Awarded Gold Status CSR Rating by EcoVadis in EMEA

    RPM Reports Fiscal 2021 3Q Results

    TCSNE (NESCT) Hosting Golf Outing on Sept. 13, 2021
    Top Companies report
    Market Research
    White Papers / Tech Papers
    Technical Papers
    Product Spec Sheets
    World Reports
    Adhesives and Sealants
    Aerospace Coatings
    Architectural Coatings
    Automotive Coatings
    Automotive Refinish
    Business Operation
    Color Trends & Forecast
    Construction Chemicals
    Corrosion Control
    Industrial Coatings
    Laboratory Equipment
    Marine Coatings
    Market Trends & Forecast
    Powder Coatings
    Production Equipment
    Radcure Coatings
    Special Purpose Coatings
    Wood Coatings
    "Green" Coatings

    PPG Adds SEM Products to PPG ADJUSTRITE Commercial Estimating System

    HGTV Home by Sherwin-Williams Launches Ovation Plus

    Nippon Paint Marine’s New Self-polishing Antifouling Paint Applied to 5 Bulk Carriers

    PPG Honors Ideal Distributors with Automotive Refinish Platinum Distributor of the Year Award

    Dunn-Edwards Launches DECOPRIME
    Additives
    Binders
    Pigments
    Solvents

    Shepherd Color Company Opens Sales Office in China

    Chromaflo Technologies Awarded Gold Status CSR Rating by EcoVadis in EMEA

    Clariant Joins EU Circular Plastics Alliance

    AOC Provides Resins for Structure, Shell of Solar Car

    HSMG Receives Notice of Allowance from US Patent and Trademark Office
    Buyers Guide
    Company Capabilities
    Distributor Guide
    Add New Company
    International Buyers Guide Companies
    Siltech Corporation

    Active Minerals

    Shepherd Color Company, The

    Eagle Specialty Products

    Clariant Additives
    Industry Events
    Webinars
    Live From Show Event
    Top Events
    Cleveland Coatings Society Zoom Meeting

    PCI Powder Coating Week

    Southern Society for Coatings Technology Annual Meeting and Technical Conference

    11th Asia Pacific Floor Fair and Guangzhou Paint & Coatings Fair

    Coatings for Africa
    Companies
    White Papers/Tech Papers
    Product Spec Sheets
    Equipment
    Literature/Brochures
    Videos
    International Buyers Guide Companies
    Keim Additec Surface USA LLC

    Shepherd Color Company, The

    Pilot Chemical Company

    Siltech Corporation

    Clariant Additives
    • Magazine
      • Current / Back Issues
      • Features
      • Editorial
      • Business Corner
      • Digital Edition
      • eNewsletter Archive
      • Editorial Guidelines
      • Subscribe Now
      • Advertise Now
    • Breaking News
    • Directories
      • Buyers Guide
      • Distributor Guide
      • Corporate Capabilities
      • Trade Associations
      • Add Your Company
    • Markets & Technologies
      • Adhesives and Sealants
      • Aerospace Coatings
      • Architectural Coatings
      • Automotive Coatings
      • Automotive Refinish
      • Business Operation
      • Color Trends & Forecast
      • Construction Chemicals
      • Corrosion Control
      • Industrial Coatings
      • Laboratory Equipment
      • Marine Coatings
      • Market Trends & Forecast
      • Powder Coatings
      • Production Equipment
      • Radcure Coatings
      • Special Purpose Coatings
      • Wood Coatings
      • "Green" Coatings
    • Raw Materials
      • Additives
      • Binders
      • Pigments
      • Solvents
    • World Reports
      • Africa Report
      • China Report
      • India/Asia Pacific Report
      • Europe Report
      • Latin America Report
      • Market Research
      • Russian Report
    • Top Companies
    • Online Exclusives
    • Slideshows
    • Experts Opinions
    • Blog
    • eBook
    • Infographics
    • Videos
    • Podcasts
    • Whitepapers
    • Jobs
    • Microsites
      • Companies
      • White Papers/Tech Papers
      • Product Spec Sheets
      • Equipment
      • Literature/Brochures
      • Videos
    • Events
      • Industry Events
      • Live From Show Event
      • Webinars
    • About Us
      • About Us
      • Contact Us
      • Advertise With Us
      • Privacy Policy
      • Terms of Use
    Blog

    Stopping Corrosion Under Insulation in Global Oil and Gas Facilities

    ...

