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Corrosion Under Insulation (CUI) Guidelines - 2nd Edition - ISBN: 9780081007143, 9780081007396

Corrosion Under Insulation (CUI) Guidelines

2nd Edition


4.0 star rating 3 Reviews
eBook ISBN: 9780081007396
Hardcover ISBN: 9780081007143
Imprint: Woodhead Publishing
Published Date: 27th November 2015
Page Count: 162
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Table of Contents

  • Introduction
  • 1: Introduction
    • Abstract
    • 1.1 Purpose of document
  • 2: Economic consideration
    • Abstract
    • 2.1 Statistical analysis
    • 2.2 Size of the issue
    • 2.3 Key performance indicators
  • 3: Ownership and responsibility
    • Abstract
    • 3.1 Senior management
    • 3.2 Engineering manager
    • 3.3 Maintenance
    • 3.4 Operations
    • 3.5 Inspection
    • 3.6 Members of a project team: CUI program
  • 4: The risk-based inspection methodology for CUI
    • Abstract
    • 4.1 Introduction
    • 4.2 High-level prioritization
    • 4.3 Data validation
    • 4.4 Challenging the need for insulation
    • 4.5 Using RBI to design CUI inspection plans
  • 5: Inspection activities/strategy
    • Abstract
    • 5.1 General considerations
    • 5.2 Typical locations on piping circuits susceptible to CUI
    • 5.3 Typical locations on equipment susceptible to CUI
    • 5.4 Examples of risk-based inspection plans
  • 6: Nondestructive examination and testing techniques for CUI
    • Abstract
    • 6.1 NDE/NDT techniques
  • 7: Recommended best practice to mitigate CUI
    • Abstract
    • 7.1 Background
    • 7.2 Current CUI prevention methods
    • 7.3 How to achieve a life expectancy of over 25 years
    • 7.4 Benefits of TSA
    • 7.5 Use of personnel protective guards
    • 7.6 Use of aluminum foil to mitigate Cl-ESCC of austenitic stainless steel
  • 8: Design for the prevention of CUI
    • Abstract
    • 8.1 Introduction
    • 8.2 Challenge the requirement for insulation
    • 8.3 Plant layout
    • 8.4 Mechanical considerations: Equipment and tanks
    • 8.5 Mechanical considerations: Piping
    • 8.6 Materials of construction
    • 8.7 Coatings and wrappings
    • 8.8 Insulation system
    • 8.9 Weatherproofing
    • 8.10 Implementation
  • Appendix A: Cost: Economic evaluation
  • Appendix B: Quality assurance
  • Appendix C: Additional guidelines on the implementation of CUI best practice
    • C.1 Maintenance and remediation issues
    • C.2 Minimum standards
    • C.3 Types of insulation service
    • C.4 Surface preparation
  • Appendix D: Coatings
    • D.1 Introduction
    • D.2 Protective coatings and protective coating selection
    • D.3 Thermal spray aluminum
    • D.4 Excerpt from NACE SP0198-2010 Section 4 protective coatings
  • Appendix E: Application of thermal sprayed aluminum
    • E.1 Thermal spray application
    • E.2 Use of organic topcoats
    • E.3 Application strategies
    • E.4 TSA specification
    • E.5 Definitions
    • E.6 Referenced codes, standards, and specifications
    • E.7 Coating philosophy
    • E.8 Coating system
    • E.9 TSA material
    • E.10 Seal coat
    • E.11 Design
    • E.12 Surface preparation
    • E.13 Weather and surface conditions
    • E.14 Application process
    • E.15 Specific requirements for on-site TSA application
    • E.16 Piping field welds
    • E.17 Inspection and acceptance
    • E.18 Documentation
  • Appendix F: Insulation material types and forms
    • F.1 Mineral fiber
    • F.2 Low density glass fiber
    • F.3 Calcium silicate
    • F.4 Cellular glass
    • F.5 Ceramic fiber paper
    • F.6 Glass rope insulation
    • F.7 Self-setting cement
    • F.8 Flexible reusable insulation cover mattresses
    • F.9 Preformed rigid polyurethane foam (polyurethane-polyisocynaurate)
    • F.10 Flexible elastomeric foam
    • F.11 Flexible elastomeric foam (EPDM)
    • F.12 Polyethylene
    • F.13 Perlite
    • F.14 Vermiculite
  • Appendix G: Cladding/jacketing materials
    • G.1 Metallic cladding materials
    • G.2 Nonmetallic materials
  • Appendix H: Use of protection guards
    • H.1 Design considerations
    • H.2 Method guidance notes
  • Appendix I: NDE/NDT techniques
    • I.1 Visual inspection
    • I.2 Manual ultrasonic thickness measurement through inspection openings
    • I.3 Radiography
    • I.4 Real-time radiography
    • I.5 Guided wave ultrasonic measurements
    • I.6 Pulsed eddy current
    • I.7 Digital radiography
    • I.8 Infrared thermography
    • I.9 Neutron backscatter
    • I.10 Dye penetrant testing

  • Description

    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.

    In the first edition of this book published in 2008, the EFC Working Parties WP13 and WP15 engaged together to provide guidelines on managing CUI with contributions from a number of European refining, petrochemical and offshore companies. The guidelines are intended for use on all plants and installation that contain insulated vessels, piping and equipment. The guidelines cover a risk-based inspection methodology for CUI, inspection techniques 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.

    The original document first published in 2008 was very successful and provided an important resource in the continuing battle to mitigate CUI. Many members of the EFC corrosion community requested an update and this has taken between 18-24 months to do so. Hopefully this revised document will continue to serve the community providing a practical source of information on how to monitor and manage insulated systems.

    Key Features

    • Revised and fully updated technical guidance on managing CUI provided by EFC Working Parties WP13 and WP 15
    • Contributions from a number of European refining, petrochemical and offshore companies
    • Extensive appendices that provide additional practical guidance on the implementation of corrosion-under-insulation best practice, collected practical expertise and case studies


    Engineers in the refining, petrochemical, power, industrial, onshore and offshore industries


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    © Woodhead Publishing 2016
    27th November 2015
    Woodhead Publishing
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