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BBS norm/standaard 04.00.3049

NORM/STANDAARD: Wec : Nee Comm. Index : B/C

Veiligheidsrapport : Nee Risico : M
TOEPASSING VAN ALUMINIUM WWW-Aannemers : Ja Classificatie : Unrestricted
FOLIE ONDER ISOLATIE VOOR Noodplan : Nee HSE kritisch : Ja
FCM gerelateerd : Nee
STAINLESS STEEL EQUIPMENT EN
PIPING (PERNIS/MOERDIJK)

Doel / scope Objective

Prevention of external choride stress corrosion of stainless steel equipment and piping.
Scope
Description of the requirements for application of aluminium foil under thermal insulation for
austenitic stainless steel equipment and piping.

Doelgroep Shell Pernis/Moerdijk plants

Toetsers DMS/7424, DMS/942, DMS/91M2

Risico This document is, according to the Risk Matrix, potential (M)iddle. The risk is covered by
this document and by training and application of this document.

Revisie info Laatste Datum Reden

revisie
B 11-04-2011 Review met wijziging in Introduction plus omzetten naar
nieuwe BBS template.
Meer revisie info

Inhoudsopgave 1. INTRODUCTION ................................................................................. 2

2. CONTEXT AND REFERENCES ......................................................... 2
3. DEFINITIONS AND ABBREVIATIONS ............................................... 2
4. DOCUMENT TEXT ............................................................................. 3

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1. INTRODUCTION
Coating of equipment and piping shall be selected and applied in accordance with BBS 04.00.4054
(new equipment) or BBS 04.00.4053 (maintenance). The preferred option for protection against
chloride stress corrosion cracking of stainless steel equipment and piping shall be application of
thermal sprayed aluminium (TSA).
Aluminium foil can be used as an alternative in lieu of TSA to provide a physical barrier between
austenitic stainless steel and the thermal insulation, but only after consultation with and approval of
the civil engineering department.
Organic coatings to protect stainless steel equipment and piping from external stress corrosion
cracking shall only be considered when neither TSA nor its alternative of aluminium foil wrapping
are technically viable options.

2. CONTEXT AND REFERENCES

Engineering guides and specification 19 GS-51.

3. DEFINITIONS AND ABBREVIATIONS

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4. DOCUMENT TEXT
19 GS-51 Approved Aug 05
Application of Aluminum Foil Under Insulation for
Stainless Steel Equipment and Piping

Engineering Guides and General Specifications

19 GS-51
Application of Aluminium Foil Under Insulation for Stainless Steel
Equipment and Piping
Table of contents
1. General 1.8 Existing Equipment and Piping
1.1 Scope 2. Materials
1.2 References
1.3 Related Documents 3. Application
1.4 Definitions
1.5 External Chloride Stress Corrosion Cracking Appendix 1 Suppliers List
1.6 Temperature Considerations Appendix 2 Application DOs and
DONTs
1.7 New Equipment and Piping

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1. GENERAL
1.1 Scope
This General Specification (GS) covers requirements for application of aluminum foil under thermal
insulation for austenitic stainless steel equipment and piping. Comment: Aluminum foil can be used
in lieu of conventional organic coatings that are used to provide a physical barrier between the
austenitic stainless steel and the thermal insulation. Aluminum foil provides some physical barrier
but acts primarily as a sacrificial anode to provide electrochemical (cathodic) protection against
external chloride stress corrosion cracking.

1.2 References
Applicable requirements in the following referenced standards and specifications shall be
considered an integral part of this GS. Unless otherwise specified, the latest edition/revision of the
standards/specifications shall be used.

1.2.1 Steel Structures Painting Council (SSPC)

SP-1 Solvent Cleaning

1.2.2 International Organization for Standardisation (ISO)

EN-ISO 12944 Paints and Varnishes Corrosion Protection of Steel
Structures by Protective Paint Systems for EU

1.3 Related Documents

CINI Handbook Insulation for Industries 2005.
BS 5970:2001 Code of Practice for Thermal Insulation of Pipework and Equipment in the
Temperature Range of -100C to +870C.

1.4 Definitions
1 mil .001 inch
40 mils equals 1000 microns or one millimeter

1.5 External Chloride Stress Corrosion Cracking

1. External chloride stress corrosion cracking (ECSCC) is cracking that may occur in austenitic
stainless steel with or without insulation.
2. If there is corrosion under insulation (CUI), ECSCC is the result of ingress of water and
chlorides. Chlorides are introduced if the insulation contains chlorides from manufacture and/or
ingress of chloride containing water.

Comment: ECSCC is the same as chloride stress corrosion cracking (Cl-SCC) that can occur in
austenitic stainless steels and certain other austenitic alloys exposed to aqueous, chloride-
containing environments above 120F (50C).

1.6 Temperature Considerations

Applicable temperature range for use of aluminum foil under insulation is 120F (50C) to 400F
(200C) for continuous service and 900F (480C) for cyclic conditions.

Comment: Aluminum melts at 1215F (657C). Austenitic stainless steel is not susceptible to Liquid
Metal Embrittlement (LME) when in contact with pure grades of molten aluminum. Zinc must be
present in the aluminum to cause LME.

1.7 New Equipment and Piping

1. New uncoated austenitic stainless steel surfaces to be covered with aluminum foil shall be
cleaned in accordance with SSPC SP-1 or EN-ISO 12944.
2. Cleaning shall remove all dirt, oil, grease, salts, moisture, chemicals, and other contamination.
3. Chlorinated solvents shall not be used for cleaning.
4. Abrasive blasting is not required.

