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  • CUI Program

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    Camilo Andrés Vargas Jiménez
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    The document discusses implementing a corrosion-under-insulation (CUI) program at chemical process industry facilities. It recommends a phased approach including: 1) identifying equipment susceptible to CUI through assessments of materials, operating temperatures and conditions; 2) performing risk assessments to prioritize inspections; and 3) implementing inspection programs utilizing methods like visual inspection, radiography and ultrasonics to detect CUI. Non-destructive examination methods are discussed along with their advantages and disadvantages for CUI detection. The goal is to help facilities develop comprehensive CUI programs to proactively manage risks from corrosion under insulation.

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    CUI-Program

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    The document discusses implementing a corrosion-under-insulation (CUI) program at chemical process industry facilities. It recommends a phased approach including: 1) identifying equipment susceptible to CUI through assessments of materials, operating temperatures and conditions; 2) performing risk assessments to prioritize inspections; and 3) implementing inspection programs utilizing methods like visual inspection, radiography and ultrasonics to detect CUI. Non-destructive examination methods are discussed along with their advantages and disadvantages for CUI detection. The goal is to help facilities develop comprehensive CUI programs to proactively manage risks from corrosion under insulation.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    24 views4 pages

    CUI Program

    Uploaded by

    Camilo Andrés Vargas Jiménez
    The document discusses implementing a corrosion-under-insulation (CUI) program at chemical process industry facilities. It recommends a phased approach including: 1) identifying equipment susceptible to CUI through assessments of materials, operating temperatures and conditions; 2) performing risk assessments to prioritize inspections; and 3) implementing inspection programs utilizing methods like visual inspection, radiography and ultrasonics to detect CUI. Non-destructive examination methods are discussed along with their advantages and disadvantages for CUI detection. The goal is to help facilities develop comprehensive CUI programs to proactively manage risks from corrosion under insulation.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    of 4

    Feature

    Cover Story
    Report

    Implementing a Corrosion-
    Under-Insulation Program
    CPI facilities need to put Phase 1
    Initiate CUI
    CUI Initial Descision Tree
    evaluation, identify
    in place a systematic suspect equipment Pre-inspection

    program for preventing


    and mitigating corrosion Is
    construction NO
    Is it
    austenitic NO
    Consult
    with materials
    material carbon stainless engineer for CUI
    under insulation steel? steel? susceptibility
    YES
    YES
    Russ Davis
    The Mistras Group, Inc. Is
    Operates Cycling Cycling operating
    NO in and out of in and out NO temperature
    between 10

