Comparative Performance Assessment of Insulative Coating Systems for Corrosion Protection and Thermal Insulation (C2026-00097)

Da Kuang, Connor McManus

Corrosion under insulation (CUI) poses a significant challenge in the oil and gas industry, arising when moisture becomes trapped on metal surfaces beneath insulation layers. Thermal insulative coatings have emerged as increasingly popular alternatives to traditional insulation systems, offering personnel protection, CUI mitigation, and enhanced thermal efficiency for high-temperature assets. Their application in new construction or retrofits demonstrates potential for significant cost reduction and accelerated project timelines by eliminating conventional insulation blankets and cladding jackets.
These thermal insulation products are typically water or solvent-based liquids containing various performance-enhancing fillers such as ceramic microspheres, aerogels, or other materials designed to increase thermal resistance. Despite their growing adoption, there exists a notable gap in systematic comparative analysis of commercially available products, particularly regarding their corrosion protection capabilities. This study addresses this gap by examining four commercially available insulative coating systems, evaluating their thermal conductivity, validating their effectiveness for personnel protection according to NACE TM21431 standards, and assessing their corrosion resistance through water condensation and salt fog testing as specified in ISO 12944-6. To further evaluate their practical performance, two coatings were selected for field pilot applications to assess their ease of application and performance under operational conditions.