- Most facility managers, engineers, maintenance and construction personnel now know that Corrosion Under Insulation (CUI) exists and left to its own devices, can cause serious problems and even catastrophic consequences.
- It is also widely known that the results of CUI are costly. How costly? That is harder to define. Most studies on the topic involve all forms of corrosion and their associated costs without providing the individual cost of corrosion related to insulation.
- What is clear, however, is that the cost of corrosion in the World continues to increase. A study completed in 2011 by a research team of corrosion specialists enlisted by Congress titled, "Corrosion Costs and Preventative Strategies in the World" reported the direct cost of corrosion to be $276 billion per year, with that number potentially doubling when indirect costs are also considered.
- Additional factors encourage CUI: the environment, insulation design and specifications, installation craftsmanship and maintenance. Let's examine what can be done to reduce the risks.
- Out of various corrosion phenomenon, the corrosion occurring on insulated piping/ equipment at any facility is particularly difficult to track & prevent. As a global issue, CUI (Corrosion Under Insulation) may directly contribute to health, safety, and environmental (HSE) issues, lost production and increased maintenance costs.
- CUI, therefore, needs to be combated and tamed eg. brought under control through systematic efforts. Historically, industry data shows that approximately 60% of pipe leaks are caused by CUI. Studies also show that the age of the piping system when the CUI leak occurred is bi-modal.
- One leak population mean is found in pipes with 16 to 20 years of service life and a second population means is in piping with the service life of greater than 26 years. Such data needs to be used while developing strategies for CUI detection and mitigation. New plants under construction must take cognizance of leaning from CUI incidents and shall use specifications on Painting, Insulation which already incorporate this leaning.
Obtain awareness of a major corrosion mechanism that affects insulated piping/ equipment used in process industries
Understand the primary parameters that influence the rate of degradation, design considerations for piping/ equipment
Understand how to develop strategies for the detection of CUI
Understand CUI Mitigation - Industry Practices
- Obtain information on all engineering disciplines that are associated with the design, inspection, and maintenance of insulated piping/ equipment including information on the types of insulation, external weather protection, and protective coatings currently in use
- The course content will cover why CUI has become a major problem in today's context and also cover various corrosion mechanisms which affect the insulated piping/ equipment and the major parameters which influence the rate of degradation.
- The course will cover various NDE methods available and successfully used to detect CUI. The participant will also learn the strategies for defining the scope of work for detecting CUI based on RBI (Risk Based Inspection) approach.
- The NACE RP 0198 and API RP 583 will be discussed in detail and so also the leaning from various published case studies on CUI.
Two Days Training Agenda:
1. Introduction to Corrosion Under Insulation (CUI)
2. Why Does CUI Occur -The Causes of Corrosion Under Insulation (CUI)
o The Effect of Contaminants on Corrosion Under Insulation
o The Effect of Temperature on the Rate of Corrosion Under Insulation
o The Effect of Insulation Type and Insulation Characteristics on CUI
3. How Does CUI Occur -Common Forms of Corrosion Encountered Under Insulation
o General Corrosion
o Pitting Corrosion
4. CUI in Common Alloys
o CUI in Carbon and Low Alloy Steels
o CUI in Austenitic and Duplex Stainless Steels
o CUF in Carbon and Low Alloy Steels
5. Areas Susceptible to Damage
o Pressure Vessels
o Tankage and Spheres
6. Insulation and Fireproofing Systems
o Insulation Materials
o Insulation Jacketing
o Coatings Under Insulation & Fireproofing Systems
7. Inspection for CUI and CUF Damage
o Inspection of Piping Operating Below 32°F (0°C)
o Inspection Tools and Methods
8. Risk-Based Inspection (RBI)
o Inspection Activities and Strategy
o Non-Destructive Examination and Testing Screening Techniques for CUI
o Examples of Risk-Based Inspection Plan
9. Design Practices to Minimize Corrosion Under Insulation (CUI)
o Coatings for Hot and Cold Services
o Insulation Materials
o General Design Aspects
10.Design Practices to Minimize CUF
o Intumescent Coatings and Subliming Compounds
o Protective Coatings
11.Maintenance and Mitigation of CUI/CUF Issues
o Programmed/Condition-based Maintenance
o Mitigation of CUI/CUF Damage
o Repair Techniques/Strategies
12. Case Studies and Examples