{"id":82241,"date":"2018-09-07T00:00:00","date_gmt":"2018-09-07T00:00:00","guid":{"rendered":"https:\/\/www.corrosionpedia.com\/2018\/09\/07\/accelerated-corrosion-testing-with-calcium-silicate-and-perlite-insulations"},"modified":"2018-09-04T15:42:02","modified_gmt":"2023-12-09T18:58:53","slug":"accelerated-corrosion-testing-with-calcium-silicate-and-perlite-insulations","status":"publish","type":"post","link":"https:\/\/www.corrosionpedia.com\/accelerated-corrosion-testing-with-calcium-silicate-and-perlite-insulations\/2\/6854","title":{"rendered":"Accelerated Corrosion Testing with Calcium Silicate and Perlite Insulations"},"content":{"rendered":"

Corrosion under insulation (CUI)<\/a> is a concern that industrial owners, engineers and contractors spend a great deal of time managing every day. As a leader in the industrial insulation<\/a> market, Johns Manville conducts corrosion-based testing<\/a> to provide the industry with the information they need to make decisions. Johns Manville conducts tests using industry-accepted laboratory-scale ASTM<\/a> protocols, as well as tests under simulated “real-world” environmental and installation conditions. One of these “real-world” accelerated tests<\/a> is being finalized into a protocol by NACE<\/a> Task Group 516 and is supported by several end-users. Southwest Research Institute®<\/sup> (SwRI) is currently leading a Joint Industry Program (JIP) based on the NACE protocol that includes seven end-users including major chemical, gas and oil producers, four coating manufacturers and five insulation manufacturers, including Johns Manville.<\/p>\n\n\n\n
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In 2016, Johns Manville was the first insulation manufacturer to use the NACE TG 516 protocol to evaluate our products with SwRI<\/a>. Subsequently, in addition to participation in the JIP, we have continued to test additional products using the protocol and will be presenting the results for our Thermo-1200™ calcium silicate<\/a> and Sproule WR-1200®<\/sup> perlite<\/a> insulations in this blog. (Learn more about perlite insulation in Expanded Perlite Insulation: Why Hydrophobicity is Only Part of the Solution to Prevent CUI<\/a>.)<\/p>\n

The 6-month tests were conducted to accelerate conditions of corrosion on 2 inch carbon steel<\/a> pipes wrapped with insulation, secured with metal cladding<\/a>, and then exposed to two different environmental conditions. The first condition periodically immersed the assemblies in solutions with up to 1500 ppm chloride. Throughout the test, the pipe temperatures were cycled between ambient and up to 900°F, resulting in cyclic wet and dry conditions. The second condition maintained the pipe temperatures at 45-60°F throughout the test, periodically submerging the samples in up to 1500 ppm chloride solutions, so that the assembly remained wet for the entire duration of the test.<\/p>\n

After the test duration, corrosion rates<\/a> and depths were calculated using measurements from electrochemical, ultrasonic<\/a>, and optical measurement techniques. (These and other techniques are examined in Nondestructive CUI Detection Techniques for Process Pipelines<\/a>.) The conclusions from the third party SwRI report include the following for the Thermo-1200™ and Sproule WR-1200 insulations, but also a third insulation – a silica aerogel<\/a> blanket. The aerogel blanket was tested as a competitive benchmark.<\/p>\n