BP DOC NUMBER - GP-06-25 REV A

Document No. GP 06-25

Applicability Group
Date 15 April 2009

GP 06-25

Design for the Prevention of Corrosion

under Insulation and Fireproofing (CUI
and CUF)

Group Practice

BP GROUP
ENGINEERING TECHNICAL PRACTICES
15 April 2009 GP 06-25
Design for the Prevention of Corrosion under Insulation and Fireproofing (CUI and CUF)

Foreword

This issue of Engineering Technical Practice (ETP) GP 06-25 is a complete revision. Because the
revisions are so extensive, revisions have not been identified by a bar in the margin as is normal
practice.

If proprietary products are mentioned by their trade name, these are mentioned for illustrative purposes
only and are not meant to be recommendations of any one product over any other which may be on
offer. The suitability of particular products for each specific application should be evaluated.

Copyright © 2009 BP International Ltd. All rights reserved.

This document and any data or information generated from its use are classified, as a
minimum, BP Internal. Distribution is intended for BP authorized recipients only. The
information contained in this document is subject to the terms and conditions of the
agreement or contract under which this document was supplied to the recipient's
organization. None of the information contained in this document shall be disclosed
outside the recipient's own organization, unless the terms of such agreement or contract
expressly allow, or unless disclosure is required by law.

In the event of a conflict between this document and a relevant law or regulation, the
relevant law or regulation shall be followed. If the document creates a higher obligation, it
shall be followed as long as this also achieves full compliance with the law or regulation.

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Design for the Prevention of Corrosion under Insulation and Fireproofing (CUI and CUF)

Table of Contents
Page
Foreword ........................................................................................................................................ 2
1. Scope .................................................................................................................................... 4
2. Normative references............................................................................................................. 4
3. Terms and definitions............................................................................................................. 5
4. Symbols and abbreviations .................................................................................................... 5
5. Good design practice for minimising CUI ............................................................................... 5
5.1. General....................................................................................................................... 5
5.2. General design aspects .............................................................................................. 6
5.3. Vessels ....................................................................................................................... 7
5.4. Tanks.......................................................................................................................... 9
5.5. Piping........................................................................................................................ 10
5.6. Valves and instruments............................................................................................. 11
5.7. Insulation .................................................................................................................. 11
5.8. Protective coatings.................................................................................................... 14
6. Good design practice for minimising CUF ............................................................................ 14
6.1. General..................................................................................................................... 14
6.2. Concrete and vermiculite cement.............................................................................. 14
6.3. Intumescent coatings and subliming compounds ...................................................... 15
Annex A (Informative) Technical information on CUI/CUF............................................................. 16
A.1 Corrosion mechanism - Key factors ..................................................................................... 16
A.2 Detailed factors affecting vulnerability to CUI ....................................................................... 16
A.2.1 Environmental factors ............................................................................................... 16
A.2.2 Coating issues .......................................................................................................... 18
A.2.3 Insulation system factors........................................................................................... 19
A.2.4 Additional factors affecting the location of CUI (used to assess risk)......................... 21
A.2.5 Stainless steels - Key factors in determining the CUI risk.......................................... 21
A.3 Factors instrumental in promoting corrosion underneath fireproofing ................................... 22
Bibliography .................................................................................................................................. 23

List of Figures

Figure 1 - Designs/layout which are difficult to insulate ................................................................... 7

Figure 2 - Sealing discs on vessel nozzles...................................................................................... 8
Figure 3 - Insulation support design ................................................................................................ 9

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Design for the Prevention of Corrosion under Insulation and Fireproofing (CUI and CUF)

1. Scope

a. This GP applies to all items to which insulation has been applied. Insulation may be
applied for any one or combination of the following reasons.
1. Process control (thermal insulation).
2. Noise control (acoustic insulation).
3. Protection of personnel from accidental contact with hot or cold surfaces (personnel
protection insulation).
b. It also applies to passive fireproofing achieved by the application of concrete, vermiculite
cement, intumescent coatings, or subliming compounds.
c. It describes best design practices for the prevention of Corrosion under Insulation (CUI)
and Corrosion under Fireproofing (CUF) on piping, pressure vessels, and tanks. It can also
be applied to civil/structural assets and rotating equipment.
d. The following are key subjects in CUI and CUF which are addressed in this document:
1. Design improvements, to reduce the possibility of CUI/CUF.
2. Preventative measures, including coating to protect against CUI/CUF of carbon and
low alloy steels and stress corrosion cracking, pitting, and crevice corrosion of
stainless steel.
e. Additionally information is provided on the following:
1. Corrosion mechanisms.
2. Factors affecting vulnerability of carbon and low-alloy steels to CUI/CUF.
3. Factors affecting vulnerability of stainless steels to stress corrosion cracking, pitting,
and crevice corrosion.
f. Inspection for CUI/CUF is not specifically covered in this document. It is covered by
GN 32-004, Inspection for Corrosion under Insulation and Fireproofing (CUI and CUF).
g. Corrosion under insulation which is in service subsea is outside the scope of this
document.
Subsea insulation is required to develop strong and durable adhesion to the
substrate and to have demonstrated resistance to cathodic disbondment.

2. Normative references

The following referenced documents may, to the extent specified in subsequent clauses and normative
annexes, be required for full compliance with this GP:

• For dated references, only the edition cited applies.

• For undated references, the latest edition (including any amendments) applies.

American Society for Testing and Materials (ASTM)

ASTM C871 Standard Test Methods for Chemical Analysis of Thermal Insulation
Materials for Leachable Chloride, Fluoride, Silicate and Sodium Ions.

British Standards Institute (BSI)

BS 2972 Methods of test for Inorganic thermal insulating materials.

