Gulf refinery Penthane Spheres

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In May 2021, a large refinery on the Gulf Coast needed to replace the
traditional insulation for their Pentane spheres as part of an annual
turnaround exercise. Due to a tight maintenance schedule and high
Corrosion Under Insulation (CUI) problems, the client was in search of
an alternative solution that would return assets back to service quickly,
with less CUI risk, and improved insulation performance.

To meet these requirements, Hempel proposed the application of
Hempatherm IC 175 and Hempatherm IC 170. These high-quality
insulation coatings replace traditional insulation and promote
sustained thermal performance over the service life of the asset.

At the end of the project, the refinery achieved optimal thermal
performance on the Pentane spheres while significantly reducing
application time, and the risks of CUI. The Pentane spheres now boast
enhanced longevity and reduced maintenance needs, which further
results in lower operational costs for the customer.

Harsh environments like refineries pose constant threats to equipment integrity. Corrosion Under Insulation (CUI), triggered by water ingress, wreaks havoc on insulation, leading to safety hazards, energy loss, and costly maintenance. In the case of our client¹, their Pentane spheres faced persistent water ingress, causing traditional insulation to fail, which could jeopardise safety, efficiency, and profitability.

The refinery urgently needed a long-term solution to mitigate CUI and ensure reliable and efficient operations.

Note 1: Customer wishes to remain anonymous

Hempatherm IC 175 and Hempatherm IC 170 were recommended as the ideal solution to the refinery’s CUI challenges. When used as a system, these high-performance coatings boast exceptional hydrophobicity and film build, creating an impenetrable barrier against water, safeguarding insulation and preventing CUI over the service life of an asset – estimated at 20 to 25 years.

Tailored to the refinery’s specific needs through thermal modelling, the system combined 32mm of Hempatherm IC 175 (made with aerogel technology), with 5mm of Hempatherm IC 170, to deliver optimal thermal insulation. The system performed better compared to conventional methods, slashing application time by over 40% (7 weeks vs. 12 weeks), while minimising downtime and costs.

The application transformed the refinery. Water ingress was eliminated from the Pentane spheres, addressing the root cause of CUI. Sustained thermal performance ensured optimal energy efficiency, cutting operational costs. The faster application saved time and resources, enabling swift resumption of operations. Additionally, the reduced CUI risk improved worker safety. Two years after its application, Hempel’s Hempatherm insulation technology maintains colder operating conditions and shows no performance degradation, delivering exceptional value to the refinery.