    C
    orrosion to the external sur- and 400°F? 10 and 400°F of 120 and between 120 and
    range? 400°F? 400°F?
    face of process piping and ves- NO
    sels that is hidden under the
    insulation is referred to as No CUI expected
    YES YES YES YES
    corrosion under insulation (CUI).
    Aging piping and equipment in
    chemical plants and petroleum re- Implement
    Potential for
    Potential for risk-based
    fineries have made CUI detection CUI exists inspection stress-corrosion
    cracking exists
    and assessment requirements in- program
    creasingly important. Because the
    need to detect and assess CUI is
    critical in chemical process indus- IDMS download Perform risk
    of identified assessment
    tries (CPI) facilities, inspection and equipment to prioritize
    testing methodologies have been susceptible to CUI inspection plan
    pushed to improve. However, many
    CPI facilities lack an insulation- FIGURE 1. The initial phase
    Perform field of a comprehensive CUI pro-
    repair program. The best approach walkdown, review gram involves a team assess-
    to address the problem of CUI is to asset history,
    cyclic service, ment of process vessels and
    develop and adopt a comprehensive plant turnaround piping to determine which
    schedule pieces of equipment may be
    and facility-wide CUI program. This
    susceptible to CUI
    article describes the components of
    such a program and is designed to
    help facility managers and engi- the risk posed by CUI for potential steels are also susceptible to CUI,
    neers identify strategies to imple- exposure to hazardous chemicals, as especially in coastal geographic re-
    ment it. well as the potential fire and explo- gions where the normal atmosphere
    Industry estimates indicate that sion hazards, resulting from the loss contains chlorides and where the
    CUI costs the chemical and oil-and- of containment of highly hazardous equipment operates between 140°F
    gas industries in excess of $100 mil- chemicals. Sometimes, corrosion- (60°C) and 400°F (205°C). Chloride-
    lion annually. This cost represents preventive painting programs are induced stress corrosion cracking
    only the estimated damage to the cut when budgets are tight. (SCC) has been found in austenitic
    equipment, and does not include CUI primarily affects carbon- stainless steels due to the chloride
    the losses that may be associated steel and low-alloy steel vessels and content of the normal environment.
    with process downtime. Taking piping. Operating conditions noted
    equipment and piping out of ser- for making equipment susceptible Program components
    vice when they are needed to make to CUI range from 10°F (–12°C) It is essential that a programmatic
    product will raise the level of losses. to 400°F (205°C). Austenitic stain- approach to reducing the risk of
    This estimate also does not include less steels and duplex stainless operations includes a focus on CUI
    40 CHEMICAL ENGINEERING WWW.CHE.COM MARCH 2014
    TABLE 1. NON-DESTRUCTIVE EXAMINATION (NDE) METHODS FOR DETERMINING
    THE PRESENCE OF CUI: ADVANTAGES AND DISADVANTAGES
    Method Advantages Disadvantages
    Visual inspection of pipes t2VBMJUBUJWFJOTQFDUJPO t3FRVJSFTTUSJQQJOHPGBMMJOTVMBUJPO
    and equipment t*NNFEJBUFWBMJEBUJPOPGSFTVMUT t&YUFOTJWFTUBHJOHPSTDBGGPMEJOHNBZCF
    SFRVJSFE
    t4MPX
    t&YQFOTJWFXIFSFIB[BSEPVTNBUFSJBMT
    BSFQSFTFOU
    t1PUFOUJBMUPNJTTDSJUJDBMMPDBUJPOT
    Radiography film t2VBMJUBUJWFBOERVBOUJUBUJWFSFTVMUT t-POHFSFYQPTVSFUJNFT
    $POWFOUJPOBM9SBZUFDIOPM QPTTJCMF t"DDVSBDJFTBSFœ
    PHZXIFSFSBEJBUJPOQBTTFT t5IJDLOFTTNFBTVSFNFOUTBSFQPTTJCMF t'JMNQSPDFTTJOHJTSFRVJSFE TPSFTVMUTBSF
    UISPVHINBUFSJBMBOE t$BOJEFOUJGZDPOEJUJPOTPGCPUIPVUFS EFMBZFE
    DSFBUFTJNBHFPOGJMN EJBNFUFSBOEJOOFSEJBNFUFS t&OWJSPONFOUBMJTTVFTXJUIDIFNJDBMT
    t*NBHFBEKVTUNFOUJTOPUQPTTJCMF
    t"SDIJWBMSFTUSJDUJPOT
    Radiography CR (com- t2VBMJUBUJWFBOERVBOUJUBUJWFSFTVMUT t$PWFSTMJNJUFEBSFB
    puted radiography) QPTTJCMF t3FRVJSFTEJSFDUBDDFTTUPJOTQFDUJPO
    9SBZJNBHFTBSFEJHJUJ[FE t"DDVSBUFNFBTVSFNFOUTQPTTJCMF BSFB
    BOEEJTQMBZFEPODPNQVUFS t$BOJEFOUJGZDPOEJUJPOTPGCPUIPVUFS t$PTUDPOUSPMJTCBTFEPOBDDFTTBOE
    EJBNFUFSBOEJOOFSEJBNFUFS QSPEVDUJPOSBUF
    t/PJOTVMBUJPOSFNPWBMSFRVJSFE t3BEJBUJPOIB[BSET
    t4PGUXBSFJNBHFFOIBODFNFOUQPTTJCMF t*NBHJOHQMBUFDBSFSFRVJSFE
    t&MFDUSPOJDNFEJBGPSFBTZBSDIJWJOH
    Realtime (RT) radiography t*EFOUJGJFTPVUFSTVSGBDFDPOEJUJPOT t$MPTFQSPYJNJUZQJQJOHSVOTBOEQJQFHF
    -PXQPXFS9SBZPSJTPUPQF t"MMPXTGBTU JNNFEJBUF
    SFTVMUT PNFUSZDBOSFTUSJDUJOTQFDUJPO
    CBTFEEJHJUBMGMVPSPTDPQZ t/PJOTVMBUJPOSFNPWBMSFRVJSFE t1SPEVDUJPOTMPXFSJODMPTFTQBDFE
    FRVJQNFOUUIBUQSPWJEFT t/PSBEJBUJPOIB[BSET QJQJOH
    WJFXPGPVUFSEJBNFUFSPG t*OTQFDUJPOVOJUJTDVNCFSTPNFJOUJHIU
    pipe TQBDFT
    Guided wave inspection t3BQJEJOTQFDUJPOPGMPOHMFOHUITPGQJQF t2VBMJUBUJWFTDSFFOJOH
    6TFTMPXGSFRVFODZVMUSB BSFQPTTJCMF  UP GUE
    t3FRVJSFTTFDPOEBSZNFUIPEGPSWFSJGJDB
    TPOJDXBWFTUPEFUFDUHFO tWPMVNFUSJDDPWFSBHF UJPOPGBOPNBMJFT
    FSBMDPSSPTJPOBOEXBMMMPTT t-JNJUFEJOTVMBUJPOSFNPWBMGPSJOTQFDUJPO t(FPNFUSZDBOSFTUSJDUJOTQFDUJPO
    t"DDVSBUFMPDBUJPOPGQJQFGFBUVSFTBOE
    DPSSPTJPO
    t4FNJRVBMJUBUJWFBOBMZTJTPGXBMMMPTT
    t5FNQFSBUVSFSBOHFUP¡'
    t.PTUDPTUFGGFDUJWFNFUIPEGPSWFSZMPOH
    MFOHUITPGQJQF
    Pulsed eddy current (PEC) t'BTU t$MPTFQSPYJNJUZQJQJOHDBOMJNJUBDDFTT
    &MFDUSJDDVSSFOUJTJOUSP t/PJOTVMBUJPOSFNPWBMSFRVJSFE t*OTQFDUJPOPGQJQJOHMFTTUIBOJOJOEJ
    EVDFE UIFOTXJUDIFEPGG t&BTJMZEFQMPZFE BNFUFSJTOPUQPTTJCMF
    UPHFOFSBUFFEEZDVSSFOUT  t)JHIUFNQFSBUVSFDBQBCJMJUZ
    XIJDIBSFEFUFDUFECZSF t/PODPOUBDUNFUIPE
    DFJWFSDPJMT t2VBMJUBUJWFEBUB
    Hydrotector t*OJUJBMTDSFFOJOHGPSXFUJOTVMBUJPOCFGPSF t0OMZVTFGVMGPSXFUJOTVMBUJPOEPFTOPU
    %FUFSNJOFTNPJTUVSFDPO FNQMPZJOHPUIFS$6*NFUIPET EFUFDUESZJOTVMBUJPOUIBUIBTCFFOXFU
    UFOUJOJOTVMBUJPOCZNFBTVS t'BTU t4DSFFOJOHUPPMPOMZ
    JOHOFVUSPOTDBUUFSCZIZ t/PJOTVMBUJPOSFNPWBMSFRVJSFE t/PEBUBPOBDUVBMQJQFDPOEJUJPO
    ESPHFOBUPNTJOUIFXBUFS