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Design for the Prevention of Corrosion under Insulation and Fireproofing (CUI and CUF)

BP
GP 06-60 Painting of Metal Surfaces.
GIS 06-601 Painting of Metal Surfaces.
GP 52-10 Insulation.
GIS 52-101 Insulation.
GP 52-20 Passive Fire Protection (PFP).
GIS 52-201 Passive Fire Protection (PFP).

3. Terms and definitions

For the purposes of this GP, the following terms and definitions apply:

Corrosion under insulation (CUI)

Aqueous corrosion of the steel surface caused by water in the insulation, the water coming either from
the environment or forming as condensation within the insulation.

Corrosion under fireproofing (CUF)

Aqueous corrosion caused by the penetration of water, or formation of condensation, behind the
fireproofing. In essentials it is the same as CUI, and is identical to it if the fireproofing is provided by
insulation materials such as mineral wool.

Jacketing
The terms jacketing, cladding, and weatherproofing, are used throughout the petrochemical industry to
describe the protective covering that is applied over insulation. The term ‘jacketing’ is the one used in
this document.

4. Symbols and abbreviations

For the purpose of this GP, the following symbols and abbreviations apply:

CUF Corrosion under fireproofing.

CUI Corrosion under insulation.

SCC Stress corrosion cracking.

TSA Thermal spray aluminium.

UV Ultraviolet.

5. Good design practice for minimising CUI

5.1. General
a. There are a number of principles which if followed during the design stage help to
minimise the risk of CUI occurring.
1. Insulation shall only be applied where necessary for the process, for noise control, or
for fireproofing.
2. Cages shall be used where necessary to protect personnel from accidental contact
with hot surfaces. Insulating protective coatings may be used as an alternative to
cages subject to BP approval.

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Design for the Prevention of Corrosion under Insulation and Fireproofing (CUI and CUF)

Cages are low in cost and eliminate the potential for CUI. There are however
protective coatings available which also have thermal insulating properties and
these can be used to provide personnel protection without the need for cages.
Although these coatings can be difficult to apply, and need to be maintained, in
some cases their use is cost effective as they can provide both personnel protection
and corrosion protection in one application.
3. Risk posed by CUI to the item being insulated shall be assessed in accordance with
Table 1.

Table 1 - CUI risk versus operating temperature

Operating temperature CUI risk

Cycles from below ambient into or through the Severe
+50°C to +175°C (120°F to 350°F) range
+50°C to +120°C (120°F to 250°F) High
+120°C to +175°C (250°F to 350°F) Moderate
-4°C to +50°C (25°F to 120°F) Moderate
Above +175°C (350°F) Low
Below -4°C (25°F) Low

Steel corrosion is a chemical reaction between steel and water. Like all chemical
reactions, the rate at which the reaction takes place increases as the temperature
increases. In the case of CUI therefore the rate at which corrosion occurs, and thus
the speed with which insulated piping or vessels with active CUI could be losing
wall thickness, varies with the operating temperature.
When assessing CUI risk it is important to bear in mind the effects of predictable
temperature changes. For example, a pipe with a temperature >175°C (350°F)
when operating could have a higher CUI risk if it spends time at lower temperatures
during normal operations or plant shut downs. This point is very important when it
comes to piping dead legs and other areas where limited flow may allow the local
temperature to drop into a range in which the CUI risk is increased.
4. Good quality protective coating systems shall be applied to metal surfaces.
5. Insulation type selection shall be based on the assessed CUI risk.
6. Water penetration into the insulation shall be minimised by improved plant design
and the design and maintenance of insulation systems.
7. From the outset, minimisation of CUI shall be included as one of the objectives of
plant design.
b. The various aspects of these design principles are considered in more detail in the
following sections.

5.2. General design aspects

The general design of items that are to be insulated shall have minimisation of CUI as one of its
primary objectives.

5.2.1. Design simplification

As a general rule of thumb, complicated designs are difficult to insulate and shall be avoided.
Figure 1 is an example of a design layout which is difficult to insulate and
weatherproof and which therefore had from the outset a high potential for CUI.

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Design for the Prevention of Corrosion under Insulation and Fireproofing (CUI and CUF)

Figure 1 - Designs/layout which are difficult to insulate

5.2.2. Shelters from prevailing weather

If there is a high concentration of insulated pipework and equipment in a small area in a location
where precipitation is likely to be frequent, a permanent shelter shall be erected around the plant
to protect the insulated equipment and piping from the weather.
If rainfall is a regular feature of the local climate then insulated plant and
equipment enclosed in weatherproof shelters is less likely to suffer from CUI.

5.2.3. Small bore pipe and fittings

Small bore pipe and fittings can be particularly vulnerable to CUI because the wall thicknesses
required for pressure containment are small.
Increasing the thickness of carbon steel small bore piping to provide a corrosion
allowance can add a safety factor, but it does not prevent CUI and does not remove
the need to inspect for CUI. Some sites use stainless steel for thin wall small bore
piping and fittings. Refer to Annex A, A.2.5 for some considerations on the risks
posed by CUI to stainless steels.

5.2.4. Walkways
Steps and/or bridges as appropriate shall be provided to allow personnel to cross low level pipe
tracks without stepping on insulation.
Damage to insulation caused by foot traffic on insulated piping can be an entry
point for moisture and has been a major cause of CUI.

5.3. Vessels
For the purposes of this clause the term ‘vessels’ shall be understood to also include all major
types of static equipment, e.g., columns, heat exchangers, etc.
a. The design and orientation of any protrusions shall be configured to aid effective water
shedding.

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Design for the Prevention of Corrosion under Insulation and Fireproofing (CUI and CUF)

b. If possible seal welded sealing discs shall be installed on vessel nozzles and other
protrusions through the insulation.
Seal-welded plates are useful in diverting water away from critical locations. These
can be used, for example, on nozzles for vessel shells and tank roofs to divert water
away from the protrusion through the jacketing. However this requires attention to
design detail, particularly for horizontal protrusions. An example of sealing discs on
vessel nozzles is given in Figure 2.

