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Modelling of Corrosion Under Insulation in Oil Sands

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According to the Petroleum Safety Authority (PSA) in Norway, corrosion under insulation (CUI) caused about 50% of all hydrocarbon leaks at onshore plants. In the case of Alberta’s oil sands, CUI has also been observed in thermal operations in above ground assets carrying emulsions, steam, hot water and/or warm water that are externally insulated to ensure safe and energy efficient operations. CUI has also been observed in oil sands mining operations in various piping systems and in tanks and vessels on structural supports and insulated support rings that are frequently in contact with soil or standing groundwater.

Product Number: 51323-19209-SG
Author: Andrea Marciales, Martin Huard, Kofi Freeman Adane
Publication Date: 2023
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Corrosion Under Insulation (CUI) in Alberta’s oil sands industry has been observed in above ground assets in thermal operations carrying emulsion, steam, hot water and/or warm water that are externally insulated to ensure safe and energy efficient operations. CUI has also been observed in oil sands mining operations in various piping systems, tanks and/or vessels, and structural supports including insulated support rings, which are frequently in contact with soil or standing groundwater. Furthermore, CUI can go easily unnoticed over prolonged periods of time, only detected after an insulation or pressure containment failure occurs. Most of the CUI occurrences are usually found at the 6 o’clock position or lowest collecting point. Therefore, it is important to identify suitable methodologies to predict CUI for Alberta’s oil sands industry. This work, carried out within the Materials and Reliability in Oil Sands (MARIOS) consortium at InnoTech Alberta, explores existing methodologies for CUI prediction reported in the public domain, and provides a preliminary validation of findings using field data collected by the producer members of the MARIOS consortium.

Corrosion Under Insulation (CUI) in Alberta’s oil sands industry has been observed in above ground assets in thermal operations carrying emulsion, steam, hot water and/or warm water that are externally insulated to ensure safe and energy efficient operations. CUI has also been observed in oil sands mining operations in various piping systems, tanks and/or vessels, and structural supports including insulated support rings, which are frequently in contact with soil or standing groundwater. Furthermore, CUI can go easily unnoticed over prolonged periods of time, only detected after an insulation or pressure containment failure occurs. Most of the CUI occurrences are usually found at the 6 o’clock position or lowest collecting point. Therefore, it is important to identify suitable methodologies to predict CUI for Alberta’s oil sands industry. This work, carried out within the Materials and Reliability in Oil Sands (MARIOS) consortium at InnoTech Alberta, explores existing methodologies for CUI prediction reported in the public domain, and provides a preliminary validation of findings using field data collected by the producer members of the MARIOS consortium.

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03029 STRATEGIES TO PREVENT CORROSION UNDER INSULATION IN PETROCHEMICAL INDUSTRY PIPING

Product Number: 51300-03029-SG
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Author: Brian J. Fitzgerald, Peter Lazar III, Robert M Kay, Stefan Winnik
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Corrosion Under Insulation (CUI) in pipingc systems consumes a significant percent of the maintenance budget in the petrochemical industry. Prevention of CUI by the use of (1) thermal spray aluminum, (2) stainless steel pipe, (3) expanded metal cages for personnel protection instead of insulation and (4) aluminum foil wrapping are discussed in terms of long term protection, installed cost and Life cycle cost.
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Corrosion Under Insulation And Atmospheric Corrosion In The Refinery Industry. An Accurate Approach To Estimate Corrosion Growth Rates, A Texas Refinery Case Study

Product Number: 51322-17751-SG
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External corrosion in uninsulated pipelines is normally able to be prevented by cathodic protection (CP). Generally, external corrosion on buried pipelines cannot occur if CP current is getting onto the pipe. CP is an electrochemical means of corrosion control in which the oxidation reaction in a galvanic cell is concentrated at the anode and suppresses corrosion of the cathode (pipe) in the same cell. For instance, to make a pipeline a cathode, an anode is attached to it.
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Performance of Three Types of Coatings in a Simulated Corrosion Under Insulation Condition

Product Number: 51317--9296-SG
ISBN: 9296 2017 CP
Author: Junki Miyashita
Publication Date: 2017
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This paper evaluates the resistances to CUI of three types of coatings under severe CUI conditions using a vertical pipe test method. Certain possible improvements in the test method are also discussed.
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