    Stopping Corrosion Under Insulation in Global Oil and Gas Facilities
    Photo courtesy EonCoat, LLC
    Related CONTENT
    • Nippon Paint Marine’s New Self-polishing Antifouling Paint Applied to 5 Bulk Carriers
    • Coatings World CEO Forum Part 2
    • Applied Graphene Materials Customer Launches 2 Graphene-based Sealants
    • Future Of Egypt Paints & Coating Industry And Post Covid-19 Pandemic Impact
    • AMI's Steel Pipeline Coatings, Protection Forum Goes Virtual
    Del Williams03.16.18
    Corrosion Under Insulation (CUI) is the root cause of many of the global petrochemical industry’s most serious problems including forced shutdowns, lost production, early repair and replacement, as well as safety and environmental consequences that can cost millions of dollars per incident.  
     
    CUI, which involves the corrosion of vessels or piping beneath insulation due to water penetration, is insidious because it can remain undetected until the insulation is removed for inspection or leaks occur.  Water penetration can result from many causes including monsoons, rain, flooding, wash downs, and sprinkler systems, as well as exposure to steam, humidity, or frequent condensation and evaporation of atmospheric moisture.
     
    From upstream wells, risers, drilling rigs, or offshore platforms, to midstream pipelines, storage, and liquefied natural gas (LNG) terminals, to downstream refineries, fighting CUI and major corrosion has been an uphill battle and a major cost in the operation of oil and gas facilities, according to NACE International’s “International Measures of Prevention, Application and Economics of Corrosion Technology (IMPACT)” study.
     
    Fortunately, even when traditional coatings have allowed CUI and corrosion to occur, a new approach can stop the corrosion to dramatically extend facility and equipment life in oil and gas industry applications.
     
    Stopping Existing Corrosion and CUI
    Traditional corrosion protection typically involves applying polymer paints and rubber type coatings.  Such methods create a physical barrier to keep corrosion promoters such as water and oxygen away from steel substrates.  However, this only works until the paint is scratched, chipped, or breached and corrosion promoters enter the gap between the substrate and coating.  Then the coating can act like a greenhouse – trapping water, oxygen and other corrosion promoters – which allows the corrosion to spread. 
     
    Some of the world’s largest petrochemical companies, including China Petroleum & Chemical Corporation, however, are finding success with a new approach toward stopping CUI and corrosion.
     
    China Petroleum & Chemical Corporation, commonly known as Sinopec Corp., is one of the largest integrated energy and chemical companies in the world, with upstream, midstream and downstream operations.  In Sinopec’s Jianghan Oilfield projects, located in China’s Jianghan Plain in Hubei province, there are numerous facilities for oil and gas extraction, transport, and storage.
     
    However, with Hubei’s sub-tropical monsoon climate, CUI and corrosion are serious issues that shorten equipment life and require excessive maintenance. In this environment, traditional coatings have been ineffective, and stopping corrosion that is already underway is often the last resort.
     
    To extend production and the service life of assets already experiencing serious CUI or major corrosion, on two sample projects Sinopec turned to EonCoat, a spray applied inorganic coating from the Raleigh, North Carolina-based company of the same name. EonCoat represents a new category of tough, Chemically Bonded Phosphate Ceramics (CBPCs) that can stop the corrosion, ease application, and reduce production downtime even in very wet, humid, monsoon prone conditions.
     