Figure 2 - Sealing discs on vessel nozzles

2mm M
(3/32 in
IN
FULL FILLET WELD

MAX = FLANGE DIAMETER

MIN = PIPE OD + 50mm (2 in)
DEPENDS ON CLEARANCES
AVAILABLE FOR WELDING
NOZZLE TO VESSEL
DIMENSIONS OF SEALING DISC
2m /32 in
(3
m
MI )
N

2mm MIN
(3/32 in)

SEALING DISCS INSTALLED

IN DIFFERENT LOCATIONS

a. Attachments supporting ancillary items such as ladders, gantries, etc. on insulated vessels
shall be of a sufficient length such that they protrude beyond the insulation thickness by at
least 100 mm (4 in) when measured perpendicular to the surface of the insulation.
This is to aid insulation fit up and the achievement of a water tight seal.
b. Nozzles and manways shall be at least 76 mm (3 in) longer than the insulation thickness to
allow for the insulation and jacketing to be terminated and sealed independently of the
nozzle flange insulation and to give proper clearance for flange bolt withdrawal without
damaging the nozzle insulation.

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Design for the Prevention of Corrosion under Insulation and Fireproofing (CUI and CUF)

c. Bucket type insulation support rings, which could act as a moisture trap, shall be avoided.
d. If installed bucket type insulation support rings shall be drilled to allow water to escape.
e. If practicable, insulation support rings shall be attached to brackets which are seal welded
to the vessel shell in such a way that there is a gap between the support and the shell. An
example of such a support is given in Figure 3.

Figure 3 - Insulation support design

VESSEL

MIN GAP 10mm (3/8 in)

FLAT BAR

WELDED CLIP

f. Nameplates
1. Nameplates on insulated vessels shall be fully incorporated in the insulation.
2. Duplicate nameplates shall be prepared and attached as detailed in GIS 52-101.
3. Design of the duplicate nameplate and the location and method of attachment shall be
subject to BP approval.
Duplicate nameplates should exactly reproduce the layout and information content
of the original. The location and method of attachment of the duplicate to the
outside of the insulation may vary depending on the vessel layout and should be
agreed locally.

5.4. Tanks

5.4.1. Roof overhang on fixed roof tanks

On a tank which is to be insulated the tank roof shall overhang the shell by at least the shell
insulation thickness plus 50 mm (2 in).

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Design for the Prevention of Corrosion under Insulation and Fireproofing (CUI and CUF)

This is to ensure that water running off the tank roof is led away from the insulation.
If the tank roof is also insulated it helps prevent any moisture which has got into the
roof insulation from passing down into the insulation on the shell.

5.4.2. Ancillary attachments to tank shells and roofs

a. Ancillary attachments such as ladders, stairways, level controls, etc shall have a stand-off
of at least 4x the insulation thickness.
b. For roof-entry pipework supports, the pipe stand-off shall be a minimum of 150 mm (6 in)
greater than the combined thickness of the insulation on the tank shell and the insulation
thickness on the pipe.

5.4.3. Double shell insulated tanks

Double shell insulated tanks shall be designed in such a way as to prevent moisture getting into
the void space.
Double shell insulated tanks have the insulation installed in the void space between
the two shells.

5.5. Piping

5.5.1. Supports for insulated piping

Supports for insulated piping shall, if possible, make use of load bearing insulation/jacketing to
allow the pipe to be supported without the need to penetrate the insulation. If load bearing
insulation/jacketing cannot be used, the minimum length of the support shall be four times the
insulation thickness.
Pipe supports are difficult to seal and the above modification enables the insulation
jacketing to be continuous beneath the support clamp.

5.5.2. Water hoods

Hoods shall be fitted to vertical overhead pipe supports, to direct water away from potential
entry points where the support penetrates the insulation.

5.5.3. Separation distances for piping

The minimum separation between insulated pipes shall be 1½ x the sum of the insulation
thicknesses to be applied to the pipes.
For example, the minimum pipe to pipe separation of two lines the first with 100 mm
(4 in) of insulation and the second with 30 mm (1,2 in) shall be

Metric: (100+30) x 1,5 = 195 mm

English: (4+1,2) x 1,5 = 7,8 in.

5.5.4. Separation from structural steelwork

The distance between insulated piping and structural steelwork shall be a minimum of 2x the
insulation thickness.

5.5.5. Dead legs in insulated piping

Dead legs in insulated piping shall be avoided if possible.
Piping dead legs can be particularly prone to CUI. Heat leaking into dead legs in
cold piping or heat loss leading to cooling of dead legs in hot piping can bring the
effective operating temperature at the dead leg into a range in which the risk of CUI
is much higher.

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Design for the Prevention of Corrosion under Insulation and Fireproofing (CUI and CUF)

5.5.6. Steam tracing

If insulated piping is steam traced, joints in steam tracing pipework shall be located outside the
insulation jacketing. Steam tracing pipework shall enter and leave the insulation at the lowest
possible point.
Steam leaks often occur at joints in the tracing pipework. If the joints are inside the
insulation, leaking steam can rapidly saturate the insulation and promote very rapid
corrosion.

5.5.7. Electric tracing

a. Electric heat tracing shall be permanently fixed to the pipe independent of the insulation
material.
b. Penetrations of electric heat tracing tape through the jacketing shall be fitted with
appropriate cable grommets or glands to prevent moisture ingress. The penetrations shall
be positioned away from the prevailing weather and between the 4 o’clock and 8 o’clock
positions on horizontal pipe.

5.6. Valves and instruments

a. Valves and instruments such as pressure and temperature gauges in insulated piping shall
have stems of length equal to at least twice the thickness of the insulation.
b. If insulation will be frequently removed for maintenance or inspection, e.g., at relief
valves, the insulation on the pipework shall be terminated and capped at a location which
allows flange breaking without interference with the sealed cap. Insulation and jacketing of
isolation and relief valves shall be independent of pipe insulation.

