Corrosion under insulation CUI

Prepared by: DSc PhD Dževad Hadžihafizović (DEng)

Sarajevo 2024
Corrosion under insulation [CUI]
Corrosion under insulation [CUI] is a serious and costly problem for many industries. It is a
common issue in the refinery, pharmaceutical, maritime/marine, offshore, and petrochemical
industries. It can cause equipment failure, leaks, downtime, and even explosions. The National
Association of Corrosion Engineers (NACE) conducted a survey in 2008 and discovered that
more than half of all facilities surveyed faced significant corrosion challenges.

What exactly is corrosion under insulation?

Corrosion is a type of oxidation that happens when a material loses electrons to oxygen
molecules in the air or water around it. This material is usually a metal, such as carbon steel or
stainless steel, in the context of industrial manufacturing.
Corrosion under insulation (CUI) is oxidation on the surface of a metal pipe or vessel that has
been insulated. The insulation material traps moisture beneath it, exposing the metal to
oxygen in the water. This continuous contact aggravates the problem by increasing the rate of
corrosion.
Why Does Corrosion Occur?
Moisture
Moisture exists naturally in the air as water vapour. The vapour undergoes phase change and
condenses into a liquid at the proper temperatures and pressures. This liquid can become
trapped beneath the insulation material on the pipe's surface. Condensation on the metal
surface can start and accelerate the corrosion process.
Oxidation
When atoms on the surface of a material (usually metal) lose electrons to oxygen in the
surrounding air or water, this is referred to as oxidation. The oxygen molecules absorb the
electrons, resulting in the formation of an "oxide layer" with the metal. This thin layer may
offer some natural protection against future reactions, but the damage has already been
done. Oxidation weakens materials, making them more prone to breaks and fractures when
subjected to additional stress.
Mechanism
A corrosion reaction just needs moisture and oxygen on a metal surface
A corrosion cell forms on the metal surface by a potential difference between two points. You
just need is 100 mV potential difference between two points on an iron surface to set up a
corrosion cell to create anode and cathode. Generally, this potential difference arises from
any defects on metal surface or due to presence of impurities. At anode the metal oxidizes by
losing electrons and at cathode the oxygen in presence of water reduces by capturing those
electrons. Electrons flow from anode to cathode. The metal surface acts as conductor.

Process of corrosion

At anode, the metal loses electrons and oxidized

Fe = Fe ++ + electron

Electron uses metal plate as a conductor to travel to cathode

Reaction at cathode

O2 + e− + H2O → OH− [this is not a balanced equation]

At the cathode, the oxygen in presence of water reduces to OH [ hydroxide] ions.

Water aids in the reduction of oxygen.

This is the role of water

Finally, Fe ions produced at the anode and OH ins produced at the cathode combine and form
various iron oxides and hydroxides which are collectively called rust.
Thermodynamics
2Fe + O2 = 2FeO
It is an exothermic reaction. Therefore, it generates positive entropies. Since it is an
exothermic reaction, the enthalpy, H of the reaction is negative.
dG = dH – TdS
The Gibbs free energy, G is negative. Therefore, the corrosion is a spontaneous forward
reaction once it starts
Corrosion Prevention
Maintenance is critical to lowering corrosion costs and avoiding long-term damage. Thermally
insulated systems must be given special consideration in environments with high humidity or
spill risk.
Preventing Water Ingress
Moisture trapped beneath the insulation material is a major contributor to CUI. However,
preventing moisture ingress can be challenging. Wrapping, clamping, taping, or otherwise
attaching conventional insulation materials to piping systems is required. Moisture can easily
enter small spaces. Sealing every section of pipe can be difficult, especially in complex piping
systems.
Usual practices
Jackets with Insulation
Insulated piping systems may include a protective jacket wrapped around the insulation
material. This jacket adds an extra layer to help keep moisture out. PVC jackets may suffice in
less demanding conditions. Aluminum or stainless steel jacketing provides greater protection
in more demanding applications.
Additional Material Layering
In some cases, additional materials are incorporated into the insulated piping system.
Wrapping aluminium foil around the pipe and the insulation material, for example, can help
prevent pitting and stress corrosion cracking.
Credit: Google

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