Introduction to Protective
coating and Insulation
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Training Contents
Corrosion
Protective coating
Insulation
Corrosion
Definition of Corrosion
Corrosion is the deterioration
of a material, usually a metal,
or its properties because
of a reaction with its
environment .
Organizations Involved in Corrosion
NACE International
American Gas Association
American National Standards Institute
American Petroleum Institute
American Society of Mechanical Engineers
American Society for Testing and Materials
ASM International
Materials Technology Institute
SSPC-The Society for Protective Coatings
Steel Tank Institute
Costs of corrosion
Direct costs
Excessive Maintenance, Repair, and Replacement
Lost Production and Downtime
Product Contamination
Loss of Product
Loss of Efficiency: Oversizing and Excess Energy Costs
Increased Capital Costs
Accidents
Costs of corrosion
Indirect Consequences
Safety Risks .
Structural Collapse
Leaks
Product Contamination
Consumer Confidence
Loss of Redundancy
Appearance
Increased Regulation
Changes in Engineering
Practice
Costs of corrosion
Structural Collapse, a Fatal Highway Parking Garage Collapse Due to
Bridge Collapse into the Ohio River Deicing Salt-Accelerated Corrosion of
Reinforcing Steel3
Costs of corrosion
Ruptured Pipeline Internal Surface of Corroded
Resulting in 12 Fatalities Pipeline
Corrosion
Corrosion cell
Anode
Electrolyte Oxygen
Cathode
Water drop on metal
Corrosion
Other corrosion mechanisms
See section 4 of Block 5 Part 1
Pitting corrosion (doesn’t require 2
dissimilar metals – usually a scratch in a
protective surface)
Galvanic series
Rank of metal and alloys according to its corrosion
resistance “Nobility”
Nobility is a prosperity of metals expresses the
tendency of metals to enter into chemical reactions
Forms of corrosion
General Corrosion
Forms of corrosion
lkGalvanic corrosion
Forms of corrosion
Pitting corrosion
Forms of corrosion
Crevice corrosion
Forms of corrosion
Stress corrosion cracking
Forms of corrosion
Selective corrosion
Corrosion prevention
Metal Type
Protective Coating
Cathodic protection
Environmental Measures
Corrosion Inhibitors
Design Modification
Protective coating
Global Paints & Coatings Industry Outlook 2020-2025: $179.4
Billion
Protective coatings are a simple way to reduce corrosion, by
limiting the exposure of the metal to a corrosive environment.
Paint is a very common protective coating, but tar, pitch,
bitumen and plastics are also used.
An important consideration for protective coatings is to ensure
the coating is well adhered to the metal, and that it remains
intact or is regularly repaired/recoated.
Surface preparation
Mechanical compilation
Objective
Surface cleanliness
Surface roughen
Mechanical compilation
Grinding Smoothing Refilling
• Weld slag • Sharp edges • Under cut
• Weld spatter • Notches • Pitting >2 mm
• Lamination • Holes
• Flame cute edges • Beam tips
• Weld beads
Rust grades
Rust grade A: Steel surface largely covered with adherent mill
scale with little if any rust.
Rust grade B: Steel surface, which has begun to rust and from
which the mill scale has begun to flake.
Rust grade C: Steel surface on which the millscale has rusted
away or from which it can be scraped, but with slight pitting
visible under normal vision.
Rust grade D: Steel surface on which the millscale has rusted
away and on which general pitting is visible under normal
vision
Rust grades
Surface cleanliness
Mill scale
Rust
Dust
Oil
Grease
Contaminations
Salts
Dirt
Moisture
Surface roughen
Roughness
BS 40 < R <75 Micron
NACE 40 < R <90 Micron
Surface preparation methods
Blast Cleaning
Tool cleaning
Chemical cleaning
Fire cleaning
Water Jetting
Blast cleaning
Types of abrasives
Sand Aluminum silicate Chilled Iron
Garnet Steel shot Egg shell
Abrasive cleaning grades
Sa 1 Light blast cleaning. When viewed without magnification,
the surface shall be free from visible oil grease and dirt and
from poorly adhering mill scale, rust, paint coatings and
foreign matter.
