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Integrity management – CUI

Corrosion costs the UK economy an incredible £28 billion every year, with that figure rising to £4 trillion globally. In the oil and gas industry, Corrosion Under Insulation (CUI) poses a significant operational, safety and economic challenge.

Over 20% of the major oil and gas accidents reported within the EU since 1984 have been associated with CUI. Many assets on the UK Continental Shelf (UKCS) are operating beyond their expected design life and 60% of pipe failures are attributed to CUI. 

Our vision is to eliminate failures due to CUI by 2026 and we need new technology to make this a reality. As part of the funding competition we are looking for innovative ideas and technology for the detection, inspection and mitigation of CUI. Eliminating CUI will enhance safety, improve production efficiency and reduce fugitive emissions. 


Detecting

Submissions should have looked to improve or provide monitoring systems to detect the presence of corrosion in insulated systems.  

Key areas of interest to assist in dealing with this challenge include technologies that consider: 

  • Retrofit options to existing insulation systems 
  • Power & communication limitations associated with remote and hazardous environments 
  • Equipment interface and data integration options to existing standardised reporting and enterprise software systems 
  • Compliance with ATEX Directive 2014/34/EU 
  • Hardware size due to access restrictions and configuration of plant. 

Inspecting

We aimed to look for innovative demonstrator technologies to optimise inspection activities, as well as detection rates. These technologies were required to currently be at a minimum development of TRL6.  

TRL6 is defined as system/subsystem model or prototype demonstration in a relevant environment. Representative model or prototype system is tested in a relevant environment. Represents a major step up in a technology’s demonstrated readiness. 

These can focus on, but not limited to: 

  • Ease of deployment and interpretation of inspection results, including accurate measurement of remaining wall thickness 
  • Interface and data integration options to existing standardised reporting and enterprise software systems. 

Mitigating

Should look to improve or provide coating and insulation technologies that address the root causes of CUI, while ensuring that insulation materials and coating system functions long-term.  

Key areas of interest to assist in dealing with this challenge include technologies that consider: 

  • Water absorption, hydrophobic behaviour, compressive strength & dimensional stability of insulation materials 
  • Mechanical resistance, vapour barrier and weather protection of cladding/ jacketing solutions 
  • Accessibility for maintenance or inspection of underlying substrate 
  • Surface preparation and application requirements considering harsh environment