Important note: Corrosion under insulation (CUI) can often be very
difficult to predict and even more challenging to locate without remov-
ing the insulation. The purpose of this report is to serve as an intro-
ductory primer. For additional information and resources on CUI, we
recommend performing your due diligence. The references provided in
this report are an excellent place to start, especially API RP 583.
Overview
Corrosion under insulation (CUI) is one of the most well
known phenomena in the process industries, and yet it still
makes up an inordinately large percentage of global mainte-
nance expenditures. CUI is a subject that is well researched
and understood; extensive studies have been commissioned
to determine the causes, effects, prevention, and mitigation of
CUI.
In the simplest terms, CUI is any type of corrosion that occurs
due to moisture buildup on the external surface of insulat-
ed equipment. The buildup can be caused by one of multiple
factors that are detailed below. The corrosion itself is most
commonly galvanic, chloride, acidic, or alkaline corrosion. If
undetected, the results of CUI can lead to the shutdown of a
process unit or an entire facility, and in rare cases it may lead
to a process safety incident.
History of CUI
Corrosion under insulation has been around since insulation
started being put on pipes. However, CUI was not general-
ly understood until the release of ASTM STP 880 “Corrosion
of Metals Under Thermal Insulation” in 1985. This led to the
funding of a study by the US Materials Technology Institute
to determine the effectiveness of nondestructive evaluation
(NDE) methods in dealing with CUI. Not one single NDE tech-
nique was identified as being best, but multiple techniques
used together were seen to increase confidence levels for de-
tecting CUI. Fortunately, NDE technology and techniques
have improved significantly since that early study.
In 1998, NACE published RP 0198-98, The Control of Corrosion
Under Thermal Insulation and Fireproofing Materials - A Systems
Approach. When published, RP 0198-98 was the only standard
specifically directed at combating CUI that was available to the
public. This recommended practice suggested using protective
coatings to prevent CUI.
Significant strides have been made since the release of the RP
0198-98, and there are now several ways in which to detect and
prevent CUI.
Causes
While CUI may be one of the most well known phenomena
in the process industries, it is also the most prevalent. It is
difficult to prevent because, by and large, no matter what pre-
cautions are taken, water eventually gets into the insulation,
sometimes unnoticed until process leakage occurs.[1]
Figure 1. CUI damage found on sweating service small
bore pipe.
According to API 570, there are specific susceptible tempera-
ture ranges under which CUI may occur. For carbon steel pip-
ing systems, the range is between 25 and 250°F, particularly
where operating temperatures cause frequent or continuous
condensation and re-evaporation of atmospheric moisture.
Carbon steel piping systems that normally operate in-service
above 250°F, but that are in intermittent service, are also at
risk. CUI has even occurred in process piping operating above
600°F when insulation is soaked during downtimes by deluge
systems and rain.
There are several different types of corrosion that can occur,
the most common of which are galvanic, acidic or alkaline, and
chloride.[2] According to the National Board of Boiler and Pres-
sure Vessel Inspectors:
Galvanic corrosion generally results from wet insula-
tion with an electrolyte or salt present that allows a cur-
rent flow between dissimilar metals (i.e., the insulated
metal surface and the outer jacket or accessories). The
extent and severity of the attack on the less noble metal
depends not only on the difference in potential of the two
metals, but also on their relative areas. The complete gal-
vanic series and the voltage potential for each metal or al-
loy appear in handbooks and other standard references.[2]
Alkaline or acidic corrosion results when an alkali or
acid and moisture, are present in certain fibrous or gran-
ular insulations. For hot service above 250o F, most of the
water is driven off. This water vapor may condense at the
edge of the insulation, and dissolve the alkaline or acidic
chemicals there, resulting in corrosion of the aluminum
or steel jacketing.[2]
Chloride corrosion can be caused by the combination of
insulation containing leachable chlorides with the 300 se-
ries austenitic-stainless-steel surfaces, when moisture is
present and temperatures are above 140o F. Concentration
of the chloride ion usually results from the evaporation of
rain water, or of water used to fight fires, or of process wa-