Corrosion sensor development for ​detection of CUI

Industry context

Corrosion Under Insulation (CUI) poses a significant operational, safety and economic challenge. Since 1984, out of the 137 major oil and gas accidents reported within the EU over 20% have been associated with CUI.​

It is currently estimated that CUI incurs 40 – 60% of the process plant maintenance costs within the UK Continental Shelf (UKCS) and the value impact to the industry for better inspection techniques would be in the region of £130 million per annum to the UKCS.

Project overview

CorrosionRADAR, a UK-based company, has developed a remote sensing technology which acts as a screening method for the onset of CUI and/or for locating CUI-prone zones.​

​The project’s aim was to mature it from TRL 4 to a commercially deployable product in O&G facilities needing an ATEX-ready product and conduct two validation trials at onshore site(s) to prove that this technology can form part of the overall solution to managing CUI. There is also the potential for this technology to be extended to renewable energy sites and facilities.​

​The CorrosionRADAR CUI risk monitoring technology is built upon the core sensing principle of Electro-Magnetic Guided Radar (EMGR) that received Innovation of the year award in NACE Corrosion 2021 conference in Houston USA. ​

​The key technical innovation behind the system is a long-thin-flexible sensor that is sensitive to the corrosive environment in the insulation and detects the presence of moisture or corrosion on itself. Electromagnetic signals are sent through the sensor, and the reflected signals are interpreted using proprietary algorithms to locate corrosion.​

Outcome

Eliminates fugitive emissions

Reduces unplanned shutdowns

Potential cost saving of £130m per year to UKCS

Eliminates fugitive emissions

Reduces unplanned shutdowns

Potential cost saving of £130m per year to UKCS