Corrosion Under Insulation (CUI) in Chemical Plant Equipment and Piping

A 25 year old Gulf Coast US Chemical Plant was experiencing increased CUI failures and was in need of inputting all of their insulated equipment and piping into a managed CUI program with a prioritized inspection and maintenance list. Upon completion, all assets were in a manageable CUI program with prioritized inspection plans based on risk. More than a dozen imminent failures were identified.

Corrosion Under Insulation (CUI) in Chemical Plant Equipment and Piping

A 25 year old chemical plant in the Gulf Coast United States was experiencing an increase in Corrosion Under Insulation (CUI) failures of their insulated equipment and piping. Because of these failures, the facility recognized that implementing a CUI program for these assets was key to understanding and preventing this type of failure. Through the implementation, the facility also needed a prioritized inspection and maintenance list as a way of completing the tasks in a safe and fiscally responsible manner.

RBI consultants put together a plan for a Risk Based Inspection (RBI) program for the insulated assets that would address the needs of the facility. Asset data was collected, along with a review of the previously performed inspections, to perform a damage mechanism review based on the CUI damage mechanism. Using these results, risk was evaluated on the insulated assets and inspection plans were developed. Visual and NDE inspections were completed and the risk of each asset was reevaluated to develop a 10 year inspection plan.

The results of the CUI program implementation were that all the insulated equipment and piping was brought into a manageable CUI program, with a prioritized list of future inspections base on current and future risk. The facility also had maintenance recommendations that were prioritized and based on a multi-year budget, which included insulation and piping replacement and vessel repairs. Additionally, all of the completed prioritized inspections found more than a dozen imminent failures.

RBMI Screenshot

Case Study Inquiry

Related Services

Risk Based Inspection (RBI) Implementation and Planning

AOC has delivered thousands of sustainable Risk Based Inspection (RBI) programs earning the trust of owner operators.

Master Data Management and Data Conversion

Innovative technology that allows quick, efficient extraction of data into a knowledge-centric world

Related Training

RBI/MI Overview

What is Risk Based Inspection?

API 580 RBI Overview

What impact does Risk Based Inspection (RBI) have on my organization?

API 580 Training

Is your Risk Based Inspection (RBI) program aligned with the API 580 Recommended Practice? Are you ready for certification?

API 581 Overview

What's actually going on inside all of that fancy software? An introduction to the API 581 methodology.

Related Knowledge

Guidelines for Providing Process Conditions for RBI - Part 6: HTHA

A simple screening to determine HTHA susceptibility and factors to consider when more data is required.

Insights on Improving Inspection Effectiveness

Since the evaluation of inspection effectiveness for RBI can be so subjective, following these suggestions can greatly improve the process.

Guidelines for Providing Process Conditions for RBI - Part 5: Low Temp

This article suggests additional factors to consider when providing process conditions for equipment exposed to low temperatures.

Qualitative Risk Assessment of a Commercial Refrigeration System

A case study presenting the methods used to calculate qualitative risk for a critical refrigeration system and the results of the assessment.

Managing Reliability of Ethane Crackers using DMR, RBI, and IOWs

How RBI, DMR, and IOW programs can be used to manage reliability of Ethane crackers.

Guidelines for Providing Process Conditions for RBI - Part 4: High Temp

This article suggests additional factors to consider when calculating probablity of failure for equipment exposed to high temperatures.

Guidelines for Providing Process Conditions for RBI - Part 3: Fluids

This article offers guidance on the selection of a representative fluid for use in your RBI consequence evaluation.

Steam System Risk Mitigation Using Risk Based Inspection

The benefits of utilizing risk-based methodologies for the inspection programs of often overlooked utilities systems

5 Things to Consider When Choosing Your API Training Provider

Not all vendors are created equal. Some up-front research can go a long way toward a high-quality learning experience.

Goal: 100% API 580 Certified

A long-standing vision of AOC, we are well on our way to meeting the goal of having 100% of our RBI staff certified to API 580.