5.7. Insulation

5.7.1. General
Design and installation of insulation systems shall be in accordance with:
a. GP 52-10, clause 5.
b. GIS 52-101, clauses 6, 8, and 9.
c. This clause to minimise the risk of CUI.

5.7.2. Properties of the insulation material

a. Selection of the insulation material shall be in accordance with GP 52-10, clause 5.
b. Insulation materials with a cellular structure and low moisture permeability should be used
if the CUI risk is rated as moderate or higher. Cellular glass (CG) and flexible elastomeric
foam (FEF) are examples of insulation materials having cellular structures and low
moisture vapour permeability.
c. Fibrous insulation materials, e.g., mineral wool, shall not be capable of wicking moisture.
The requirements for water uptake and retention for mineral wool insulation are given in
GIS 52-101 and are reproduced below.
Water retention (max) Test method
0,2 kg/m2 (0,04 lb/ft2) [partial immersion] BS 2972
3 3
20 kg/m (1,2 lb.ft ) [total immersion] BS 2972

d. Insulation materials shall be chemically inert and shall not contain more than the following
permitted amounts of water leachable chloride when tested in accordance with
ASTM C871.

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Design for the Prevention of Corrosion under Insulation and Fireproofing (CUI and CUF)

Mineral wool 10 mg/kg (10 ppm)

Polyisocyanurate/polyurethane 50 mg/kg (50 ppm)
Cellular glass 45 mg/kg (45 ppm)
Flexible elastomeric foam 50 mg/kg (50 ppm)

5.7.3. Insulation jacketing

a. Insulation jacketing shall be in accordance with GP 52-10 and GIS 52-101.
b. Non metallic jacketing systems may be proposed for use. In such cases the jacketing
vendors shall be approached to provide installation training to the subcontractor’s
personnel prior to work commencing.

5.7.4. Insulation system design

Design of the insulation system shall have minimisation of CUI as a primary objective. In
particular the design shall address the following:
a. Installation of insulation material in such a way as to present an external surface that is as
uniform as possible and to which jacketing can be applied and sealed.
b. If the CUI risk is rated as moderate or higher but the use of fibrous insulation material is
unavoidable, it should be installed with a stand off between the insulation and the pipe or
vessel surface.
The intention is to keep potentially wet insulation from direct contact with the
insulated surface. A stand off for the insulation material eliminates the risk of a
poultice of wet insulation fibres being held against the surface causing rapid
corrosion.
c. Jacketing shall be designed and installed without horizontal flat surfaces and in such a way
as to shed water.
d. Jacketing seams and joints
1. Longitudinal jacketing seams shall be installed between the 4 o’clock and 8 o’clock
positions in horizontal pipework and on the side away from the prevailing weather in
vertical pipework.
2. Joints in jacketing shall be installed so that water tends to run off rather than
underneath the sheets. Where appropriate the top lapped sheet shall be installed with a
rolled edge to act as a siphon break.
e. Design of the insulation system shall allow for expansion and/or contraction of insulation
material relative to the insulated surface.
Some insulation materials have coefficients of linear expansion which are
significantly different to steel. This difference needs to be allowed for with
expansion and contraction joints or cracking of the insulation material (and GRP
jacketing if installed) can be the result. Such cracks can be entry points for moisture.
f. Parts of the insulation system which need to be removed and replaced during operations,
e.g., valve boxes, shall be designed to undergo several removal/replacement cycles and
still maintain the integrity of the insulation system.
Damaged or poorly fitting boxes can be entry points for moisture.
g. Drain holes in jacketing for hot insulation systems
1. Drain holes 6 mm (1/4 in) in diameter shall be installed in rigid insulation jacketing
on insulated hot insulated piping to allow any water accumulating in the insulation to
escape.

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Design for the Prevention of Corrosion under Insulation and Fireproofing (CUI and CUF)

2. Drain holes shall be located at the bottom of vertical pipe runs and along the bottom
of horizontal piping.
A typical spacing for drain holes along the bottom of horizontal piping is 500 mm
(20 in) centres.
3. Drain holes in metal jacketing shall be countersunk so that water running along the
outside of the jacketing tends to drip off the jacketing at the hole.
Drain hole countersunk details are shown in Figure 11 of GIS 52-101. The drain
hole may need to penetrate the complete depth of the insulation thickness, especially
for hydrophobic insulation materials, to allow any water accumulated between the
insulation and pipe wall to be drained.

5.7.5. The insulation specification

a. The insulation specification shall be available to plant designers to ensure that appropriate
design features are incorporated to aid successful application and jacketing of the
insulation.
b. The insulation specification shall be sufficiently clear and prescriptive that it allows ready
identification of the insulation system to be installed on any given item.
c. The insulation specification shall, as a minimum, include the following:
1. A requirement that drawings of proposed insulation designs are issued by the
insulation subcontractor for BP approval before the commencement of any work.
2. A requirement that insulation installation work does not commence until surface
preparation and coating of the surface to be insulated has been completed and the
coating system has fully cured.
3. A requirement that the insulation materials to be used comply with GP 52-10,
GIS 52-101, this GP, and appropriate national and international standards.
4. A prohibition of use of insulation materials containing asbestos.

5.7.6. Quality control

A system shall be established for controlling the quality of the applied insulation systems. The
quality control system shall include the following:
a. A quality plan for the work prepared by the insulation subcontractor and submitted for
approval by BP to include:
1. All steps in the insulation procurement and installation process.
2. Details of personnel responsible for inspection of insulation materials and for
supervising installation work.
3. All hold and witness points.
b. Nominated inspection personnel independent of the insulation subcontractor to be utilised
to ensure the specification is followed and work is done to an acceptable standard.
c. Copies of certificates of conformance for the insulation materials obtained from the vendor
by the insulation subcontractor and subject to BP approval.
The certificates of conformance should be sufficiently detailed to show that the
insulation materials supplied meet the requirements of GP 52-10 and GIS 52-101
and comply with all applicable national or international regulations.

