Corrosion Under Insulation (CUI) Detection and Repair Techniques

This case study documents a comprehensive CUI inspection program at a major Gulf Coast refinery. Ultrasonic thickness testing revealed localized wall thickness reductions exceeding critical thresholds. The inspection team used a combination of visual inspection, ultrasonic thickness gauging, and radiography to identify and quantify corrosion under insulation. Repair recommendations included encapsulation, coating upgrades, and targeted replacement of severely thinned sections.