    In contrast to traditional polymer coatings that sit on top of the substrate, the corrosion resistant CBPC coating bonds through a chemical reaction with the substrate, and slight surface oxidation actually improves the reaction.  The surface of steel is passivated as an alloy layer is formed.  This makes it impossible for corrosion promoters like oxygen and humidity to get behind the coating the way they can with ordinary paints. 
     
    Although traditional polymer coatings mechanically bond to substrates that have been extensively prepared, if gouged, moisture and oxygen will migrate under the coating’s film from all sides of the gouge. 
     
    By contrast, the same damage to the ceramic coated substrate will not spread corrosion because the carbon steel’s surface has been chemically transformed into an alloy of stable oxides.  Once the steel’s surface is stable (the way noble metals like gold and silver are stable) it will no longer react with the environment and therefore cannot corrode.
     
    Visible in scanning electron microscope photography, EonCoat does not leave a gap between the steel and the coating because the bond is chemical rather than mechanical.  Since there is no gap, even if moisture was to get through to the steel due to a gouge, there is nowhere for the moisture to travel.  This effectively stops atmospheric corrosion and CUI on carbon steel assets.
     
    The corrosion barrier is covered by a ceramic layer that further resists corrosion, water, fire, abrasion, impact, chemicals, and temperatures up to 400 °F.  Beyond this, the ceramic serves a unique role that helps to end the costly maintenance cycle of replacing typical barrier type coatings every few years.
     
    “CUI is the silent killer,” explains Merrick Alpert,” President of EonCoat.  “The insulation creates a terrarium on the steel in which corrosion is guaranteed to occur if traditional coatings are used. And the insulation then hides the corrosion from being detected until it’s too late.”
     
    Sinopec’s first sample project using the CBPC coating involved addressing CUI on a 500 cubic meter petroleum storage tank in an oil-extraction facility in the Jianghan Oilfield.
     
    While the storage tank’s original coatings were wrapped beneath a mineral wool insulating layer, due to rain, condensation, and moisture invasion through the damaged insulating layer, these coatings had failed, allowing CUI in a number of areas.
     
    After peeling off the insulating layer, the metal surface underneath was prepared by sandblasting, then the CBPC coating was applied.  The application has effectively stopped the CUI issue and is expected to extend the storage tank’s functional life for years to come.
     
    After the success of the first project, Sinopec opted to utilize the CBPC coating to address serious corrosion on a container-type water injection pumping station in another Jianghan Oilfield facility.  Because of the pumping station’s outdoor location with very high saline alkali content soil, along with a very humid container environment, shutdown for corrosion maintenance was typically required every three years.
     
    A traditional three coat system was routinely used to maintain corrosion protection for the pumping station, so coating application took at least three days to allow drying time for each layer.  Including surface preparation, total required maintenance downtime was at least seven days, which hindered production.
     
    One of the greatest benefits of the CBPC coating, however, is the quick return to service that minimizes facility downtime.  The time saved on an anti-corrosion coating project with the ceramic coating comes both from simplified surface preparation and expedited curing time. 
     
    With a typical corrosion coating, near white metal blast cleaning (NACE 2 / SSPC-SP 10) is required to prepare the surface.  But with the ceramic coating, only a NACE 3 / SSPC-SP 6 commercial blast is typically necessary.
     
    With traditional coatings, extensive surface preparation is required and done a little at a time to avoid surface oxidation, commonly known as ‘flash rust’, which then requires re-blasting.  But with the CBPC coating, the flash rust is actually desirable. There is no need to ‘hold the blast’.  The reason for this unique CBPC characteristic is due to the presence of iron in the rust, which helps to create the magnesium iron phosphate alloy layer.  It is this alloy layer that allows CBPCs to so effectively protect carbon steel from corrosion.
     