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Design for the Prevention of Corrosion under Insulation and Fireproofing (CUI and CUF)

5.8. Protective coatings

5.8.1. General
Coating of items which are to be insulated shall be in accordance with GP 06-60.
There is always a chance that water will get into an insulation system. In such an
eventuality the coating is all that is preventing corrosion from occurring. It is
therefore more than usually important that the ETP requirements on surface
preparation, coatings selection, environmental limits on coating work, etc are
properly followed.

5.8.2. Carbon steel

a. Carbon steel surfaces which are to be insulated shall be coated, regardless of the operating
temperature.
b. The coating system chosen shall be appropriate for the operating temperature.
Consult GP 06-60 for painting requirements. If the operating temperatures lie
outside those for which GP 06-60 recommends coating systems, suitable heat
resistant coatings should be proposed for BP approval.

5.8.3. Stainless steel

a. The coating system chosen shall meet the requirements of GP 06-60 and GIS 06-601 for
coatings on stainless steel and shall be appropriate for the operating temperature.
b. Insulated austenitic stainless steel surfaces and insulated duplex and super duplex stainless
steel surfaces shall be coated regardless of operating temperature.
Austenitic, duplex, and super duplex stainless steels are at risk from chloride
induced SCC if in contact with wet insulation. The coating is applied to protect the
stainless surface from contact with chlorides. Additionally austenitic, duplex, and
super duplex stainless steels are at risk from pitting corrosion if in contact with wet
insulation.

6. Good design practice for minimising CUF

6.1. General
a. If insulation materials are used to provide fireproofing, e.g., cellular glass, mineral wool,
etc, clause 5 shall be followed.
b. If fireproofing is provided by concrete, vermiculite cement, intumescent coating, or
subliming compound, GP 52-20 and GIS 52-201 shall be followed.
c. To minimise the potential for CUF 6.2 and 6.3 shall be applied.

6.2. Concrete and vermiculite cement

a. Structural steelwork and vessel skirts with concrete or vermiculite cement fireproofing
shall be either hot dip galvanised or painted as required by GP 06-60.
b. Fireproofing shall be applied with a top surface that is water shedding.
c. Shields shall be fitted, where feasible, at the top edges of fire proofing to lead water away
from the fireproofing/steel interface.
CUF occurs when water penetrates between fireproofing and the substrate steel. As
the steel corrodes, corrosion products, which occupy a much greater volume then
the uncorroded steel, can cause the fireproofing to spall. In colder environments this
can be exacerbated by the expansion which occurs as the water freezes.

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Design for the Prevention of Corrosion under Insulation and Fireproofing (CUI and CUF)

d. As per GIS 52-201, potable water shall be used in mixing concrete and cement
fireproofing.
The use of non-potable water and poor mixing may lead to reduced durability of
concrete and cementitious fireproofing. The use of water containing high levels of
chloride can lead to accelerated corrosion beneath concrete and cementitious
fireproofing and the resultant corrosion products may cause cracking and spalling
of the fireproofing.

6.3. Intumescent coatings and subliming compounds

a. Surfaces which are fireproofed with intumescent coatings or subliming compounds shall be
painted as required by GP 06-60.
b. Paint products and details of surface preparation and film thicknesses shall be approved by
the manufacturer of the fireproofing.
Coatings which provide fireproofing by intumescing or subliming develop good
adhesion to properly painted steel. The risk of CUF with these coatings is therefore
much reduced. It is important however that the painting work carried out prior to
the application of the fireproofing is done to a high standard and that the coatings
are allowed to properly cure before the fireproofing is applied. Additionally the
fireproofing may require overcoating as described in GP 06-20 to protect it from
exposure to UV light, which can be damaging in the long term. The fireproofing
manufacturer shall be consulted for their recommendations on overcoating.

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Design for the Prevention of Corrosion under Insulation and Fireproofing (CUI and CUF)

Annex A
(Informative)
Technical information on CUI/CUF

This section provides technical information to enhance the understanding of CUI/CUF.

A.1 Corrosion mechanism - Key factors

a. Key factors affecting the corrosion of carbon and low alloy steels are given below:
1. Water phase.
The presence of a liquid water phase in contact with the steel under insulation is
necessary for corrosion to occur. In some equipment operating at elevated
temperatures, semi-solid salts can sometimes form on hot surfaces and can also
cause corrosion even though liquid water may not be present.
2. Oxygen.
Oxygen from the air dissolves in water and provides a primary driving force for the
electrochemical corrosion reaction.
3. Uncoated surfaces.
Corrosion of carbon steel and low alloy steels can readily occur if there is no
protection by a coating.
4. Temperature.
Corrosion of carbon steel and low alloy steels increases with temperature, as long
as the surface remains wet.
b. Stainless steels can also be affected by corrosion in certain conditions.
1. In the presence of chlorides austenitic, duplex, and super duplex stainless steels can
be vulnerable to SCC, and austenitic stainless steels can suffer from pitting corrosion.
2. Stainless steels are thus also at risk from CUI/CUF. See A.2.5 for a more detailed
discussion of the threat posed by CUI to stainless steels.

A.2 Detailed factors affecting vulnerability to CUI

The following factors should be considered when determining where to inspect for CUI. For
more details of inspection requirements see GP 32-42 and GN 32-004.
Specific locations to inspect for CUI are difficult to determine. CUI in particular is
often found in places where it was not predicted to be, yet is absent from where it
might be expected to be from a consideration of all of the pertinent factors.

A.2.1 Environmental factors

A.2.1.1 Water ingress from precipitation and other sources

Poor design/installation of insulation and inadequate sealing of jacketing can lead to water
ingress the extent of which can be influenced by:
a. Condensation (depending on relationship between substrate and ambient temperatures).
b. Frequency of precipitation.
c. Proximity to cooling tower spray/vapour.

