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Corrosion under insulation (CUI) guidelines

Edited by S Winnik, ExxonMobil, UK

European Federation of Corrosion (EFC) Series No. 55

 - guidelines cover inspection methodology for CUI, inspection techniques, including non-destructive evaluation methods and recommended best practice
 - case studies are included illustrating key points in the book

Corrosion under insulation (CUI) refers to the external corrosion of piping and vessels that occurs underneath externally clad/jacketed insulation as a result of the penetration of water. By its very nature CUI tends to remain undetected until the insulation and cladding/jacketing is removed to allow inspection or when leaks occur. CUI is a common problem shared by the refining, petrochemical, power, industrial, onshore and offshore industries.

The European Federation of Corrosion (EFC) Working Parties WP13 and WP15 have worked to provide guidelines on managing CUI together with a number of major European refining, petrochemical and offshore companies including BP, Chevron-Texaco, Conoco-Phillips, ENI, Exxon-Mobil, IFP, MOL, Scanraff, Statoil, Shell, Total and Borealis. The guidelines within this document are intended for use on all plants and installations that contain insulated vessels, piping and equipment. The guidelines cover a risk-based inspection methodology for CUI, inspection techniques (including non-destructive evaluation methods) and recommended best practice for mitigating CUI, including design of plant and equipment, coatings and the use of thermal spray techniques, types of insulation, cladding/jacketing materials and protection guards. The guidelines also include case studies.

ISBN 1 84569 423 6
ISBN-13: 978 1 84569 423 4
March 2008
176 pages  234 x 156mm  hardback  
£125.00 / US$210.00 / €150.00

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About the editor

Dr Stefan Winnik is a Materials and Corrosion Specialist with ExxonMobil chemical company in the UK.

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Contents

Introduction
 - Purpose of document
 - References

Economic consideration
 - Statistical analysis
 - Size of the issue
 - Key performance indicators (KPI’s)

Ownership and responsibility
 - Senior management
 - Engineering manager
 - Maintenance
 - Operations
 - Inspection
 - Members of a project team – CUI program

The risk-based inspection (RBI) methodology for CUI
 - Introduction
 - Unit level prioritisation
 - Challenging the need for insulation
 - Data validation
 - Using risk-based inspection to design CUI inspection plans
 - References

Inspection activities/strategy
 - General considerations
 - Typical locations on piping circuits susceptible to CUI
 - Typical locations on equipment susceptible to CUI
 - Examples of risk based inspection plan

Non-destructive examination and testing screening techniques for corrosion-under-insulation
 - NDE/NDT Techniques
 - References

Recommended Best Practice to Mitigate CUI
 - Background
 - Current CUI prevention methods
 - How to achieve a life expectancy of over 25 years
 - Benefits of thermal sprayed aluminium (TSA)
 - Use of personnel protective guards
 - Use of aluminium foil to mitigate Cl-ESCC of austenitic stainless steel
 - References

Design for the prevention of CUI
 - Introduction
 - Challenge the requirement for insulation
 - Plant layout
 - Mechanical considerations – equipment & tanks
 - Mechanical considerations – piping
 - Materials of construction
 - Coatings & wrappings
 - Insulation
 - Weatherproofing
 - References