4.3.3 CORROSION UNDER INSULATION (CUI)

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Description Of Damage

Corrosion of piping, pressure vessels and structural components resulting from water trapped under insulation or fireproofing.

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.

Affected Materials

1. Carbon steel
2. Low Alloy steels
3. 300 Series SS
4. Duplex stainless steels

Critical Factors

1. It affects externally insulated piping and equipment and those that are in intermittent service or operate between:


• 10F (-12C) and 350F (175C) for carbon and low alloy steels.
• 140F (60C) and 400F (205C) for austenitic stainless steels and duplex stainless steels.

2. Corrosion rates increase with increasing metal temperature up to the point where the water evaporates quickly 212F (100C) and 350F (121C).

3. Poor design and / or installations that allow water to become trapped will increase CUI.

Figure 4-73 – Tee in a 1000 psig ethylene line before insulation removal.
Figure 4-74 – Close-up of Tee CUI of a Tee in Figure 4-73 after insulation removal.
Figure 4-75 – CUI of a 30 inch CS Butadiene line showing highly localized corrosion which could only be found by stripping the entire line. Note the 0.25 in (6.5 mm) diameter hole at arrow.
Figure 4-76 – CUI of nozzle on a bottom head.
Figure 4-77 – CUI of nozzle on a top head.
Figure 4-78 – CUI of vessel wall. Note: leak at rrow.

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