Sa 2: Thorough blast cleaning. When viewed without
magnification,the surface shall be free from visible oil grease
and dirt and most of the millscale, rust, paint coatings and
foreign matter. Any residual contamination shall be firmly
adhering.
Abrasive cleaning grades
Sa 21/2: Very thorough blast cleaning. When viewed without
magnification, the surface shall be free from visible oil grease
anddirt and from mill scale, rust, paint coatings and foreign
matter.Any remaining traces of contamination shall show only as
slight stains in the form of spots or stripes.
Sa 3: Blast cleaning to visually clean steel. When viewed
without magnification the surface shall be free from visible oil
grease and dirt and shall be free from mill scale, rust, paint
coatings and foreign matter. It shall have a uniform metallic
colour.
Tools
Tool cleaning
Hand brush
Hand tools
Scrubber
Tool
cleaning Power brush
Power tools
Needle gun
Fire cleaning
• Rust :
consists of hydrated
iron(III) oxides
Fe2OnH2O and
iron(III) oxide-
hydroxide (FeO (OH),
Fe(OH)3).
• Fire cleaning is unsafe
in cleaning of high steel
thickness
Chemical Cleaning
Suitable for cleaning of internal side of low size piping
Degreasing
Pickling by HCL 10% Or H2 SO 45% to remove the mill scale & rust
Neutralizing by soda ash 2%
Passivation by Zinc phosphate or Zinc chromate
Water jetting
Advantage Disadvantage
Environmental Friendly No roughness
High Productivity Produce bad surface
No salts in the surface appearance
low cost of water Used in maintenance project
High fixed cost
Need inhibitors
Need special painting types
Painting application
Application methods
Brush Roller
Air spay Air less spray
Brush
Advantage Disadvantage
Good penetration Bad appearance
Good for stripe coat Low productivity
Low paint consumption Problems with thick paint
Easy for use Poor distribution for
thickness
Roller
Advantage Disadvantage
Low paint consumption Fair appearance
Easy for use Low productivity
Problems with thick paint
Low thickness per coat
Poor distribution for
thickness
Bad penetration
Brushes Rollers
Air spray
Air spray
Advantage Disadvantage
Good penetration Paint contamination by air
Excellent finishing Over spray
Good distribution for paint Need repeating filling
Relative high thickness per Problems with thick paint
coat Need trained technician
Need source of compressed
air
Air less spray
Most popular method in painting application
Airless spray
Advantage Disadvantage
Good penetration Over spray
Excellent finishing Need trained technician
Good distribution for paint Need source of compressed
high thickness per coat air
Very good productivity Machine needs
Suitable for thick paint
maintenance regularly
Other methods of application
Galvanization
Other methods of application
Electrostatic coating
Other methods of application
Metalizing
Painting Technology
Painting system
Painting constituents
Binder
Additives Painting Solvents
Pigment
Binder
Solid or high viscous liquids
The most important part in paint
Responsible for film formation
Give adhesive & cohesive prosperities
Responsible for the mechanical & physical properties
Types as Epoxy, Alkyd ,Polyurethane
Pigment
physically powder and give the paints color & opacity
Types :
Color Pigments
Catholically Pigments
Rust inhibitive Pigments
Laminar Pigments
Biocides
Additives
Microns of materials add to the painting during
manufacturing to improve prosperities
Types :
Driers
Anti Settling agents
thixotropic agents
Leveling agents
Stabilizers
Plasticizers
Antifoaming
Safety and control
Hazards associated with blasting and painting
processes
Duties for painting supervisor
PPEs for blasting and painting
Recovery for blasters and painters
Waste control
Insulation
Insulation types
Hot insulation
Thermal Cold insulation
insulation
Insulation Personal
protection
Acoustic
insulation
o
Insulation used in industry to prevent excessive heat
loss or to maintain the temperature at low level .