    In contrast, a corrosion resistant coating for carbon steel utilizing the ceramic coating in a single coat requires almost no curing time.  Return to service can be achieved in as little as one hour, which can potentially save hundreds of thousands of dollars per day in reduced oil and gas facility downtime.
     
    Because of these unique properties, total coating application including surface preparation of the Sinopec pumping station will take two days and the asset can be put into service immediately.
     
    With CUI and corrosion a perennial problem for oil and gas facilities with massive carbon steel structures, utilizing CBPC coatings that can control corrosion for decades and reduce downtime will only help the bottom line.





    Del Williams is a technical writer based in Torrance, Calif.
     
    Related Searches
    • paint
    • sinopec
    • paints
    • coatings
    Suggested For You
    Resins Update Resins Update
    Nippon Paint Marine’s New Self-polishing Antifouling Paint Applied to 5 Bulk Carriers Nippon Paint Marine’s New Self-polishing Antifouling Paint Applied to 5 Bulk Carriers
    Coatings World CEO Forum Part 2 Coatings World CEO Forum Part 2
    Applied Graphene Materials Customer Launches 2 Graphene-based Sealants Applied Graphene Materials Customer Launches 2 Graphene-based Sealants
    Future Of Egypt Paints & Coating Industry And Post Covid-19 Pandemic Impact Future Of Egypt Paints & Coating Industry And Post Covid-19 Pandemic Impact
    AMI AMI's Steel Pipeline Coatings, Protection Forum Goes Virtual
    AGM Presenting Nanotechnology for Water-based Epoxy Coatings at Corrosion 2021 AGM Presenting Nanotechnology for Water-based Epoxy Coatings at Corrosion 2021
    PPG Introduces Premium Iso-free Primer Surfacer, Catalyst PPG Introduces Premium Iso-free Primer Surfacer, Catalyst
    Greenkote Reports Increased Anticorrosion Coating Orders Greenkote Reports Increased Anticorrosion Coating Orders
    IFS Coatings Launches IFS Pureflex FBE for Rebar IFS Coatings Launches IFS Pureflex FBE for Rebar
    PPG Debuts PPG HI-TEMP 1027HD Coating for Corrosion-Under-Insulation Applications in North America PPG Debuts PPG HI-TEMP 1027HD Coating for Corrosion-Under-Insulation Applications in North America
    LINE-X Launches Dealer Program with International Truck LINE-X Launches Dealer Program with International Truck
    PPG Donates Coatings, Sealants to Help Restore Douglas C-54 Skymaster Aircraft PPG Donates Coatings, Sealants to Help Restore Douglas C-54 Skymaster Aircraft
    AkzoNobel Supplying Powder Coatings for Landmark Water Pipeline in China AkzoNobel Supplying Powder Coatings for Landmark Water Pipeline in China
    Emulsion Polymers Market to Hit $66 Billion by 2027: Transparency Market Research Emulsion Polymers Market to Hit $66 Billion by 2027: Transparency Market Research

    Related Blog

    • Breaking News
      BCF: Anti-viral Surfaces Could Tackle COVID-19 Crisis

      BCF: Anti-viral Surfaces Could Tackle COVID-19 Crisis

      The webinar set out to identify the challenges and share knowledge on techniques that could prevent the spread of infection, both in the present and the future.
      British Coatings Federation 05.05.20

    • Breaking News
      IGL Launches Plant-Based Surface Sanitizer

      IGL Launches Plant-Based Surface Sanitizer

      ...
      IGL Coatings 04.28.20

    • Breaking News | Construction Chemicals
      You’re on Deck: 3 Tips for Preserving Life, Warranties of Parking Deck Coatings

      You’re on Deck: 3 Tips for Preserving Life, Warranties of Parking Deck Coatings

      ...
      Western Specialty Contractors 04.23.20


    • Corrosion Control

      Can South Africa’s Coastal Infrastructure Survive Corrosion?

