Eliminating CUI and Enhancing Efficiency on Oil Heater with Thermally Insulated Paint System

Our client’s Train-A Oil Heater onboard their FPSO was suffering from recurring and problematic Corrosion Under Insulation (CUI). Traditional insulation methods, while initially providing thermal insulation, were failing due to moisture ingress. This trapped moisture created a hidden corrosive environment, leading to asset degradation and the loss of crucial heat and energy retention. Our client, having experienced these issues repeatedly, sought a more effective and innovative long-term solution to prevent CUI and improve the operational efficiency of their oil heater. They required a solution that could not only insulate effectively but also eliminate the conditions conducive to corrosion, ideally with minimal operational disruption.

TEXO’s proposed cutting-edge solution involved the application of a Thermally Insulated Paint system, an innovative approach offering the dual benefits of effective thermal insulation for optimal oil heater performance and proactive CUI prevention through a continuous, impermeable barrier that eliminates the risk of corrosion by preventing moisture ingress. A key differentiator was the feasibility of applying this system while the oil heater remained operational at its high working temperature of 165 degrees Celsius, a feat achieved through meticulous planning and the expert development and implementation of robust Risk Assessments and Method Statements (RAMS).

The project execution encompassed the preparation phase, which included erecting encapsulated scaffold with ventilation and carefully stripping the existing insulation; a thorough surface treatment involving shot blasting to remove corrosion and applying a primer coat for enhanced protection; and the precise application of the 5000-micron Thermally Insulated Paint system using a high-efficiency spray pump, covering both the main vessel and intricate pipework. To guarantee the highest quality application of this novel system, TEXO proactively invested in their technicians’ training, sending the team overseas for comprehensive technical and application instruction.

The implementation of TEXO’s Thermally Insulated Paint system yielded significant positive outcomes, effectively eliminating the risk of CUI through a continuous, impermeable seal on the oil heater, thus preventing future moisture ingress and external corrosion. This innovative coating also delivered enhanced thermal efficiency, reducing the surface temperature from 165 degrees Celsius to a safe 17 degrees Celsius and improving energy retention, which in turn positively impacted the crude oil’s operational process and boosted overall efficiency. Furthermore, by proactively addressing CUI, our client can anticipate substantial reductions in long-term maintenance costs associated with corrosion repair and insulation replacement, while the live application capability and efficient project execution minimised disruption to their operations. Ultimately, this durable and protective coating provides a long-term solution, safeguarding the integrity of the oil heater and extending its service life, demonstrating TEXO’s commitment to innovative,
effective solutions and their technical expertise in delivering tangible value within the oil and gas sector.