Thermal insulation functions are :
Safety “Personal protection
Hot and cold conservation
Operation costs
Hot insulation
The insulation that will retard the transfer of heat
energy from the insulated surface when the
temperature in the system is higher than ambient
temperature.
Hot insulation used to maintain the temperature of the
product high enough for the product to flow, or flow
at a higher rate than it would at ambient temperature
for protection cost reasons .
Hot insulation materials
Calcium silicate < 1000 c
Hot insulation materials
Mineral wool < 850 c
Hot insulation materials
Foam glass < 430 c
Hot insulation materials
Polyisocyanorate < 140 c
Hot insulation materials
Pearlite < 1200 c
TABLE “E”
INSULATION THICKNESSES FOR HEAT CONSERVATION
NPS
(INCHES) OPERATING TEMPERATURES °C
PERLITE MINERAL FIBRE
60 67 94 122 150 177 205 233 261 288 316 344 372 400 428 455
to to to to to to to to to to to to to to to to
66 93 121 149 176 204 232 260 287 315 343 371 399 427 454 483
0.5 40 40 40 40 40 40 40 40 40 40 50 50 50 50 65 75
0.75 40 40 40 40 40 40 40 40 40 40 50 50 50 65 75 75
1.0 40 40 40 40 40 40 40 40 40 40 50 50 65 65 75 90
1.5 40 40 40 40 40 40 40 40 40 50 65 65 65 65 90 100
2.0 40 40 40 40 40 40 40 40 50 65 65 75 75 90 100 100
2.5 40 40 40 40 40 40 40 50 50 65 75 90 90 100 100 115
3.0 40 40 40 40 40 40 40 50 65 75 75 90 100 100 115 115
4.0 40 40 40 40 40 40 50 65 65 75 90 90 100 115 115 125
6.0 40 40 40 40 40 50 65 65 75 75 90 100 115 115 125 125
8.0 40 40 40 40 50 50 65 75 75 75 100 100 115 125 125 125
10.0 40 40 40 50 50 65 65 75 75 90 100 115 125 125 125 140
12.0 40 40 50 50 65 65 75 75 90 90 115 115 125 125 140 150
14.0 40 50 50 65 65 65 75 75 90 90 115 115 125 140 150 150
16.0 50 50 65 65 65 65 75 90 90 90 115 125 140 150 150 150
18.0 50 50 65 65 65 65 90 90 90 90 125 125 140 150 150 165
20.0 50 50 65 65 65 75 90 90 90 100 125 140 150 150 165 165
24.0 50 50 65 65 65 75 90 90 100 100 140 140 150 150 165 165
30.0 50 50 65 65 65 75 90 100 100 115 140 150 150 165 165 175
36.0 50 65 65 65 75 75 90 100 115 115 140 150 150 165 165 175
FLAT 65 65 75 75 75 90 100 115 125 125 150 150 150 165 165 175
Cold insulation
The insulation that will retard the transfer of heat energy from
the insulated surface when the temperature in the system is
Lower than ambient temperature.
Hot insulation used to maintain the temperature of the product
low enough for the product to flow, or flow at a higher rate
than it would at ambient temperature for protection cost
reasons .
Cold insulation materials
Cellular “Foam “ glass > -270 c
Cold insulation materials
Polyisocyanorate > -145 c
Cold insulation materials
Polyurethane foam > -100 c
Acoustic Insulation
Acoustic insulation applied to piping which gases , fluids or
particle solids are transported at high velocities .
The use of high density mineral wool is commom practice to
reduce the noise level .
Lead vinyl sheets may used over the mineral wool and then
protected by metal jacket
Other types of acoustic insulation includes perforated metal or
plastic sheets may be used .
Acoustic insulation materials
Lead vinyl sheets -50 c -100 c
Safety and control
Hazards associated with Insulation .
Duties for insulation supervisor
PPEs for insulation activities
Waste control