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d. Periodic testing of fire water spray systems.

e. Steam venting nearby.
f. Steam tracing leaks.
g. Proximity to the sea.

A.2.1.2 Contaminants
The presence of contaminants dissolved in the water phase and derived from the external
environment can increase corrosivity. Examples include:
a. Process plant atmospheres and spills (CO, CO2, H2S, SO2 and SO3 vapours, etc.).
b. Chlorides.
Chlorides are present at up to 100 ppm in rainwater. At around 200 km (125 mi)
from the coast they are in the atmosphere generally at around 10 ppm.

A.2.1.3 Operating temperature

a. As previously stated, the rate at which CUI proceeds varies with temperature. As the
temperature increases past the boiling point of water however there comes a point at which
liquid water evaporates and is driven off by the heat of the substrate. From this point on the
rate at which CUI proceeds starts to decrease with increasing temperature. The overall risk
posed by CUI is therefore greatest within a particular temperature range.
b. According to API 570, piping and equipment at risk from CUI is that operating in the
temperature range -4°C to 120°C (25°F to 250°F). However, different industry documents
give risk temperature ranges that differ from that in API 570. Differences arise because
reference is made in some cases to the actual metal temperature; in others to the process
temperature, in yet others a wider temperature range is quoted to introduce a margin of
safety. For information, some examples of quoted temperature ranges in which CUI is
considered to be a significant risk in other documents are as follows:
1. –12°C to 175°C (10°F to 350°F) for carbon and low alloy steels and 60°C to 205°C
(140°F to 400°F) for austenitic stainless steels – API 510 Pressure Vessel Inspection
Code; 9th Edition.
2. 100°C to 120°C (212°F to 250°F) - Most aggressive range for CUI .according to API
RP 571.
3. –10°C to 175°C (14°F to 350°F), and most aggressive 50°C to 95°C (120°F to
200°F). API Pub 581, Appendix V, Technical Module 9.
4. –5°C to 200°C (23°F to 390°F), and most aggressive 60°C to 120°C (140°F to
250°F). BP Sunbury Report No. S/UTG/309/01.
c. Operators may also choose to adjust the defined critical temperature range for their plant to
ensure that adequate inspection is planned for ancillary components or particular pieces of
plant and equipment which could be exposed to temperatures within the critical range for
CUI, even when the main item operates outside the range, e.g., at cooling vanes, stiffening
rings, flanges, etc. on vessels, and branches and pipe supports on piping runs.
d. BP’s approach has been to take the range quoted in API 570 as a basis and to further define
the risk posed by CUI as shown in Table 1 in clause 5 of this GP.
e. Items that are operating outside the critical temperature range may also be at increased risk
of CUI if they are in intermittent service, for example:
1. Cool branches in hot piping systems.
A given hot piping system may be operating above the CUI temperature range;
however, branches where flow is restricted are cooler and may be in the vulnerable

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temperature range. Examples include dead-legs, relief valve piping, by-pass piping,
etc. In addition, pipe supports which penetrate the insulation may form a cool path
for the adjacent pipe, thereby bringing it into the vulnerable temperature range,
even if the nominal operating temperature of the pipe is outside the established
limits. This can also be an issue with vessel supports and insulation support rings on
equipment in which poor thermal efficiency results in excessive heat transfer.
2. Warm branches on cold systems.
In cold systems operating below the –4°C (25°F) nominal limit for CUI conditions
system geometries such as those described for hot piping above can result in
sections that are either permanently, or intermittently, sitting at temperatures above
0°C (32°F). This can lead to significant CUI, if there is water in the insulation
3. Cyclic/intermittent service.
Items in cyclic or intermittent service and which operate for part of the time at
temperatures in the critical temperature zone are at risk of CUI. This risk can be
severe if the lower operating temperature in the cycle is below ambient and the
upper temperature is 120°C (250°F) or above. If in such cases condensation can
form in the insulation at sub ambient temperatures a continually renewed source of
water is available to cause rapid CUI as the item heats up during the temperature
cycle.
f. SCC of austenitic stainless steels is also a temperature dependent phenomenon. According
to API 570 the critical temperature range is 65°C to 204°C (150°F to 400°F), though BP’s
view, along with other operators, is that 50°C (120°F) is a safer minimum to use. Pitting
corrosion in austenitic stainless steel is also a risk in insulated service, but here the risk
varies more with the alloy used than it does with temperature.

A.2.1.4 Galvanic effects

Corrosion of carbon steel can be increased if it is coupled to a more noble metal and both are
exposed to the same continuous water phase. CUI rates can therefore be accelerated if dissimilar
metals are in intimate contact beneath wet insulation.

A.2.1.5 Vibration
Vibration or movement, from wind or any other disturbance, can result in damage to seals on
jacketing and/or produce gaps between adjacent sections of insulating material, which then
allows water ingress and CUI to commence.

A.2.2 Coating issues

A.2.2.1 Presence or absence of a coating and coating type

Application of a coating (metallic or non-metallic) is one of the most important measures that
can be taken to protect against CUI.
If there is no protective coating, the insulated surface is vulnerable to corrosion
immediately after it comes into contact with water.
a. For protection to be effective, the entire insulated surface needs to be coated, including
field welds. The correct choice of coating type is also critical to the successful protection
of the substrate.
The coating type is critical because conditions existing inside wet insulation,
particularly wet insulation which is hot, are very destructive to coatings. For this
reason high quality immersion grade coatings are required for optimum corrosion
protection. More details on the types of coatings are given in GP 06-60 and
GIS 06-601.

