Comprehensive CUI Strategies: Understanding, Mitigating, and Inspecting Corrosion Under Insulation
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
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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