    detection and mitigation. In gen- the vessels and piping identified process vessels and piping to de-
    eral, a comprehensive CUI program in the first phase termine what is susceptible to CUI.
    should consist of at least the follow- t1FSGPSNJOH FGGFDUJWF BOE FGGJ- The team should evaluate and con-
    ing aspects: cient inspection and testing of the sider the operating temperatures
    t1SFWFOUJPOPG$6* FRVJQNFOUBOEQJQJOH and material of construction of
    t&BSMZEFUFDUJPO For each phase of the CUI program, FBDI PG UIF QJFDFT PG FRVJQNFOU UP
    t.JUJHBUJPO this article includes a decision tree NBLF UIF EFUFSNJOBUJPO 5IJT JO-
    t.FDIBOJDBMJOUFHSJUZ QSFWFOUB- that is designed to assist engineers GPSNBUJPONBZDPNFGSPNQMBOUFO-
    tive maintenance programs de- BOENBOBHFSTUPTZTUFNBUJDBMMZBQ- gineering files and operational his-
    TJHOFEUPDPOUJOVBMMZBEESFTTUIF proach CUI assessments, repairs UPSZ  PS JU DBO CF EPXOMPBEFE GSPN
    hazards of CUI and documentation. The decision the inspection data management
    The process for addressing CUI trees can be found in Figures 1–4. TZTUFN *%.4
    