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b. When assessing the risk posed by CUI to existing insulated plant and equipment it is
necessary to establish whether or not the steel surface was coated prior to application of the
insulation, and whether or not any coating included the field welds. If the steel was coated,
the coating type and suitability for the operating temperature range needs to be established.
c. The use of TSA coatings for the protection of surfaces which are to be insulated has been
increasing in recent years and experience to date has generally been positive. However
there have been numerous instances of premature failure, the reasons for which are not
always well understood, though it is known that the quality of the application plays an
important role in ensuring good performance.
Selection of a protective coating for thermally insulated plant and equipment in
intermittent high temperature service is a particularly difficult problem. At one time,
inorganic zinc silicates were thought to be a good solution, but experience has
shown that they do not provide adequate protection without a sealer coat.
d. Thermally insulated stainless steels also require protection from CUI by the application of
protective coatings appropriate for the applicable temperature range.

A.2.2.2 Quality control during coating application

Maintenance of good standards of surface preparation and coating application is always
important in ensuring good protective performance from any given coating system. They are
particularly important if the coating is to provide protection in the very aggressive conditions
which exist under wet insulation.

A.2.2.3 Coating age/condition

Even properly selected and applied paint coatings deteriorate with age.
a. Typically an organic coating would not be expected to continue to provide effective
protection beyond about 10 years.
b. Experience to date with TSA coatings suggests that when well applied and sealed they
should be capable of giving protection for longer periods, but unexplained failures have
occurred and periodic inspection is necessary to ensure that protection is being maintained.

A.2.3 Insulation system factors

A.2.3.1 Insulation material type

a. Use of insulation types that can absorb and retain water increase the risk of CUI occurring.
b. Insulation materials that can release corrosive chemicals when in contact with water or
affected by temperature likewise increase the risk of damage.
c. Insulation materials which are impervious to moisture and which are chemically inert are
the best choice for piping and equipment operating in the critical temperature range.

A.2.3.2 Jacketing
a. Non-metallic jacketing materials are increasingly becoming available as alternatives to
traditional metal sheeting. Each system has its strengths and weaknesses and details of the
insulation design need to be adjusted accordingly. A brief discussion of the points to
consider is given below.
1. Metal jacketing
a) Metal jacketing is applied as thin sheets in sections. Common jacketing
materials include galvanized steel, aluminized steel, aluzinc (aluminium/zinc
alloy) coated steel, aluminium, and austenitic stainless steel.

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b) Metal sheeting is the traditional jacketing material for insulation. Among its
strengths are long service life and familiarity with its use, which means there are
plenty of experienced contractors and skilled personnel available.
c) Its main weakness is the difficulty of effective sealing against moisture ingress,
and the vulnerability of the joints to damage in service (it is particularly
vulnerable to damage by foot traffic). When using metal jacketing, therefore, it
is important to pay attention to draining of the insulation system as a whole and
to provide a means of escape for moisture which has entered through the
jacketing.
2. Non metallic jacketing
The recognised weaknesses of sheet metal jacketing for insulation has led to the
development of an increasingly wide range of non-metallic alternatives. Non-metallic
jacketing falls into two main classes:
a) Preformed
Preformed non-metallic jacketing is supplied and applied in sheet form and in
this regard is analogous to metal sheeting. The sheets are generally made from
chlorosulphonated polyethylene (Hypalon type), with or without woven glass
fibre reinforcement. The strengths of this type of system include its ability to
form water tight joint seals (using appropriate adhesives) and its resilience and
resistance to damage once in service. It is much less prone to damage from foot
traffic than metal jacketing, for example. It is also easier to remove and reinstate,
e.g., to allow inspection.
Its weaknesses include difficulties with application and sealing around complex
shapes (cf. metal sheeting) and a lack of contractor experience with its
installation, though this latter is being addressed as it is used more widely.
b) Form in place
This type of jacketing is glass fibre reinforced epoxy or polyester applied to the
outside of the insulation in an uncured state. The epoxy or polyester then cures
in place to form a rigid jacket.
Epoxy jacketing has been used for some time but its application is a complex
factory based procedure and the epoxy takes time to cure. This has restricted its
use to specialist areas such as long straight pipe runs, liquefied natural gas
loading lines for example, where factory based application is viable. It is not
considered further here.
Polyester jacketing which cures when exposed to UV light is the most recent
development in this area. It can be easily formed in the uncured state but cures
rapidly when exposed to ambient UV light (curing can be accelerated using UV
lamps if necessary).
The strengths of the UV curing polyester type of jacketing are its ease of sealing
due to its good adhesion to itself (and to metal jacketing at overlaps), its ability
to conform to complex shapes while being applied, its resistance to mechanical
damage, and its ease of removal and reinstatement once cured.
Contractor experience with its installation is a current weakness but this is again
being addressed as it is used more widely. One of its strengths, rigidity, is
however also a source of potential weakness. When using UV cured polyester it
is important to take full account of the likely movement of the insulated pipe or
equipment caused by thermal expansion or contraction. This movement needs to
be allowed for with expansion/contraction joints as appropriate or it could cause
the jacketing to crack, forming a leak path for water.

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b. Non-metallic jacketing materials need to be periodically inspected to ensure that the effects
of ageing are not compromising their fitness for purpose.

A.2.4 Additional factors affecting the location of CUI (used to assess risk)
The following areas are most at risk from CUI and should be prioritised for inspection.
a. Low points
Water drains by gravity to low points where it may be trapped and collect.
b. Small bore piping
Small bore piping (<DN 50 (NPS 2)) is particularly vulnerable due primarily to its reduced
wall thickness compared to larger diameter piping. It is also often installed in complex
geometries that are difficult to seal and, due to its relative lack of stiffness, can be prone to
vibration.
c. Areas adjacent to insulation protrusions
The inherent design of certain components makes the insulation difficult to seal. For
example:
1. Lifting lugs.
2. Pipe supports, hangers, and trunnions.
3. Vents and drains.
4. Valves/fittings.
5. Dead legs.
6. Small diameter/short nozzles on vessels.
7. Thermocouple and instrument locations.
8. Inspection ports on vessels.
9. Other complex geometric shapes associated with ancillary attachments.
d. Design features that can trap water
For example:
1. Vessel/skirt areas.
2. Vacuum support rings and insulation support rings.
3. In hotter areas of equipment, external rings may act as a cooling fin and cause
condensation resulting in corrosion of the shell under the ring. Similarly on
refrigerated equipment, support steelwork can act as a heat ingress route thereby
lifting the steel temperature and allowing corrosion to occur.
4. Pipe support hangers welded directly to the pipe.
e. Special locations
1. Insulated buried pipelines.
2. Steam tracing leaks.
3. Heat traced items in which there is water in the insulation.

