Engineering Procedure

00-SAIP-74 March 07, 2018

Inspection of Corrosion under Insulation and Fireproofing

Document Responsibility: Inspection Engineering Standards Committee

Table of Contents

1 Scope………………………………………….. 2
2 Conflicts and Deviations…………………….. 2
3 Applicable Documents………………………. 2
4 Definitions……………………………………... 3
5 Responsibilities……………………………….. 4
6 Insulation and Fireproofing Materials………. 5
7 Susceptible Systems for CUI……………….. 5
8 Common Locations of CUI in Susceptible
Systems……………………………………….. 6
9 Guidelines for Inspection Program of CUI.... 7
10 Inspection for Corrosion Under
Fireproofing (CUF)…………………………… 9

Previous Issue: August 01, 2009 Next Planned Update: March 07, 2021
Contact: Lodhi, Zeeshan Farooq (lodhizf) on +966-13-8804518
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Document Responsibility: Inspection Engineering Standards Committee 00-SAEP-74
Issue Date: March 07, 2018 Inspection of Corrosion
Next Planned Update: March 07, 2021 under Insulation and Fireproofing

1 Scope

This SAEP provides guidelines to inspection personnel on the development of an

inspection program for corrosion under insulation (CUI) and corrosion under
fireproofing (CUF) for plant facilities. Inspection for CUI includes insulation for cold
and hot services in piping systems, pressure vessels and tanks.

2 Conflicts and Deviations

2.1 Conflicts

Any conflicts between this standard and other applicable Mandatory Saudi
Aramco Engineering Requirements (MSAER) or industry standards, codes, and
forms shall be resolved in writing through Chairman, Inspection Engineering
Standards Committee of Saudi Aramco.

2.2 Deviations and Waivers

Direct all requests to deviate or waive the requirements of this MSAER

according to the internal company procedure SAEP-302, Instructions for
Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement.

3 Applicable Documents

The following documents are to be used as references for this procedure.

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-20 Equipment Inspection Schedules
SAEP-1135 On-Stream Inspection Administration
SAEP-343 Risk-Based Inspection (RBI) for Saudi Aramco Facilities

Saudi Aramco Engineering Standard

SAES-N-001 Basic Criteria, Industrial Insulation

Saudi Aramco Standard Drawings

AA-036911 Insulation Details for Hot Piping
AA-036912 Insulation Details for Hot Vessels
AA-036913 Sht 1 Insulation Details for Cold Piping
AA-036913 Sht 2 Insulation Details for Cold Vessels

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Document Responsibility: Inspection Engineering Standards Committee 00-SAEP-74
Issue Date: March 07, 2018 Inspection of Corrosion
Next Planned Update: March 07, 2021 under Insulation and Fireproofing

AC-036915 Details Fireproofing for Column and Vessel Skirts

3.2 Industry Codes and Standards

American Petroleum Institute

API-510 Pressure Vessel Inspection Code: Maintenance
Inspection, Rating, Repair, and Alteration
API-570 Inspection, Repair, Alteration, and Re-rating of
in-Service piping systems
API-653 Tank Inspection, Repair, Alteration, and
Reconstruction
API-571 Damage Mechanisms Affecting Fixed Equipment in the
Refining Industry
API RP 583 Corrosion Under Insulation and Fireproofing
API-2218 Fireproofing Practices in Petroleum and
Petrochemical Processing Plants

National Association of Corrosion Engineers

NACE RP 0198 The Control of Corrosion Under Thermal
Insulation and Fireproofing Materials- A systems
Approach

4 Definitions

Corrosion Under Insulation (CUI): CUI is an external corrosion which takes place as
a result from the collection of water in the annulus space between the insulation and the
metal surface. Sources of water may include rain, water leaks, humidity condensation,
cooling water tower drift, deluge systems and steam tracing leaks. It is a localized form
of corrosion that occurs if certain operating conditions are met. It also includes chloride
stress corrosion cracking of austenitic stainless steel under insulation.

Susceptible Systems for CUI: Equipment and plant facilities that have greater
tendency to become damaged by corrosion under insulation (CUI), due to its
construction materials, process operating parameters or its geographical location (i.e.
offshore or onshore as defined by SAES-H-001.)

Vulnerable Location: are locations within susceptible systems for corrosion under
insulation that, due to its geometrical shape or insulation condition, will be damaged by
CUI more than other locations. The inspection program for corrosion under insulation
shall monitor these locations which will represent the general condition of the insulated
facility.

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Document Responsibility: Inspection Engineering Standards Committee 00-SAEP-74
Issue Date: March 07, 2018 Inspection of Corrosion
Next Planned Update: March 07, 2021 under Insulation and Fireproofing

5 Responsibilities

5.1 The inspection unit supervisor shall:

5.1.1 Verify inspection programs for Corrosion under Insulation (CUI) and
Corrosion under Fireproofing (CUF) are established and all susceptible
systems for corrosion under insulation are being inspected and
monitored.

5.1.2 Ensure issuing of defect notification in SAIF system for any major
findings and a logbook entry for any minor findings for CUI/CUF
program.

5.2 The plant corrosion engineer shall:

5.2.1 Identify all locations in the susceptible systems that are vulnerable for
corrosion under insulation.
Commentary Note:

The corrosion engineer should interface with the process engineer to identify
all piping systems and plant equipment that are susceptible to corrosion
under insulation. He should also verify that all existing insulation on piping or
equipment is needed either for energy conservation or personnel protection.
All unneeded insulation shall be removed and related drawings and
documents should be updated.