    XJUIJO UIF DPNQSFIFOTJWF GBDJMJUZ After the team has determined
    specific program should consist of Phase I XIBU FRVJQNFOU XJMM CF JODMVEFE
    at least these three phases: 5IF JOJUJBM 1IBTF  EFUFSNJOBUJPO in the program, it is good practice
    t%FUFSNJOJOH XIBU FRVJQNFOU JT PGXIBUFRVJQNFOUJTUPCFJODMVEFE UPQSJPSJUJ[FUIPTFFRVJQNFOUJUFNT
    in the program JOUIF$6*QSPHSBNHFOFSBMMZDPO- CZQFSGPSNJOHBSJTLBTTFTTNFOUUP
    t1FSGPSNJOH B GJFME XBMLEPXO PG sists of a team assessment of the determine where the higher-conse-
    CHEMICAL ENGINEERING WWW.CHE.COM MARCH 2014 41
    Phase 2 Initial Field Visit

    Cover Story
    Initiate visual
    inspection of Perform
    applicable assets – NO engineering
    quence events would occur if there Field walkdown assessment
    to defer
    was a loss of containment. The team inspection
    must always fully understand the
    Inspection
    operating process and include those methodology
    Are
    vessels that are frequently idle, there any areas selection
    even if they operate in a tempera- with damaged
    insulation
    ture range not usually noted for
    Implement
    susceptibility to CUI. YES inspection plan
    The team should be composed YES
    of at least one member who is fa- Document areas
    miliar with the materials of con- on asset ISO
    drawing.
    struction of the vessels and piping Perform moisture
    NO
    being evaluated, as well as at least detection to isolate
    suspect areas
    one member knowledgeable in the FIGURE 2. In the field-walkdown
    process temperatures at which the Document areas on
    stage of the CUI program, subject-
    equipment operates, and a mem- asset ISO drawing matter experts inspect equipment
    Determine
    that are suspect recommended to determine which method(s) will
    ber knowledgeable about the CUI for CUI. inspection plan be most effective to evaluating
    damage mechanism. In addition Establish methodology whether and how CUI is affecting
    the team should include a member inspection each equipment item
    methodology
    who is familiar with the inspection to be utilized
    history of the vessels and piping
    within the program.
    The analysis team should use a
    formalized approach to the deter- Phase 3 Field Inspection
    mination. A logic decision tree can
    be very helpful (Figure 1).
    The team’s initial assessment
    Recommend Inspection Excecute
    should pay particular attention to Field work and paint and complete. inspection
    follow up
    the following equipment and piping inspection
    re-insulate asset Document finding plan
    susceptible to CUI: Document Mark ISO drawing Follow up on
    t"SFBTFYQPTFEUPNJTUPWFSTQSBZ recommendation with location NDE findings and
    inspected, update make necessary
    from cooling water towers Remove Follow-up asset files repairs
    t"SFBT TVCKFDUFE UP QSPDFTT TQJMMT  insulation re-insulation
    at suspect of asset and Follow up Perform
    ingress of moisture or acid vapors locations close work re-insulation engineering
    order and close fitness for service
    t%FBEMFHT BOE BUUBDINFOUT UIBU work order when required
    is, drains, vents and so on
    Inspector Document
    t1JQFIBOHFSTBOEPUIFSTVQQPSUT performs corrective action
    t7JCSBUJOHQJQJOHTZTUFNT visual asset
    Update ISO and
    inspection NO YES
    t4UFBNUSBDFEQJQJOHTZTUFNTUIBU at exposed follow closure of
    NBZFYQFSJFODFUSBDJOHMFBLT locations work order
    and document

