Average facilities waste over 10% of their maintenance budget on identifying, mitigating, and managing Corrosion Under Insulation (CUI). Additionally, industry leaders estimate that 40-60% of pipe maintenance costs are the result of CUI. Facilities that continually experience unexpected failures due to CUI are forced to spend additional time and money fixing the issues caused by CUI instead of investing that time and money initiatives that prevent CUI from happening in the first place. CUI costs can be reduced by properly identifying and inspecting the areas of an asset that are suspectable and mitigating the effects of CUI.

To reduce CUI costs, facilities should:

    • Identify susceptible corrosion locations and prioritize assets based on their level of susceptibility
    • Implement a minimally invasive inspection screening process
    • Mitigate effects of CUI
    • Manage field documentation and evergreening systems

Identify Susceptible Corrosion Locations

Facilities need to identify their susceptible corrosion locations and prioritize assets based on their level of susceptibility. To begin, facilities should first evaluate the current state of their program:

    • Do you have a prioritized list of assets based on CUI susceptibility?
    • Have you implemented a minimally invasive inspection plan?
    • Do you have a mitigation program specifically for CUI?
    • Have you collected consistent and repeatable data? If so, is it being held in either your IDMS system or CMMS system?

Once a facility identifies its current state, it can begin identifying its susceptible corrosion locations using the API 583 guidelines:

While the guidelines provide a good starting point for calculating the likelihood of CUI occurring rating, facilities will benefit from a more comprehensive and optimized strategy. In addition to evaluating the API 583 areas, PinnacleART assesses the following areas to rank assets based on their susceptibility:

Implement Minimally Invasive Inspection Screening

Invasive inspection tasks can be very costly for a facility and should only be used after susceptible areas have been screened. Each inspection strategy has its own advantages and disadvantages and should be selected based on the specifics of the facility, For example, Pulsed Eddy Current (PEC) may be a great screening tool to use if you are not wanting to remove your asset’s insulation, but may not be as effective for facilities needing full access to their assets.

Mitigate CUI

Mitigation tactics are circumstantial and are dependent on a variety of factors such as the facility’s pain points and bad actors. When facilities are evaluating which mitigation tactic they should use, they should evaluate which circuits have the greatest return on investment potential to help determine the criticality of the asset.

Additional mitigation tactics include:

    • Better training for site personnel to decrease foot traffic which can cause damage to the jacketing of an asset and eventually cause CUI
    • Removing as much insulation as possible
    • Replacing insulation with an insulative coating
    • Installing buffer spikes

Watch the Full Recording & Download the E-Book

Dive into the information listed above in greater detail and access
example deliverables by watching the full event recording here.

View Other Cost Reduction Topics

To access the e-book, fill out the form below.

Have any questions for the presenters?