CUI is a global problem in the chemical industry. This insidious failure mechanism can lead to expensive repairs and safety risks if not managed correctly. Fortunately, companies like Sitech, with innovative techniques and strategic approaches, can combat the cost of CUI without safety risks. “Corrosion under insulation is atmospheric corrosion of insulated metal pipes and vessels that come into contact with water or moisture”, explains Peter Janssen, Corrosion & Materials expert at Sitech. “This problem is exacerbated by factors such as temperature changes, salts in the environment and failure of coating systems.”
Key influencing factors
At Sitech, a leading service provider in the chemical process industry, pipes and vessels operating under CUI-sensitive conditions are monitored preventively. Janssen emphasizes that temperatures between -4 and 175 degrees Celsius and the presence of salts (for example: chlorides) significantly increase the risk of corrosion. “For example, carbon steel can corrode at rates of 0.3 to 1.0 millimeters per year within this temperature range”, he says.
Innovative monitoring and inspection
One of the most effective ways to manage CUI is to use innovative inspection and monitoring techniques. Sitech uses sensors to continuously monitor the condition of insulated pipes. Peter Bosmans, Customer Solutions Manager at Sitech, explains: “The sensors can, for example, detect moisture and signal where water is entering, allowing us to intervene quickly before serious damage occurs.”
Bosmans also points out the use of a dashboard for real-time monitoring, which helps to make reliable risk analyses and plan long-term maintenance. “With this technology we can reduce the annual costs of CUI at the Chemelot site in Geleen, where a total of 15 million euros is spent per year, to 6 million euros in the future,” he says.
Strategic risk-driven approach
Sitech takes a risk-driven approach to managing CUI, starting with a thorough inventory and risk ranking of assets. This approach helps prioritize maintenance and repairs based on the likelihood and consequence of failure. “We focus on factors such as the lifespan of the coating and that of the corrosion allowance on the material,” Janssen explains. “This helps us determine how long a pipe can remain in operation without a leak occurring.”
Prevention and maintenance
Prevention is the best way to control CUI. Regular inspections and a good maintenance plan are crucial. “Incorrect or poorly applied insulation contributes to CUI,” Janssen warns. “It is important to regularly check whether the insulation plating is intact and has a good waterproof finish.”
Cost savings without compromise
Avoiding both over-inspection and under-inspection is essential to save costs without taking safety risks. Bosmans emphasizes the importance of using sensor technology to find this balance. “Over-inspection leads to unnecessary costs, while insufficient inspection can result in leaks and have serious consequences,” he explains. “Sensors can help us to find this balance and save up to 60 percent on costs.”
Conclusion
Through a combination of innovative technologies and a strategic, risk-driven approach, Sitech can significantly reduce the cost of CUI without compromising safety. Awareness of CUI and commitment to regular inspections and maintenance are critical to maintaining safe and efficient chemical processes. As Janssen says: “CUI is a simple failure mechanism, but a silent killer that can have serious consequences. Awareness and the correct measures are essential.”
Would you like to know more about this approach of Sitech? If so, please contact us at info@sitech.nl