    Phase 2 YES
    1IBTFDPOTJTUTPGBGJFMEXBMLEPXO Is
    NO Does
    evidence of
    CZRVBMJGJFETVCKFDUNBUUFSFYQFSUT corrosion present?
    paint meet
    plant
    4.&T
     5IFTF FYQFSUT EFUFSNJOF (cracks or criteria? Inspection
    thinning) decision
    XIBU OPOEFTUSVDUJWF FYBNJOBUJPO
    /%&
     NFUIPEPMPHZ JT CFTU TVJUFE YES
    for discovering whether and how
    FIGURE 3. When the field inspection
    CUI may be affecting each vessel Inspector to decide between:
    plan is carried out, the need for more
    a. advanced NDE;
    BOE QJQJOH TZTUFN 5IF 4.&T DBO b. additional insulation removal; extensive testing can be determined
    also determine the most efficient c. engineering assessment; and possible recommendations for
    d. combination of a, b, c options repair can be developed
    and effective method for perform-
    ing the inspection and tests. Table
     TIPXT B CSJFG BOBMZTJT PG /%& QJQJOHDBOBMTPCFBOBMZ[FE%FUFS- inspection and testing field. Inspec-
    methods that can be used to deter- NJOJOH GPSFYBNQMF XIFSFTDBGGPME- UPST BSF BCMF UP QFSGPSN BOZ /%&
    mine the presence of CUI. ing must be utilized or where rope method from ropes, thus reducing
    %VSJOH UIF 1IBTF  GJFME BTTFTT- access is needed can be of signifi- the need for scaffolding and greatly
    ment, accessibility issues associated cant value. Rope access has made reducing the cost of inspections.
    with each piece of equipment and a tremendous contribution to the There must be anchor points avail-
    42 CHEMICAL ENGINEERING WWW.CHE.COM MARCH 2014
    Inspector to determine:
    Inspection a. advanced NDE
    decision b. insulation removal
    c. engineering analysis
    d. combination of a, b, c options

