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CUI Risk Reduction by NonIntrusive Inspection

Mohammad Shamim
BP Sharjah Ltd

Outline

Introduction
CUI Mechanism
BP Sharjah CUI Risk
NII Techniques for CUI
Risk Based Mitigation Methodology
Results: 2007-8 Inspection
Conclusion

Introduction
Corrosion of metals covered by hot or cold insulation due to
various factors

More CUI Examples

CUI Mechanism
Carbon and low alloy
steels operating in a
process temperature
range of 10 to 350F (12 to 175C)
Austenitic stainless
steels operating in a
process temperature
range of 140 to 400F
(60 to 205C).

Difficult /
expensive to
inspect
Out of
sight, out of
mind

SCC of
Stainless
steel

Water
Ingress

Factors
Related to
CUI

Water
absorption
of
insulation

Absence
of adequate
coating
Non-uniform
corrosion
rates

CUI Mechanism
Corrosion Under Insulation caused by:
Ingress of water thu insulation
Water vapours condensation

Corrosion promoted by:

Trapping of water
Elevated temperatures
Temperature gradient
Temperature cycling
Absence or poor condition of coating
Poor/broken insulation/cladding

CUI Severity Factors


Key issues regarding
Corrosion and barriers to
CUI are as follows:
Metal type
Carbon steel
corrodes readily when wet.
Coating
Presence,
type and age.
Insulation
Type and
water absorbency.
Jacketing Condition and
sealing.
Water
Amount of
water present.

3,500 BPD of Liquid Propane Product.


3,000 BPD of Liquid Butane Product

BP SHARJAH
GAS PRODUCTION FACILITIES

3 x 3,000 BBL C3 Storage Spheres


[+50 DegC/ 250 psig].
2 x 3,000 BBL C4 Storage Spheres
[+50 DegC/ 70 psig].
1 x 377,000 BBL C3 Refrigerated, atm.
storage tank [-44 DegC/ atmos].
1 x 305,000 BBL C4 Refrigerated, atm.
storage tank [-6 DegC/ atmos].

MOL SIEVES

GAS

Dehydration
Sweetening

LPG TRAINS

Liquids
Recovery
LPG
Separation

FIELD
WELLS

INLET
SEPARATORS

Primary
Cond.

Stabiliser

PRODUCTS

Sales Gas
Propane
Butane
Condensate

HCs

Produced
Water

Degassers

Settling Tank

Evap Basin

CUI at BP Sharjah
CUI due to cold insulation in LPG plant
Plant situated near coast and over 25 years old
Limited Inspection in the past

Limited insulation rehabilitation


Material, coating and insulation
Current insulation condition

BP Sharjah CUI Risk


CUI identified as a major
threat to the integrity of BP
Sharjah Assets.
Day time dew point is
between 48-88F (9-31C).
Insulation is generally old
Very little inspection,
rehabilitation in the past 25
years
Small bore, temp cycling etc
are common
A CUI Leak in 2007

10% of all leaks are


CUI
92% on piping
system, 6% on vessels
20% of these result in
production loss;
between 1-10 days

80% of CUI failure on


piping
Pipes < 4 inch dia are
most vulnerable
CUI is highly
unpredictable

Risk Reduction Challenges


Insulation Removal not practical
No single technique suitable for all situations
Most of the available technology only offers
screening
Slow speed of radiography
Access and piping congestion
Pipe supports/branching
P & IDs and Inspection Iso
Technology limitations

Risk Reduction Plan


Fast Track Program
Criticality surveys/analysis
Removal of insulation where not required
Visual Inspection of selected critical
locations
Radiography of Critical locations
Repair/Rehabilitation

Further risk reduction

Risk Based Strategy


Defines rules to determine CUI Threat
Defines rules to determine inspection
scheduling
Defines appropriate CUI detection
techniques
Defines rules to determine inspection
anomalies
Defines Rules for Remedial Actions

RBI: Maximum Inspection Intervals

Corrosion Rate Estimation


Corrosion Rate Vs Temprature
50
Mils / Year

40
30
20
10
0
0

20

40

60

80

100

Temprature, Deg C

120

140

160

CUI Inspection Scope


Fast Track Program
Further Risk reduction
High, Medium, Low Risk
Features
Small Bores/Cyclic Lines
Profile radiography/Visual
Inspection
UT Inspection of Damaged
locations
Other NII techniques
Evaluation/Trial

Profile Radiography

RADIOGRAPHS OF 3/4 CORRODED BRANCH


CONNECTION ON 18-4-P-095-AL-CI

RADIOGRAPHS OF LINE # 03-4-P-087-A-CI

RADIOGRAPHS FOR P 4502B-DISCHARGE PIPE


DRAIN12-4-P-020-AL-CI

RADIOGRAPHS OF LINE # 10-4-P060-A-CI (PT4246)

CUI Inspection & Repair

Profile Radiography Results


Reasonably accurate and fast for
small bore piping
Calculated Corrosion rates Vs
radiograph indications
Find Rate: 30% (2007), 15% (2008)
Save Rate: 10% (2007), 3.5% (2008)
Coatings not found at CVI locations

Conclusions
CUI Detection is a challenge; It is
highly unpredictable
Radiography as a technique
Limitations of Technology
Localized corrosion Vs overall metal loss

RBI approach to risk reduction


Prevention is better than cure
Avoid insulation if possible
Design: Coating, cladding, workmanship
etc.

END