SUCCESSFUL METHODS FOR MITIGATION

OF CORROSION UNDER INSULATION (C.U.I.)

AND OTHER CREVICE CORROSION USING
SURFACE CONVERSION TECHNOLOGY

Patrick J, Dunn Sr.

Vice President Mechanical Products Division
Polyguard Products, Inc.
P.O. Box 755
Ennis, Texas 75120
pjd@polyguardproducts.com
 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 RP0198-981 is a good source of
information, but electrolytes will eventually find their way
into even the best system
Corrosion Under Insulation
Selecting the Correct Coating System
Performance
Operating Temperatures
Moisture Resistance
Anti-Corrosion Properties
Application
Surface Prep
Dry/Cure Time
Labor & Equipment Requirements
Total Cost
Product
Application
Ease of Maintenance
Comparison of TOTAL installed cost is recommended
 Anti-Corrosion Gel
Performance
Operating Temperatures up to 350
Moisture Resistance Hydrophobic
Anti-Corrosion Properties Mineralization & Buffering
Technology
Application
Surface Prep SP-2 or better
Dry/Cure Time - None
Labor & Equipment Requirements - Minimal
Cost
Installed cost is typically lower than other systems
 Technology
The technology works in three basic ways
Barrier system The specially formulated products have
great adhesion characteristics and are hydrophobic to help
keep moisture away from the substrate.
Mineralization - Growing an engineered surface, or surface
conversion creating a surface which resists corrosion even
if moisture gets to it .
Buffering system If moisture migrates through the gel, it
is buffered to a high pH which is alkaline enough not to
corrode metal.
 Basic Science
Metal surface:
Oxides
Metal carbonates
Metal hydroxides
METAL
Surface conversion technology, also known as
mineralization, is the ability to grow very thin minerals on
metal surfaces. The mineral forms when reactants are Metal surface
delivered to the surface of a metal or metal containing
article. Substrates contribute ions that form a thin layer of METAL

mineral, which chemically bonds to the surface of the metal

and has been measured to be 50-200 angstroms thick.
Lattice-forming oxides anchor to this surface layer and Polymerized metal
silicate lattice
polymerize into a three-dimensional inorganic framework METAL
until the final surface is formed.
Protected surface
Extended surface
Patents and patent applications cover unique formulations Mineral formation

as well as the mineralized layer that is formed.

METAL
 Surface Formation
Untreated steel surface Mineralized steel surface

10 um 10 um

The presence of the mineralized layer can be confirmed by

conventional analytical surface methods such as x-ray
Photoelectron Spectroscopy (XPS) or Atomic Force
Microscope (AFM)
 History of the Technology
Automotive
Technology has been used in automotive applications for
approximately 30 years.
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
2 Year Salt Water Immersion Test

Samples were prepared with fiberglass pipe insulation, surface

conversion gel technology and placed in a 5% aerated salt bath. 11
 2 Year Salt Water Immersion Test
10 DAYS

365
DAYS

81 DAYS

138 DAYS

Samples were removed at timed intervals to determine protection of substrate

2 Year Salt Water Immersion Test

TWO YEAR IMMERSION

55mil PER YEAR CORROSION RATE

13
 2 Year Salt Water Immersion Test

One uninsulated pipe in the test proved that the Gel does not undercut14
 Undercutting Test
2000 hrs 2000 hrs
ASTM B117 Salt Spray ASTM B117 Salt Spray
Gel Protected Steel Panel Gel Removed

One unique property of gel surface conversion technology is that the

gel will not undercut like a hardening barrier coating will.
Isothermal Testing

16
Weight Loss Testing

17
Corrosion Under Insulation (CUI)
Corrosion Under Insulation (CUI)
Ammonia Piping Remediation
CUI - North Slope 2003
CUI - North Slope
2010 Inspection
 CUI Bundled Pipe
Corrosion Remediation of Bundled Pipe System (BIR)
CUI Bundled Pipe (BIR)

X-Ray Inspection Through Insulation

 CUI Bundled Pipe (BIR)

Remove Metal Jacket

Remove Insulation
 CUI Bundled Pipe (BIR)

Removal of Aged Mastic

 CUI Bundled Pipe (BIR)

Physical Inspection of Pipes

Removal of Rust Scale with

wire brush and pot scrubber
 CUI Bundled Pipe (BIR)

Install of Corrosion Gel

Uniform Thickness Trowel

 CUI Bundled Pipe (BIR)

Install Stand-offs and

Insulation

Install Metal Jacketing

DOWNHOLE CORROSION PROTECTION
 Benefits of the Technology:
Practical products and applications
Multiple delivery systems
Ease of application
Insensitive to surface preparation and application
conditions (SP-2 Hand Tool Cleaning or better)
Superior anti-corrosion performance
Environmentally benign
Easy to inspect
 Companies With Product Installations
Budweiser OxyChem
General Mills Equistar
Nestle Union Carbide
Green Giant Cytec
British Petroleum Phillips
Best Brands Foods MODOT-Missouri Dept of Transportaton
Philadelphia Gas Nicor
Fred Meyer Foods Tesoro Refinery
Unocal AK Oil Platforms Monarch Foods
Dot Foods Safeway
ExxonMobil U.S. Navy
-Sakhalin Island Steam Lines Kraft Foods
Phase I Dow Chemical
Phase II Schepps Dairy
-Downhole Wells Alaska ConocoPhillips - downhole
Alta-Dena Dairy Coors Brewing
Conagra Canada Hydro
Tyson Foods Indiana University Chiller Pipe
Tyson Chicken Southgate Foods
Tyson Fresh Meats Wal-Mart
Kroger Scotia Bank Toronto (CHW)
US Cold Storage Shepps Dairy
Publix Grocers Chevron
Tombstone Pizza

The entities listed above have used and/or specified surface conversion technology on one or more projects,
however, the naming of these entities do not imply advertisement or public endorsement of the product.