Published on 14-Jul-2025

Industry Embraces Advanced Strategies to Combat Corrosion Under Insulation

Industry Embraces Advanced Strategies to Combat Corrosion Under Insulation

Sources - @Inspenet

The chemical industry is stepping up its efforts to manage one of the most concealed yet destructive threats to infrastructure integrity—Corrosion Under Insulation (CUI). Highlighting the urgency of adopting advanced mitigation methods, Dr. G. H. Thanki, Principal Corrosion Management Consultant at CorroSafe Consultant, emphasizes the growing role of technology and risk-based strategies in addressing this persistent challenge.

“Identifying CUI without removing insulation has historically been a significant hurdle, necessitating a shift towards innovative non-destructive testing techniques,” said Dr. Thanki in his expert column published by Indian Chemical News.

CUI occurs when moisture infiltrates insulation systems, causing corrosion in underlying piping or metal surfaces—particularly at operational temperatures between –4 °C and 175 °C. Often undetected until critical damage is done, CUI remains a major cause of unplanned shutdowns and asset failures in process industries.

In response, plants are now turning to advanced Non-Destructive Testing (NDT) methods such as Pulsed Eddy Current (PEC), Guided Wave Ultrasonic Testing (GWUT), and Neutron Backscatter. These techniques allow technicians to assess corrosion levels without dismantling insulation, greatly improving inspection efficiency and safety.

Furthermore, Dr. Thanki advocates for the use of Risk-Based Inspection (RBI) frameworks to prioritize assets based on their susceptibility to CUI. Such strategies integrate operational history, insulation materials, temperature ranges, and corrosion records to guide inspection frequency and maintenance schedules.

Modern preventive approaches also include the adoption of hydrophobic insulation materials, sealed jacketing systems, and moisture-resistant coatings like thermal spray aluminium and epoxy linings. Together, these efforts reduce water ingress and prolong asset life.

Looking ahead, the industry is exploring digital twin technologies, predictive analytics, and smart insulation embedded with sensors to anticipate corrosion before it escalates. These innovations are expected to transform CUI management from a reactive to a proactive discipline.

The shift toward advanced diagnostics, coupled with materials science and data integration, signals a significant evolution in plant reliability and safety management across the chemical sector.

Reference: https://www.indianchemicalnews.com/opinion/advanced-strategies-for-corrosion-under-insulation-management-in-chemical-industry-dr-g-h-thanki-principal-corrosion-management-consultant-corrosafe-consultant-26748

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