Industry Group Launches New Effort to Reduce Corrosion Under Insulation
A joint industry project led by SIRRIS has completed its first phase of research into corrosion under insulation, evaluating new coating test methods and moisture monitoring technologies to improve asset integrity across the oil and gas industry.
(P&GJ) — A coalition of energy companies, coating manufacturers and research organizations has completed the first phase of a joint industry project aimed at improving the detection, prevention and long-term management of corrosion under insulation (CUI), one of the oil and gas industry's most persistent asset integrity challenges.
The project, led by Belgian research and innovation center SIRRIS, evaluated new coating test methods and moisture monitoring technologies designed to help operators better understand coating degradation and reduce the risk of CUI-related failures.
CUI remains a leading cause of equipment degradation across the oil, gas and petrochemical sectors and is estimated by DNV to contribute to roughly half of all hydrocarbon leaks in the industry.
"Despite continuous improvements in materials, inspection and maintenance practices, CUI continues to be a leading cause of asset degradation and integrity loss," said Jeroen Tacq of SIRRIS. "Bringing together asset owners, coating experts and research partners is essential to reducing both CUI risk and lifecycle costs."
The project focused on evaluating moisture sensors installed beneath insulation and comparing accelerated laboratory testing with longer-term exposure testing to better understand how protective coatings perform under realistic operating conditions.
Testing subjected coated steel to repeated wet-dry cycles between 80°C (176°F) and 140°C (284°F) to simulate operating environments commonly found in industrial facilities.
Participants also assessed the use of electrochemical impedance spectroscopy (EIS) as a tool for evaluating coating degradation beneath insulation. While researchers said the technique shows promise, additional work is needed before it can be widely adopted for field inspections.
"Continuous monitoring of moisture in insulation is an important goal for controlling corrosion under insulation," said Peter Janssen, expert lead for corrosion and materials at EbertHera and consultant for SABIC. "The project has given us valuable insight into how continuous moisture monitoring methods depend on system design and insulation type."
The project also established a collaborative forum for operators, coating suppliers and researchers to compare testing methods and share operational experience.
"Creating a structured forum where coatings experts, asset owners and researchers can exchange experiences leads to deeper technical understanding," said Jenny Manvik, R&D manager, specialty coatings, at Jotun.
A second phase of the project is scheduled to begin this summer. Researchers plan to further investigate coating degradation mechanisms, refine laboratory testing methods, expand evaluation beyond epoxy coatings to multi-polymeric systems and continue improving EIS and visual inspection techniques. The group will also assess whether the findings could support future industry testing standards.
"The long-term goal is to estimate remaining coating life in the field by combining laboratory testing with moisture monitoring data," Tacq said. "By continuing the project, we want to foster further collaboration and help tackle this safety-critical and costly damage mechanism."
The first phase of the project included participation from Shell, Equinor, BP, Chevron, SABIC, Dow, Gassco, AkzoNobel, Carboline and Jotun.