Corrosion under Insulation (CUI)

CUI is a particularly severe form of localized corrosion that has been plaguing
chemical process industries since the energy crisis of the 1970s forced plant
designers to include much more insulation in their designs.

Intruding water is the key problem in CUI. Special care must be taken during
design not to promote corrosion by permitting water to enter a system either
directly or indirectly by capillary action. Moisture may be external or may be
present in the insulation material itself. Corrosion may attack the jacketing, the
insulation hardware, or the underlying equipment.

For high temperature equipment, water entering an insulation material and

diffusing inward will eventually reach a region of dryout at the hot pipe or
equipment wall. Next to this dryout region is a zone in which the pores of the
insulation are filled with a saturated salt solution. When a shutdown or process
change occurs and the metal-wall temperature falls, the zone of saturated salt
solution moves into the metal wall.

Upon reheating, the wall will temporarily be in contact with the saturated solution,
and stress-corrosion cracking may begin. The drying/wetting cycles in CUI
associated problems are a strong accelerator of corrosion damage since they
provoke the formation of an increasingly aggressive chemistry that can lead to the
worst corrosion problems possible, e.g. stress corrosion cracking, and premature
catastrophic equipment failures.

Types of Corrosion Under Insulation

By understanding the types of corrosion that can occur under insulation, the proper
materials and construction can be employed to prevent them. Intruding water is the
key problem in CUI. Special care must be taken during design not to promote
corrosion by permitting water to enter a system either directly or indirectly by
capillary action. Moisture may be external or may be present in insulation.

What is the Mechanism of Corrosion Under Insulation?

The mechanism of corrosion under insulation involves three requirements:

1. Availability of oxygen.
2. High temperature.
3. Concentration of dissolved species.

Normally, as the temperature increases, the amount of oxygen dissolved in solution

decreases as the boiling point is reached resulting in reduced corrosion rates.
However, on the surface covered by insulation, a poultice effect is created which
holds in the moisture which essentially makes it s closed system. In fact the
measured corrosion rates associated with corrosion under insulation follow trends
to higher corrosion rates commonly associated with only pressurized systems.
Furthermore, in cases where precipitation becomes trapped on the metal surface by
insulation, corrosive atmospheric constituents such as chlorides and sulfuric acid
can concentration to also accelerate corrosion. In some cases, chlorides are present
in the insulation which greatly promotes corrosion of the underlying surface which
it becomes laden with moisture.

How do I Inspect for Corrosion Under Insulation?

The most common and straightforward way to inspect for corrosion under
insulation is to cut plugs in the insulation that can be removed to allow for
ultrasonic testing. However, many times such plugs can be the source of moisture
leakage. The main problem with this technique is that corrosion under insulation
tends to be localized and unless the inspection plug is positions in the right spot the
sites of corrosion can be missed. Other techniques that are available include special
eddy current techniques, x-ray, remote TV monitoring and electro-magnetic
devices.

How do I Prevent Corrosion Under Insulation?

The most serious problem is the system already in service with a know corrosion
under insulation problem. Inhibitors have been tried with varying success since
repeated wet / dry cycles may make inhibitors ineffective. This is an area of
opportunity. However, long terms performance and efficacy must be proven. Water
proofing to prevent the ingress of water from outside sources is another method.
However, it has been shown that sometimes these techniques tend to lock in
moisture which can also increase corrosivity. Careful selection of insulation
materials to prevent those that contain high levels of corrosive impurities such as
chlorides is critical to reducing corrosion under insulation.

One of the best but most expensive options to prevent corrosion under insulation is
the use of protective coating systems. Unfortunately, in most cases, coatings that
have been successful for atmospheric service are used under insulation with
disastrous results. In it often a surprise that under-insulation service is a more
severe condition than straight atmospheric service. Special coating system must be
utilized that have proven performance. In some applications inorganic zinc has
worked well, but not in others. Anticorrosion and inhibitive coatings are being are
also being proposed or considered for longer term performance.

Corrosion Under Insulation (CUI):

What it is and how to prevent it
Corrosion under insulation (CUI) is the corrosion of piping and vessels that occurs
beneath insulation as a result of water penetration. The water can come from rain
water, leakage, deluge system water, wash water, or sweating from temperature
cycling or low temperature operation such as refrigeration units.

Unfortunately, because the corrosion is hidden under the insulation, CUI tends to
remain undetected until the insulation is removed for inspection or when leaks occur.
CUI is a common problem across many industries, including refining, petrochemical,
power, industrial, onshore and offshore industries.