    the most effective and economical


    method for follow-up inspections.
    Figure 4 is a logic flow for determin-
    If stainless-steel ing whether or not follow-up inspec-
    asset, perform YES YES Perform
    localized SCC crack additional tions should be performed, as well
    penetrant-test present inspections
    exam as if advanced non-destructive eval-
    VBUJPO "/%&
     NFUIPET TIPVME CF
    NO used in lieu of insulation stripping.
    Strip the larger of:
    a. all suspect
    It is costly to remove and replace in-
    Carbon steel Document and damaged sulation, especially if it is not fully
    asset with and close insulation
    corrosion scale locations; necessary. In many cases, the most
    or pits
    b. 20% of asset economical method could be an
    area/length "/%&NFUIPE5IFBEWBOUBHFTBOE
    NO
    EJTBEWBOUBHFT PG "/%& NFUIPET
    Does are also discussed in Table 1.
    the piping NO
    Is cross waterway? Is
    wall loss
    greater than NO Is the piping a class 1 YES asset
    suitable for
    Summary remarks
    or class 2 circuit?
    corrosion
    Is the calculated risk-
    advanced $6* JT B TFSJPVT IB[BSE BGGFDUJOH
    allowance? ANDE?
    based inspection the safety and reliability of chemi-
    consequence
    A or B? cal plants, petroleum refineries,
    YES YES midstream terminals and just about
    all oil-and-gas operating facilities.
    Inspect 100% To best address the problem, CUI
    of carbon steel Perform ANDE must be addressed in a systematic
    asset with ANDE
    or programmatic approach. The
    program must be fully defined and
    Note 1: staffed with qualified personnel. Ef-
    1. If there are additional findings, then follow-up inspection will be required in accordance fective and economical inspection
    with this process. If there are no additional findings, then spot repairs will be completed
    and inspection results documented in the asset inspection files. and testing methodologies should
    CFVUJMJ[FEBTQBSUPGUIF$6*EFUFD-
    FIGURE 4. If corrosion is observed at suspect CUI locations, more in-depth assess- tion program. By addressing CUI
    ments, probably involving advanced non-destructive testing methods, are undertaken effectively, the risk of operations
    is reduced significantly and the
    able for the rope access team to use Phase 3 equipment and plant reliability is
    for anchoring their ropes. The field 1IBTFPGUIFQSPHSBNTIPVMEDPO- JODSFBTFE"TBGFMZBOESFMJBCMZPQ-
    assessment can determine where sist of the most effective and efficient erating facility is the product of a
    rope access would be effective and methods of testing and inspection proactive CUI program. ■
    which NDE method will yield the for the detection of CUI. Inspection Edited by Scott Jenkins
    most significant data at the right and testing findings can be evalu-
    cost level. Figure 2 is an example of ated, and additional inspection and Author
    Russ Davis is the National
    the logic flow the field team can fol- testing needs can be quickly deter- "TTFU*OUFHSJUZ.BOBHFNFOU
    low to determine the most effective mined. Recommendations can then 4FSWJDFT "*.4
     NBOBHFS JO
    the services division of the
    inspection and test methodology. be developed to address those issues .JTUSBT (SPVQ *OD 
    The field walkdown team should that were identified in the previ- 6OEFSXPPE 3PBE  -B1PSUF 
    59  1IPOF 
    pay particular attention to: ous phase. Vessel and piping repair  &NBJM 3VTT%BWJT!
    NJTUSBTHSPVQDPN
     %BWJT
    t5IF CPUUPN PG IPSJ[POUBM MJOFT plans can be developed and next has spent over 26 years in
    in piping systems susceptible to JOTQFDUJPOEBUFTTFU'JHVSFJTBO mechanical-integrity pro-
    gram development and
    CUI FYBNQMFPGBMPHJDGMPXGPS1IBTF implementation. His experience includes pres-
    t"OZ CSFBL JO UIF WBQPS SFUBSEFS that the testing and inspection team sure vessels, aboveground storage tanks, and
    piping inspection, testing and evaluation. Davis
    on cold lines can use during the screening part of has an extensive background in process safety
    t%BNBHFE PS NJTTJOH JOTVMBUJPO the implementation phase. NBOBHFNFOU JODMVEJOHIB[BSEBTTFTTNFOUBOE
    consequence evaluation. He has developed and
    jacketing It is not economical or feasible to EJSFDUFENFDIBOJDBMJOUFHSJUZ .*
    QSPHSBNTGPS
    t-PDBUJPO XIFSF JOTQFDUJPO QMVHT expect that the inspection and test- aBOglobal chemical company. Davis has served as
    .* DPOTVMUBOU  BT XFMM BT FYUFSOBM DPOTVM-
    have been removed ing will cover 100% of the equip- UBOUGPSUIFJNQMFNFOUBUJPOPG.*QSPHSBNT)F
    t1JQJOHTZTUFNTXJUIEFUFSJPSBUFE ment and piping susceptible to CUI. has a solid working knowledge of NDE, damage
    mechanisms, and materials of construction for
    coatings or wrappings Screening inspections and testing equipment in the petroleum refining, chemical
    and energy industries. He is also experienced
    t5FSNJOBUJPO PG JOTVMBUJPO will be conducted to identify suspect in equipment failure analysis, lifecycle analysis
    at flanges and other piping areas. Once these areas are identi- BOE GBJMVSF GSFRVFODJFT %BWJT JT BO"1*DFSUJ-
    GJFE JOTQFDUPS  BO *4"  'VOEBNFOUBMT 4QF-
    components fied, the decision will be made on cialist and a certified safety professional.
    CHEMICAL ENGINEERING WWW.CHE.COM MARCH 2014 43

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