A.2.5 Stainless steels - Key factors in determining the CUI risk

a. Stainless steels are resistant to general corrosion under wet insulation and some operators
have therefore used stainless steel to replace carbon steel. However, in the presence of
chlorides they can be susceptible to pitting and SCC under certain conditions.

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1. Pitting
a) Pitting corrosion is affected by both temperature and chloride content. Type 304
SS and 316 SS may suffer pitting above ambient temperature (about 25°C to
35°C (77°F to 95°F)) in the presence of chlorides.
b) High alloy duplex 2507, super duplex stainless steel, and 254SMo austenitic
steel suffer pitting above about 80°C (176°F) and 2205 duplex stainless steel
above about 50°C (120°F).
2. SCC
SCC susceptibility is strongly dependent on temperature, and on chloride
concentration in contact with the material. Austenitic stainless steels are particularly
sensitive to SCC above 65°C (150°F), but may also be susceptible at lower
temperatures.
b. These modes of potential failure should be considered when evaluating the use of stainless
steel in chloride containing environments.

A.3 Factors instrumental in promoting corrosion underneath fireproofing

a. Poor fireproofing design and finishing resulting in water traps

Fireproofing needs to be installed to be water shedding. If appropriate, shields may be
installed which lead water away from fireproofing terminations.
b. Absence of a protective coating from the substrate
Substrates to which fireproofing is to be applied need to be coated for corrosion protection.
If intumescent or subliming fireproofing compounds are to be used, the fireproofing
manufacturer needs to provide a list of coatings approved for use with their material.
c. Ineffective coating
Poor quality or poorly applied coatings can break down rapidly beneath fireproofing
allowing corrosion to begin.
Inorganic zinc coatings used on their own are not effective coatings under
fireproofing. Zinc is amphoteric and can be attacked in the alkaline conditions that
exist beneath concrete and cementitious fireproofing.
d. Poor quality materials and material preparation.

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Bibliography

General documents covering various aspects of CUI

[1] ASTM STP 880, Corrosion of Metals under Thermal Insulation. Editors, W.I.Pollock & J.M.Barnhart.
ASTM 1985.
th
[2] API 510, Pressure Vessel Inspection Code; 9 Edition.

[3] API 570, Piping Inspection Code.

[4] API RP 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry.

[5] API Pub 581, Risk-based Inspection Base Resource Document; Appendix V, Technical Module 9.

[6] Corrosion under Wet Insulation - Editor W.I.Pollock NACE Symposium Corrosion 1989.

[7] Minutes of EFC WP15 Corrosion in the Refinery Industry 30 September 2003.

[8] NACE RP0198, The Control of Corrosion under Thermal Insulation and Fireproofing Materials - A
Systems Approach.

[9] Corrosion Under Insulation - D.Fairhurst, BP E&P Report No. S/UTG/309/01, December 2001.

[10] Corrosion under Thermal Insulation and Fireproofing - An Overview, J.F. Delahunt, NACE Corrosion
2003 Paper 03022.

[11] IOM3 Corrosion under Insulation Seminar - January 2004, UK.

Coatings
[12] NACE Publication 6H189, A State of the Art Report on Protective Coatings for Carbon Steel and
Stainless Steel Surfaces under Thermal Insulation and Cementitious Fireproofing 1989.

[13] Corrosion of Underground Insulated Pipelines - J.F. Delahunt, Journal of Protective Coatings and
Lining, January 1986.

[14] US Navy Experience with High Temperature Corrosion of Lagged Piping System Components Using
Sprayed Aluminium Coatings - R. Parks & R.A. Kogler Materials Performance July 1990.

[15] Thermal Spray Aluminium, Past, Present and Future - T. Rosbrook, M.A.M. Swidzinski & C.J.
Houghton NACE Corrosion 1999 Paper 616.

Insulation
[16] BP RP 52-1, Thermal Insulation.

[17] Large Diameter Wire, High Deposition Metalizing: A Competitive Edge for Long-Life Coating,
M.S.Wixom NACE Corrosion 1998 Paper 498.

[18] ASTM C929, Standard Practice for Handling, Transporting, Shipping, Storage, Receiving and
Application of Thermal Insulation Materials for Use in Contact with Austenitic Stainless Steel.

[19] A NM-I-00-E, Non-Metallic Materials—Insulation—Engineering Specification.

[20] A NM-I-00-G, Non-Metallic Materials—Insulation—Guide.

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[21] A NM-I-HOT-C, Non-Metallic Materials—Insulation—Hot Insulation—Specification.

Coating and insulation

[22] Corrosion under Insulation, New Approaches to Coating & Insulating Materials, M.J. Mitchell, NACE
Corrosion 2003 Paper 03016.

Stainless steel
[23] Issues Surrounding Insulated Austenitic SS and Cracking under Thermal Insulation - Refinery
Experiences in Tropical Environments, J.P. Richert, NACE 2003 Paper 03026.

BP Group Practices and Guidance Notes

[24] GP 32-42, In Service Inspection and Testing of Piping Systems.

[25] GN 32-004, Inspection for Corrosion under Insulation and Fireproofing (CUI and CUF).

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