In 2001, a study commissioned by Congress was completed by a research team of

corrosion specialists. The study, titled “Corrosion Costs and Preventive Strategies in
the United States” reported the direct cost of corrosion to be $276 billion per year,
with that number potentially doubling when indirect costs are also considered.
Another study, commissioned by ExxonMobile Chemical and presented to the
European Federation of Corrosion in September 2003 indicated that:

 The highest incidence of leaks in the refining and chemical industries are due to
CUI and not to process corrosion
 Most piping leaks – 81% – occur in diameters smaller than 4-inch nominal pipe
size
 Between 40% and 60% of piping maintenance costs are related to CUI
Causes of Corrosion Under Insulation
For CUI to form there must be two basic ingredients: moisture and warm
temperatures. For iron products like carbon steel piping and equipment, oxygen is
also required. To have chloride stress corrosion cracking (SCC) of 300 series
stainless steel, there also must be the presence of chloride ions.
Obviously, oxygen is abundant and readily available. But maybe surprisingly, so too
are chloride ions, which can be found in a wide variety of places from seawater,
drinking and process water, and chloride chemical compounds to roadway de-icing
salts. The presence of acids, acid gases, strong bases and salts can also create and
accelerate corrosion.

Moisture in its many forms can find numerous ways to get under an insulation
system. Rainwater is the most obvious method, but there is also flooding of
insulation systems in low-lying areas and water from pressurized water wash down
or local steam leaks. Water can also come from fire protection sprinkler systems,
which can be as bad as or worse than any rainstorm.

The next source of moisture is water vapor penetrating and soaking down the
insulation systems operating at or below ambient temperatures. The final source is
ice, normally cold service insulation systems operating below the freezing point.
Although insulated piping and equipment under a layer of ice do not corrode
significantly since the temperature limits the available heat and oxygen (two of the
three necessary elements of corrosion), it provides a near ideal corrosion area where
the ice is continually freezing and thawing.
Operating temperature is the next most important element. Above 300 F, most
moisture that finds its way into the insulation system evaporates before it can get to
the surface and start corrosion. Below 32 F, because of relatively low energy levels,
corrosion rates are dramatically reduced and the formation of ice limits the amount of
oxygen available. However, between 32 F and 300 F is where CUI can happen for
carbon steel, and between 140 F and 300 F for 300 series stainless steel. The
“optimum” temperature range for aggressive corrosion on both carbon steel and 300
series stainless steel is between 200 F and 240 F. In this range, there is plenty of
heat energy but not enough heat to efficiently evaporate moisture before it contacts
the equipment surface.

Pipe Corrosion Inspection and Prevention

The most common and straightforward way to inspect for corrosion under insulation
is to cut plugs in the insulation that can be removed to allow for ultrasonic testing.
However, many times these plugs can be the source of moisture leakage. The main
problem with this technique is that corrosion under insulation tends to be localized
and unless the inspection plug is positioned in the right spot, the corrosion can be
missed.

Using removable insulation solutions is quite convenient at times like this.

Removable insulation solution like insulation jackets help make this removal process
painless and inexpensive, since the jackets can be reapplied after the inspection is
completed.
Other techniques that are available include special eddy current techniques, x-ray,
and remote TV monitoring and electro-magnetic devices.

Since most elements in the environment that contribute to CUI are very difficult or
impossible to control, the only hope of prevention lies in properly dealing with the
other factors contributing to CUI: insulation design and specification, installation
craftsmanship and maintenance.

Pipe Design and Specification

Often the original design of the equipment is the start of CUI problems. Piping or
manway openings for equipment that are sized too short to extend past the weather
barrier of the insulation system provide an optimal pathway for water, corrosive
chemicals and contaminates to get into the insulation to start corrosion. Facility
designs like pipe racks that do not leave adequate room for insulation to be installed
without interfering with the insulated pipe or equipment next to it also provide a likely
spot for future corrosion.

Insulation Installation Craftsmanship

Installation craftsmanship can have a significant effect on an insulation system’s
performance and life. A poorly installed insulation system ultimately lets moisture or
corrosive chemicals into the insulation and often to the insulated surface, allowing
the start of CUI.

Insulation jacketing or weather barriers can be installed improperly by not providing a

proper rainshed. On vertical sections of pipe, for example, this happens when lower
sections of the jacketing material are installed over the top of the upper sections,
allowing easy access for water into the insulation system. Insulation terminations or
end caps are other places where jacketing can be installed improperly with
dangerous CUI possibilities.

Caulking and sealants are the final barrier to moisture intrusion and may be installed
improperly in a number of ways, or not at all.

Insulation Maintenance
Proper insulation maintenance is primarily about early detection and correction.
Periodic inspection of insulation systems will help identify early failure signs,
especially CUI problems. Some staining on the jacketing can suggest moisture under
the jacket. Once problems with insulation systems are identified, they should be
repaired as quickly as possible to prevent further contamination and corrosion,
including the resealing of inspection ports.