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Start Date : 24 Aug ,2025
End Date   : 28 Aug ,2025
Duration    : 5 Days
 
Overview: 
Corrosion Under Insulation (CUI) is a common and challenging problem that occurs in industrial facilities where pipes, vessels, and equipment are insulated for various purposes such as temperature control, energy conservation, and personnel protection. The insulation serves as a protective barrier to prevent heat transfer, but if it becomes compromised or damaged, it can lead to the onset of corrosion on the underlying metal surface.
Course Objectives: 
Explain what CUI is, including the components of a typical CUI system and why it is required in a range of industrial settings
Explain the importance of lab testing on the selection of CUI system components
Identify the common types of coatings applied under insulation and describe their advantages and disadvantages
Outline the factors that need to be considered when selecting insulation
Describe the types of insulation and jacketing commonly used within CUI Protective Systems
Describe the different types of spray-on insulation and their advantages and disadvantages
Summarize the differences between intumescent coatings, high density concrete coatings and cementitious coatings
Explain common design practices used to minimize CUI
Outline the common steps involved in installing a CUI Protective System
Identify the key components of risk-based inspection programs and describe their benefits within a CUI context
Discuss the inspection methods that can be utilized with and without the removal of the CUI Protective System
Course Content: 
 
Introduction to Corrosion Under Insulation (CUI)
Corrosion: Basic Concepts and Terminology
Why Does CUI Occur -The Causes of Corrosion Under Insulation (CUI)
The Corrosivity of Water and Moisture
The Sources of Water
How Much Water Is Required for CUI to Occur
The Effect of Contaminants on Corrosion Under Insulation
How Does CUI Occur -Common Forms of Corrosion Encountered Under Insulation
General Corrosion
Pitting Corrosion
Crevice Corrosion
Chloride External Stress Corrosion Cracking (Cl-ESCC)
CUI in Common Alloys
CUI in Carbon and Low Alloy Steels
CUI in Austenitic and Duplex Stainless Steels
CUF in Carbon and Low Alloy Steels
CUI on Aluminum Piping
Areas Susceptible to Damage
General Areas of Damage
Pressure Vessels
Piping
Tankage and Spheres
Heat-traced Systems
Shutdown/Mothballing
Insulation and Fireproofing Systems
Insulation Materials
Insulation Jacketing
Caulking
Fireproofing Materials
Coatings Under Insulation & Fireproofing Systems
Inspection for CUI and CUF Damage
Inspection of Piping Operating Below 32°F (0°C)
Inspection Tools and Methods
Risk-Based Inspection (RBI)
Inspection Activities and Strategy
Examples of Risk-Based Inspection Plan
Design Practices to Minimize Corrosion Under Insulation (CUI)
Coatings for Hot and Cold Services
Insulation Materials
Jacketing
General Design Aspects
Insulation
Heat-traced Systems
Protective Coatings and Caulk
Shutdown/Mothballing
Quality Control/Quality Assurance  
Design Practices to Minimize CUF
Dense and Lightweight Concrete
Lightweight Cementitious Products
Intumescent Coatings and Subliming Compounds
Protective Coatings
Quality Control/Quality Assurance
Maintenance and Mitigation of CUI/CUF Issues
Programmed/Condition-based Maintenance
Execution
Deluge System Issues
Mitigation of CUI/CUF Damage
Repair Techniques/Strategies
Case Studies and Examples
Examples of a Qualitative Likelihood Assessment System
Examples of Insulation Techniques for Various Applications
Case Studies
Targeted Audience: 
 
Specifiers and Designers
Metals, Coatings and Risk Based Inspectors
Coating Contractors
Maintenance personnel and project engineers
Manufacturers of insulation materials and equipment
Unit managers involved in CUI