      ...
      Simon Norton, International Zinc Association 04.21.20

    • Making Sense of Sustainability

      ...
      Lux Research 04.20.20

    • Breaking News
      BCF: Helping Members Navigate Path Through Coronavirus Pandemic

      BCF: Helping Members Navigate Path Through Coronavirus Pandemic

      ...
      David Park, Public Affairs Manager, British Coatings Federation 03.27.20


    • Breaking News
      BCF: Raw Material Shortages Could Impact on Availability of Food Packaging

      BCF: Raw Material Shortages Could Impact on Availability of Food Packaging

      Printing ink manufacturers across Europe are reporting reduced availability of ethanol and n- propanol, per BCF.
      British Coatings Federation 03.23.20

    • Breaking News
      Sun Chemical Addresses Coronavirus Concerns with Supply Chain Update, Q&A for Customers

      Sun Chemical Addresses Coronavirus Concerns with Supply Chain Update, Q&A for Customers

      “The potential supply chain impact of the Coronavirus around the world is vast and unpredictable," said Jeffrey Shaw, chief supply chain officer, Sun Chemical.
      03.02.20

    • Breaking News | Industry News
      EU’s Titanium Dioxide Ruling Sparks Concern

      EU’s Titanium Dioxide Ruling Sparks Concern

      Classification of TiO2 as a category 2 suspected carcinogen by inhalation is a concern to industry groups.
      George Fuchs, NAPIM, and David Savastano, Ink World 02.20.20


    • Additives | Breaking News
      BCF: Workers, Users Shouldn

      BCF: Workers, Users Shouldn't Be Alarmed by TiO2 Classification

      The EU published a delegated regulation classifying TiO2 as a category 2 suspected carcinogen by inhalation under EU Regulation (EC) No 1272/2008.
      British Coatings Federation 02.18.20

    • What Are VOCs?

      What Are VOCs?

      Understanding the environmental effects of these harmful chemicals.
      ECOS Paints 02.04.20

    • Breaking News
      BCF: Government Must Understand Need for Alignment on Chemicals with EU

      BCF: Government Must Understand Need for Alignment on Chemicals with EU

      ...
      01.24.20


    • Breaking News | Paint & Coatings Manufacturer News
      BCF: Coatings Industry

      BCF: Coatings Industry 'Cautiously Welcomes' New Brexit Deal

      82% of BCF members have expressed concerns over new UK chemical regulations.
      10.18.19

    • Architectural Coatings | Color Trends & Forecast
      Improve Employee Morale with the Right Paint Color

      Improve Employee Morale with the Right Paint Color

      Offices can benefit from some color, and so will employees.
      Jennifer Bell, Freelance Writer 10.15.19

    • Breaking News | Industry News | Paint & Coatings Manufacturer News
      BCF: Coatings Industry Prepared for

      BCF: Coatings Industry Prepared for 'No-deal' Brexit but Fear Border Delays, UK REACH

      Moreover, 82% of those surveyed by the BCF have expressed concerns over new UK chemical regulations.
      10.03.19

    Trending
    • Raw Material Availability, Prices Hikes May Be 2021’s Biggest Issue For Coatings, Ink Sectors
    • Raw Material Price Increases Pile Pressure On Paint Manufacturers
    • HGTV Home By Sherwin-Williams Launches Ovation Plus
    • Eastern Coatings Show 2021 Organizers Call For Papers
    • PPG Adds SEM Products To PPG ADJUSTRITE Commercial Estimating System
    Breaking News
    • Barentz Expands Canadian CASE Team
    • Shepherd Color Company Opens Sales Office in China
    • Chromaflo Technologies Awarded Gold Status CSR Rating by EcoVadis in EMEA
    • RPM Reports Fiscal 2021 3Q Results
    • TCSNE (NESCT) Hosting Golf Outing on Sept. 13, 2021
    View Breaking News >
    CURRENT ISSUE

    April 2021

      View More >

    Cookies help us to provide you with an excellent service. By using our website, you declare yourself in agreement with our use of cookies.
    You can obtain detailed information about the use of cookies on our website by clicking on "More information”.

