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Corrosion Under Insulation (CUI) Guidelines by S Winnik

By S Winnik

Corrosion-under-insulation (CUI) refers back to the exterior corrosion of piping and vessels that happens beneath externally clad/jacketed insulation due to the penetration of water. through its very nature CUI has a tendency to stay undetected until eventually the insulation and cladding/jacketing is got rid of to permit inspection or whilst leaks ensue. CUI is a typical challenge shared by means of the refining, petrochemical, strength, business, onshore and offshore industries.

In the 1st version of this e-book released in 2008, the EFC operating events WP13 and WP15 engaged jointly to supply guidance on coping with CUI with contributions from a couple of ecu refining, petrochemical and offshore businesses. the tips are meant to be used on all vegetation and set up that include insulated vessels, piping and kit. the ideas disguise a risk-based inspection method for CUI, inspection strategies and instructed most sensible perform for mitigating CUI, together with layout of plant and gear, coatings and using thermal spray recommendations, sorts of insulation, cladding/jacketing fabrics and safety guards. the tips additionally contain case studies.

The unique rfile first released in 2008 used to be very winning and supplied a massive source within the carrying on with conflict to mitigate CUI. Many individuals of the EFC corrosion group asked an replace and this has taken among 18-24 months to take action. optimistically this revised rfile will proceed to serve the neighborhood offering a realistic resource of data on how one can visual display unit and deal with insulated systems.

  • Revised and entirely up-to-date technical counsel on handling CUI supplied through EFC operating events WP13 and WP 15
  • Contributions from a few eu refining, petrochemical and offshore companies
  • Extensive appendices that supply extra useful assistance at the implementation of corrosion-under-insulation top perform, accrued useful services and case studies

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4 to 49 °C And 111 to 149 °C Conventional coating 8–15 years Or TSA > 20 years Average condition, conventional design and construction Medium Integrity Design Medium wetting rate (20–50% of the time) ? ? ? CS-3 Corrosion-Under-Insulation (CUI) Guidelines: Revised Edition CS-2 External environment Total CUI susceptibility score Class Score 50–110 °C Or Sweating conditions Coating > 15 years Or Unpainted Or Unknown ? ? Poor condition, damaged, wet, or broken seals Or Insulation older than 25 years where there is a risk of extensive insulation material degradation ?

Published by Elsevier. Limitations, advantages, and disadvantages of different NDE/NDT techniques for CUI NDE/NDT technique Advantages Disadvantages Comments External/visual inspection Requires removal of insulation—“strip off and inspect” Can see the problem— positively identifies all areas of CUI Can apply a range of tools to quantify the problem Gives confidence - Expensive and requires other techniques to quantify metal loss - Cannot directly measure remaining wall thickness External/visual inspection without removing insulation - Generally carried out as a first pass and is usually limited by access - Very easy to cut windows Little cost for an initial evaluation Only covers small areas, will only provide a guide to potential problem areas Ultrasonic thickness measurement through inspection openings Ultrasonic thickness measurement Only a very small area is inspected It gives remaining wall thickness NB: UT measurements can be very effective for general CUI when taken internally It can be difficult to obtain readings on a corroded surface The most effective inspection method If insulation is removed on a sample basis, may not strip off “worst areas” and may give false confidence Can be very effective for a first pass on an installation with a CUI program Windows can be a source of water ingress Generally not used for CUI Requires removal of insulation and limited by surface condition It gives remaining wall thickness following external and internal corrosion Can be difficult to obtain thickness readings on a corroded surface.

However, for a low risk item in the same conditions an interval of 4 years may be acceptable. 12. The risk assessment matrix or table can have any form depending on each individual company’s philosophy, but must be consistent with the risk assessment procedures for other hazards. 9 Susceptibility factors CS-1 Operating temperature Coating status when new or last applied Cladding/ insulation condition External coil/steam tracing Continuously below −4 °C Or Above 175 °C Full QA coating <8 years Or TSA < 15 years Good engineering standards Or Renewed (<5 years) Not present Inside building, not steam traced and not sweating Default negligible risk ?

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