Corrosion Under Insulation

A practical prevention guide as per API 570

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 Moisture Sources
W
Water Leaks
L k

Mist Spray
from Condensation
Cooling Towers

CUI

Deluge
Rains
systems

Leaking
Process fluids

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 Common Forms

Chloride Stress
Localized Corrosion of
Corrosion of Austenitic
Carbon Steel
Stainless Steels

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 Susceptible Piping Systems

Mist of
A
Areas exposedd to Cooling Towers
St
Steam Vents
V t D l Systems
Deluge S t P
Process SSpills
ill A id VVapors
Acid

Carbon Steel Systems insulated for

Carbon Steel Systems operating above
Human pprotection operating
p g between
240 deg
d C withith iintermittent
t itt t service
i
-4 deg C – 120 deg C

SSystems
t where
h operating
ti temperatures
t t AAustenitic
t iti SS systems
t with
ith operating
ti
cause frequent condensation and Temperature between 65 deg C to
re-evaporation of atmospheric moisture 204 deg C (Chloride Stress Corrosion)

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 Susceptible Piping Systems

Deadlegs and attachments protruding Vibration systems with damaged

from insulation Insulation and jacketing

S
Systems withh ddeterioratedd coating andd
Steam tracing systems with tracing leaks
wrapping

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 Susceptible Common Locations

Penetrations/breaches in Damaged/missing
jacket jacketing

Hardened, separated, or Piping low points in systems that have

missing caulking insulation breach

Jacket seams on top of horizontal piping Carbon or low-alloy steel components in

or improperly lapped/sealed jacket high-alloy systems

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 Susceptible Common Locations

Termination in insulation at flanges Termination of insulation in a vertical

and other piping components pipe

Bulges or staining of insulation or

jacketing system (bulges may indicate
corrosion products)

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 Special Considerations

Insulation damage at higher elevations

Insulation removal, RT may be required
May cause CUI at lower elevations

Expand inspection as necessary

Systems may be excluded:

1. Remaining life > 10 years
2
2. Ad
Adequately
l protectedd externally
ll

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 Piping Service Classes

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 Recommended Inspection Interval

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 CUI Inspection Targets

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 THANKS
‐ thePetroStreet team

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