COURSE OVERVIEW:

Corrosion Under Insulation (CUI) remains one of the most significant and costly challenges for the integrity of piping and pressure vessels in the process industries. This course provides a comprehensive deep dive into the mechanisms that drive this hidden threat, focusing on how moisture becomes trapped within insulation systems to create a corrosive micro-environment. Participants will analyze the specific temperature ranges and environmental conditions that accelerate metal loss, particularly in carbon and stainless-steel assets.

The scope of this training includes the latest industry methodologies for risk screening and the development of robust CUI management programs. We will examine the selection of high-performance coating systems, the design of moisture-resistant insulation cladding, and the application of Risk-Based Inspection (RBI) principles to prioritize high-risk areas. The course addresses the limitations of traditional inspection and highlights modern non-destructive testing technologies capable of detecting CUI without the need for full insulation removal.

Coverage also extends to maintenance strategies and the implementation of best practices for design and installation to prevent water ingress from the outset. Attendees will explore the lifecycle management of insulated assets, from initial material selection to end-of-life assessment. By the end of this course, participants will be able to implement an effective control framework that minimizes the likelihood of catastrophic leaks and extends the operational reliability of insulated equipment.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Identify the fundamental chemical and physical mechanisms that cause Corrosion Under Insulation.
• Distinguish between CUI in carbon steels and Chloride Stress Corrosion Cracking (ESCC) in stainless steels.
• Analyze the critical temperature ranges where CUI activity is most aggressive and unpredictable.
• Evaluate the performance of various insulation materials regarding moisture retention and leachable halides.
• Apply risk screening criteria to prioritize piping circuits and vessels for focused inspection.
• Design effective weather stripping and cladding systems to prevent water ingress into the insulation.
• Select appropriate protective coating systems specifically formulated for under-insulation service.
• Compare different Non-Destructive Testing (NDT) methods for detecting CUI through insulation.
• Develop a comprehensive CUI management plan aligned with API 583 and other industry standards.
• Implement best practices for the installation and sealing of insulation at supports and penetrations.
• Calculate the remaining life of assets affected by localized CUI pitting and wall loss.
• Recommend repair and mitigation strategies for damaged assets found during CUI inspections.

TARGET AUDIENCE:

This course is designed for Integrity Engineers, Inspection Engineers, Asset Managers, Maintenance Supervisors, Coating and Insulation Specialists, and Process Plant Operators responsible for the reliability of insulated piping and equipment.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.