InnovateCUI | Data-driven monitoring of corrosion under insulation

Detecting corrosion risks before damage occurs

Corrosion under insulation (CUI) remains one of the most persistent and costly challenges in industrial installations. InnovateCUI evaluates advanced sensor technologies for the early detection of moisture beneath insulation while improving the understanding of how protective coatings degrade over time. The project helps industrial companies optimise inspection strategies, better estimate coating lifetime and move towards condition-based maintenance.
 

Target group

The project is relevant for:

• Petrochemical and chemical companies
• Oil and gas operators
• Energy and power generation facilities
• Port and maritime infrastructure operators
• Industrial asset owners and maintenance organisations
• Inspection and integrity management specialists
• Coating suppliers

Context

Corrosion under insulation develops out of sight, making it one of the most difficult degradation mechanisms to detect. Moisture trapped beneath insulation can remain unnoticed for years before causing leaks, failures or costly repairs.

Most inspection programmes rely on periodic inspections that provide only a snapshot of an asset's condition. At the same time, new sensor technologies promise earlier detection of moisture and corrosion risks, but their performance under realistic industrial conditions has not yet been independently validated.

Another challenge concerns the long-term behaviour of protective coatings. Although these coatings play a crucial role in preventing CUI, little independent information is available on how they degrade under different operating conditions or how this affects their lifetime.

©Sirris

Objectives & results

InnovateCUI evaluates technologies that help industrial companies detect corrosion risks earlier and better understand the long-term performance of corrosion protection systems.

The project aims to:

• Evaluate different sensor technologies for detecting moisture beneath insulation 
• Assess their performance under realistic industrial conditions 
• Investigate how protective coatings degrade over time under different exposure conditions 
• Improve test and analysis methodologies for coating evaluation 
• Link sensor measurements with coating degradation to support better integrity assessments 
• Provide practical guidance for risk-based inspection and maintenance
   

Key results:

• Independent validation of commercially available CUI sensor technologies 
• A unique dataset generated through more than 18 months of testing 
• Improved understanding of the strengths and limitations of different sensing technologies 
• New knowledge on the degradation mechanisms and lifetime of CUI protective coatings 
• Improved test guidelines that can contribute to future standards like ISO 19277
• Practical recommendations for integrating sensor data and coating performance into Risk-Based Inspection (RBI) programmes 
   

These results help industrial asset owners move from periodic inspections towards condition-based and risk-driven maintenance.

Approach

Sirris and the project partners developed a dedicated testing infrastructure in the port of Antwerp to evaluate both sensor technologies and corrosion protection systems under realistic industrial conditions.

The work focuses on four complementary activities:

1.    Realistic testing environment
A 50-metre replica of an industrial piping system reproduces typical insulated installations using pipe sections, bends and flanges. Controlled water injection makes it possible to simulate moisture ingress beneath insulation.

2.    Sensor validation
Different sensing technologies are evaluated for their ability to detect moisture, locate affected areas and provide reliable information under various insulation systems and operating conditions.

3.    Coating degradation assessment
Accelerated laboratory tests and long-term ageing tests on coated pipe sections are used to study how protective coatings degrade over time. 
The project also evaluates Electrochemical Impedance Spectroscopy (EIS) as a reliable method for assessing coating condition in both laboratory and field applications.

4.    Towards industrial deployment
Building on the results of the first project phase, InnovateCUI Phase 2 will investigate sensor performance and coating degradation analyses under even more realistic conditions, including different insulation materials, complex geometries and varying environmental conditions. 
Future testing will also include climate-controlled experiments to simulate installations operating in different regions and weather conditions.
 

Funding

• Type of project: Joint Industry Project (JIP)
• Industrial consortium with 11 partners from the oil & gas, energy, coating and industrial asset management sectors.

External links

• Article “Industry collaboration brings new insights on CUI”, Jotun
• Article “Corrosion under insulation is a silent killer in the industry”, Industrylinqs