How is CUI Monitoring Changing Asset Integrity Management? 

Dr. Prafull Sharma, Chief Technology Officer of CorrosionRADAR and Theo Knijff, Senior Asset Integrity Expert at KAI-CON and former Dow Hydrocarbons Business, recently had an insightful conversation on the evolving landscape of asset integrity management, focusing on the question: How is CUI Monitoring Changing Asset Integrity Management? 

The Global Challenge of CUI 

CUI is a widespread issue across various climates, from the humid Gulf Coast in the U.S. to the dry Middle East. Despite the differing environmental conditions, CUI remains a global problem. It’s often underestimated in arid climates, but even there, the risk exists. 

Understanding the Complexity of CUI 

CUI, often described as an octopus with many tentacles, is influenced by numerous factors. Moisture is a primary contributor, but temperature, environmental conditions, and even the quality of insulation and coatings play significant roles. Moisture can infiltrate through even minor breaches in insulation, leading to corrosion if not managed properly. 

Regional Practices in CUI Management 

While global companies follow similar concepts for CUI management, regional practices may vary based on regulatory requirements. For instance, the U.S. often adheres to API standards, whereas Europe may follow DNV standards. These differences impact inspection scopes and intervals. 

The Persistent Problem of CUI 

Despite existing management practices, CUI remains unpredictable. Corrosion doesn’t always occur at visible damage points; it can travel and manifest in less obvious areas. This unpredictability necessitates a cautious approach, often inspecting only a percentage of susceptible areas due to cost constraints. 

Challenges in Inspection and Maintenance 

Inspecting for CUI is costly, not just in terms of inspection but also in accessing and preparing the inspection sites. This expense often limits the frequency and scope of inspections, leaving some areas unchecked and potential issues undetected. 

The Impact of Aging Infrastructure 

As facilities age, maintaining them becomes more challenging. Aging coatings and insulation exacerbate CUI risks, and deferring maintenance can lead to increased problems over time. Regular inspections and proactive repairs are essential to manage aging assets effectively. 

Temperature and CUI 

CUI typically occurs within a temperature range of -12°C to 175°C. However, transitional zones and intermittent operations can complicate matters, leading to unpredictable corrosion rates. For instance, equipment that fluctuates between cold and hot temperatures, such as loading and unloading pipelines, is particularly susceptible. 

Risk-Based Inspection and Difficult Assets 

Risk-Based Inspection (RBI) is a valuable tool but not a complete solution for all assets. Cyclical operations and transition zones require conservative estimates and more frequent inspections. RBI should be combined with expert judgment to ensure comprehensive coverage. 

The Role of Monitoring in CUI Management 

New technologies, like continuous monitoring and analytics, offer significant advantages. Corrosion monitoring systems provide 24/7 data, allowing for more precise and timely interventions. This approach can reduce inspection costs and enhance the predictability of CUI, leading to a more proactive maintenance strategy. 

Conclusion 

In conclusion, managing CUI effectively requires a combination of traditional inspection practices, advanced monitoring technologies, and a deep understanding of the influencing factors. As we continue to evolve our strategies, integrating new tools and approaches will be crucial in mitigating CUI risks. 

 To watch the full conversation, click this link.