    • About Us
    • Privacy Policy
    • Terms And Conditions
    • Contact Us

    follow us

    Subscribe
    Nutraceuticals World

    Latest Breaking News From Nutraceuticals World

    Kyowa Hakko Launches Heat-Treated Probiotic Strain for Eye Health
    CGA-7 Green Coffee Extract by Vidya Herbs Achieves Self-Affirmed GRAS Status
    Nutritional Complex Evidenced to Reduce Preterm Birth
    Coatings World

    Latest Breaking News From Coatings World

    Barentz Expands Canadian CASE Team
    Shepherd Color Company Opens Sales Office in China
    Chromaflo Technologies Awarded Gold Status CSR Rating by EcoVadis in EMEA
    Medical Product Outsourcing

    Latest Breaking News From Medical Product Outsourcing

    CMS Establishes New Payment for Pelvalon’s Eclipse System
    Varian, Google Cloud Partner to Bring Convenience to Cancer Therapy
    Resonetics Leases New Manufacturing Space in Costa Rica
    Contract Pharma

    Latest Breaking News From Contract Pharma

    Frontage Expands Capabilities at its Clinical Site in Secaucus, NJ
    Ascendia Pharmaceuticals Poised for Expansion
    Bora Pharmaceuticals Adds Roller Compaction Capabilities
    Beauty Packaging

    Latest Breaking News From Beauty Packaging

    Revlon Unveils New Fragrances Featuring Megan Thee Stallion & Sofia Carson
    Henkel Management Board Welcomes Wolfgang König
    Mielle Organics Gets a Major Investment
    Happi

    Latest Breaking News From Happi

    Nature’s Beauty Debuts Vegan Natural Body Care at Walgreens
    Estée Lauder Expands 'Beautiful' Fagrance Collection
    Mushrooms Are Key Ingredients in Beauty & Wellness
    Ink World

    Latest Breaking News From Ink World

    SE-DA Invests in Kornit Presto S
    Kumon North America Adds Speedmaster XL 106 from Heidelberg
    Iron Oxide Pigments Market to Register 4.7% CAGR from 2021 to 2028: GVR
    Label & Narrow Web

    Latest Breaking News From Label & Narrow Web

    Dantex elevates Joseph Sanchez to digital business development manager
    Mactac's Kevin Clunie joins TLMI panel
    MacDermid announces two new global sales roles
    Nonwovens Industry

    Latest Breaking News From Nonwovens Industry

    Precision Textiles Offers Biodegradable Medical Fabric
    Northshore Launches Megamax Briefs in New Colors
    Essity Acquires Distribution Rights to Sorbact in Australia and New Zealand
    Orthopedic Design & Technology

    Latest Breaking News From Orthopedic Design & Technology

    New Biosealant Could Stabilize Cartilage, Boost Healing After Injury
    Google Executive Joins SeaSpine's Board of Directors
    HSS and LimaCorporate Open Provider-Based 3D Design and Printing Facility
    Printed Electronics Now

    Latest Breaking News From Printed Electronics Now

    Tive Multi-sensor Tracker Solo 5G Relies on Sensirion SHT33
    VTT in 2020: Successful Year Despite Globally Challenging Times
    Lux Research: 3D Printing Market to Reach $51 Billion in 2030

    Copyright © 2021 Rodman Media. All rights reserved. Use of this constitutes acceptance of our privacy policy The material on this site may not be reproduced, distributed, transmitted, or otherwise used, except with the prior written permission of Rodman Media.

    AD BLOCKER DETECTED

    Our website is made possible by displaying online advertisements to our visitors.
    Please consider supporting us by disabling your ad blocker.


    FREE SUBSCRIPTION Already a subscriber? Login