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The
corrosion processes are well understood but yet CUI often goes undetected until the damage is significant which
may lead to catastrophic failures, e.g. on equipment operating under high pressure. CUI May occur on:
NDE/inspection costs with a high confidence level for detecting CUI are equal to or exceed field painting costs
Approximately 10 % of the total maintenance budget is spent repairing damage from CUl
CUI risk:
General temperature ranges in which risk of CUI is present:
Carbon steel: -4 C to + 175 C: Risk of CUI (highest risk area: +60 C to +120 C)
Insulation of process equipment is normally implemented when the outer steel temperature exceeds 50 C (due to
the risk of work-related injuries as well as heat loss).
Carbon steel:
Insulated carbon steel corrodes due to:
Infiltration of water under insulation (rain, process liquids, fire water, etc.)
Condensation water
1. Chlorides (or other halides) in presence of water are transported to the hot surface
3. The chloride concentration reaches a critical level causing stress corrosion cracking (SCC)
4. (The critical chloride concentration depends on: Temperature and alloy type) The insulation material may also
contribute to CUI:
Good design of the item to be insulated e.g. it is difficult to insulate around flanges, taps, flowmeters, supports,
etc.
Organic coatings
Once the protective life is reached, field re-painting is necessary (or periodic NDE in order to monitor CUI).
Coatings may be damaged during handling and installation leaving unprotected areas.
Important parameters for coatings used for CUI prevention: High permeability resistance (barrier protection)
High flexibility (for cyclic temperature service)
Methods of protection:
Has been recorded to provide 25-30 years of maintenance and inspection-free CUI service.
No under-rusting
Quality control
Price
CUI Prevention Strategy:
Data from operating facilities shows that water-free insulation is not practical in ageing facilities. Thus a CUI
prevention strategy is necessary in order to provide long-term and reliable prevention of CUI:
Choice between strategies:
1. Organic coatings on carbon steel; Ongoing re-painting; NDE (does not prevent CUI but predicts remaining life).