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1.8 Existing Equipment and Piping

1. Existing coated austenitic stainless steel surfaces to be covered with aluminum foil shall be
washed with low pressure water cleaning (LPWC).
2. LPWC shall remove grime, loose and chalky paint, salt contaminants, and loose rust. If fresh
water (water with less than 250 ppm chlorides) is used for LPWC, the surfaces shall be rinsed
with water containing less than 10 ppm chlorides.
3. LPWC shall be done with the water nozzle approximately perpendicular to the surface.

Comment: Using excessive pressure and low nozzle angle may cause undue damage to the
existing coating.

Comment: Demineralized water may be used to clean chloride contamination from uncoated
stainless steel.

4. Existing aluminum foil shall be completely removed.

5. Surfaces to be covered with aluminum foil shall be inspected for sharp edges, weld spatter,
and protuberances. If any such conditions exist, the purchaser shall have them ground smooth
or rounded.

2. MATERIAL
1. Aluminum foil shall have an aluminum content of 99%, equivalent to Alloy 1100.
2. Aluminum foil shall have a minimum nominal thickness of 2.5 mils (64 micrometer) or 46 swg.
3. Self-adhesive foil may be used for complex configurations, such as vessel heads and
attachments. Adhesive shall contain less than 10 ppm chlorides. No other adhesive or sticky
tape is allowed unless it contains less than 10 ppm chlorides.

3. APPLICATION
1. Aluminum foil shall be applied as soon as practical after the surfaces are cleaned.
2. Foil shall not be applied if the cleaned surface temperature is less than 5F (3C) above the
dew point.
3. Unless otherwise specified, foil shall not be applied if the relative humidity is greater than 85%.
4. Personnel who apply the foil shall wear gloves to avoid touching the stainless steel surfaces
with bare hands.
5. Torn or damaged foil shall not be used.
6. Foil shall be applied as tightly as possible without any creases.
7. Where partial coatings exist, stainless steel wire shall be used to hold the foil in place. Wire
shall be grounded to equipment/piping flanges.

Comment: The aluminum foil cannot provide electrochemical protection against chloride
stress corrosion cracking unless there is elektrical contact between the foil and the
metal. Paintings or coatings may act as an insulator and should preferably be
removed unless sufficient elektrical contact exists between the aluminum wrapping
and the austenitic stainless steel.

8. Foil shall be applied prior to installing elektrical or steam tracing.

9. Foil shall be applied bottom to top so that it sheds water.
10. Foil shall be applied so that it has a minimum overlap of 2 in. (5 cm) at joints.
11. Insulation and weatherproof finish shall be applied immediately after the foil is applied.
12. Application DOs and DONTs are provided in Appendix 2.

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APPENDIX 1: SUPPLIERS LIST

Alcan Aluminum Corp.
Alcan Light Gauge Products
5901 North 13th St, Terre Haute, IN 47805
440 423-6800
http://www.alcan.com

Alcoa Inc.
Alcoa flexible Packaging, Louisville Foil Plant
Louisville, KY 41211
412- 553-4545 or
Richmond, VA 23224
804- 230-5200

Coastal Aluminum Rolling Mills,

Williamsport, PA 17701
570-323-4430

Corus Aluminium Rolled Products

Cap-de-la-Madeleine, Quebec, GBT 7W9
819-373-6363

Ekco Products,
Clayton, NJ
856-881-3600

J W Aluminum Co
Holly, SC 29419
Charleston, SC
843-572-1100

Norandal USA, Inc

Franklin, TN
615-778-2000

Premium Foil Products Co

Louisville, KY
502-459-2820

Republic Foil
Danbury, CT
203-743-2731
EU (NL) Supplier

Hanko Handelmaatschappij BV
Postbus 6904 4802 HX
BREDA Charles Petitweg 39
4827 HJ BREDA bedrijfsnummer 9530

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BBS norm/standaard 04.00.3049
19 GS-51 Approved Aug 05
Application of Aluminum Foil Under Insulation for
Stainless Steel Equipment and Piping

Appendix 2 Application DOs and DONTs

DOs D O N T s

A p p l y f o i l b o tto m to to p so it
sh e d s w a t e r

F o i l sh a l l b e a p p li e d so t h a t it h a >2
s a m i n i m u m ov e r l a p o f 2 a t j o
in ts.

F o i l sh a l l b e a p p lied a s ti g h tly a s
p os si b l e w i t h ou t a n y c r e a se s o r
w r i n k l e s.

F o i l sh a l l b e a p p li e d p r i o r t o i
n st a l l i n g st e a m or e l e c t r ic a l tr
a c in g

F o i l sh a l l b e a p p li e d p r i o r t o i
n st a l l i n g su p p or t s or ot h e r b ol
t e d ob j e c t s.

A d a p t f o i l si z e t o d i a m e te r t o
p r e v e n t w r in k l e s.

W h e r e p a r t ia l c o a ti n g s e x i st , st
a i n l e ss st e e l w i r e sh a l l b e u se d
t o h old t he f o i l i n p la c e . W i r e
sh a l l b e g r ou n d e d t o e q u i p m e n
t /p i pi n g f l a n ge s.

Engineering Guides and General Specifications Page 7 of 7

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A 25-10-2005 Eerste uitgave

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