Corrosion is undoubtedly one of the costliest problems facing industry today. Due to corrosion of piping and equipment under insulation many companies have to repair and/or replace major parts at a considerable cost, reported to run into billions of dollars annually. Clearly this considerably reduces the potential service life of industrial facilities. More frequently, essential shutdowns and overhauls impair plant efficiency, driving up operating costs.Industrial plant insulation is everywhere. A medium-sized oil refinery contains 356 miles of insulated piping and more than 25 football fields worth 1.4 million ft² of insulated equipment, vessels and tanks. The plant temperature can easily exceed 1100°F, making insulation essential to protect people and maintain operational efficiency.
Prompt and proper maintenance
In many cases, insulation is not promptly or properly maintained,simply because it is not considered to be a risk. For years,industry has estimated that 10% to 30% of exposed insulation becomes damaged or missing within one to three years of installation. That percentage is likely to rise over time, depending on the operating environment and exposure to the elements. Many plant operators know that steam-generating capacity must be increased when it rains to continue to provide the heat the plant needs to operate efficiently.
Damaged insulation leads to increased heat losses and corrosion costs
The impact of damage can be substantial. In many cases, the actual reduction in heat loss is up to 40% more than expected. Damaged insulation cladding often allows water to penetrate into the insulation, which can cause corrosion. Costs due to corrosion,downtime and additional unanticipated energy losses are substantial. The costs of inspection and repair, which can often be carried out during operation, are negligible compared to the potential savings
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