5.2.2 Review all repair procedures and make sure that factors promoting
corrosion under insulation are being eliminated if possible.

5.3 The area Inspection shall:

5.3.1 Ensure all insulated lines in the plant are considered for inspection for
CUI program.

5.3.2. Ensure all susceptible systems for CUI/CUF are identified and
monitored by the OSI program as per SAEP-1135.

5.3.3 Perform inspection on the vulnerable locations for CUI/CUF as per the
inspection interval given in section 9.

5.3.4 Verify appropriate inspection methods are used for each vulnerable
location for CUI/CUF.

5.3.5 Perform visual inspection as per external inspection guidelines in

SAEP-20.

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Document Responsibility: Inspection Engineering Standards Committee 00-SAEP-74
Issue Date: March 07, 2018 Inspection of Corrosion
Next Planned Update: March 07, 2021 under Insulation and Fireproofing

5.3.6 Issue a defect notification in SAIF system for any major findings and a
logbook entry for any minor findings.

5.3.7 Track the closure of issued defect notifications.

6 Insulation and Fireproofing Materials

6.1 For application purposes, insulation materials can be classified into three
categories: Granular, Fibrous, and Cellular type. Commonly used insulation
materials are specified in API 583.

6.2 Commonly used fireproofing material in operating plant are Dense Concrete,
Lightweight Concrete, or other Spray-applied Fire-resistant Materials. Each type
of material has their own unique advantages and disadvantages, and detail
information are specified in API 583.

7 Susceptible Systems for CUI

7.1 Piping Systems

Insulated piping systems shall be included in an inspection program for

corrosion under insulation if any of the followings conditions apply:

7.1.1 Piping systems made of carbon steel and operating temperature

between 10ºF (-12ºC) and 350ºF (175ºC).

7.1.2 Piping systems made of carbon steel and operating temperature above
350ºF (175ºC) or below 10ºF (-12ºC) but in intermittent service.

7.1.3 Piping systems made of austenitic stainless steel and operate between
140ºF (60ºC) and 400ºF (205ºC).

7.1.4 Piping located in areas exposed to mist overspray from cooling water
towers.

7.1.5 Piping systems located in areas exposed to steam vents.

7.1.6 Piping systems exposed to deluge systems.

7.1.7 Piping systems subject to process spills, ingress of moistures or acid

vapors.

7.1.8 Deadlegs and protrusions from insulted piping that operates at different
temperatures of the main line.

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Document Responsibility: Inspection Engineering Standards Committee 00-SAEP-74
Issue Date: March 07, 2018 Inspection of Corrosion
Next Planned Update: March 07, 2021 under Insulation and Fireproofing

7.1.9 Steam traced piping systems that may experience tracing leaks,
especially at tubing fittings beneath the insulation.

7.1.10 Piping systems with deteriorated coating and wrapping, damaged

insulation cladding, or insulation that might be damaged by piping
vibration.

7.2 Insulated Drums, Vessels and Heat Exchangers:

Insulated equipment shall be inspected for corrosion under insulation if any of

the following conditions apply:

7.2.1 Equipment operating between 10ºF (-12ºC) and 350ºF (175ºC).

7.2.2 Equipment operating above 350ºF (175ºC) or below 10ºF (-12ºC), but
in intermittent operation.

7.2.3 Equipment made of austenitic stainless steel and operate between

140ºF (60ºC) and 400ºF (205ºC).

7.2.4 Equipment protected by deluge water system.

8 Common Locations of CUI in Susceptible Systems

8.1 Common locations in piping systems as per API 570 and NACE RP0198:

Piping systems susceptible to CUI as stipulated in 7.1 may have specific

locations, which will be more vulnerable to CUI than the rest of the piping
systems.

8.1.1 All penetrations or breaches in the insulation jacketing such as

deadlegs (vents, drains, instrument tapping and similar items), pipe
hangers and supports and steam tracing tubing penetrations.

8.1.2 Irregular insulation surfaces such as valves and fittings.

8.1.3 Bolted-on shoes.

8.1.4 Terminations of insulation at flanges and other piping components.

8.1.5 Damaged or missing insulation jacketing or when the seams of the

insulating jacketing are located on the top of horizontal piping.

8.1.6 Termination of insulation in a vertical piping.

8.1.7 Caulking that has hardened, has separated or is missing.

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Document Responsibility: Inspection Engineering Standards Committee 00-SAEP-74
Issue Date: March 07, 2018 Inspection of Corrosion
Next Planned Update: March 07, 2021 under Insulation and Fireproofing

8.1.8 Bulges or staining of insulation or jacketing.

8.1.9 Low points in piping systems that have a known breach in the
insulation system, including low points in long unsupported piping
runs.

8.1.10 Carbon or low-alloy steel flanges, bolting and other components under
insulation in high-alloy piping systems.

8.1.11 UT measurement windows in the insulation jacketing.

8.2 Common locations of CUI in insulated vessels and tanks as per API 510,
API 653 and NACE RP0198.

Insulated vessels and tanks that are susceptible for CUI have locations that are
more prone to CUI than the rest of the equipment. Examples of highly suspect
areas include, but not limited to the following:

8.2.1 Stiffening rings and insulation suppport.

8.2.2 Areas around nozzles and manways.

8.2.3 Areas around protrusions; like lifting lugs and platforms supports.

Commentary Note:

If practical, these locations can be inspecteed internally by thickness

measurements during equipment T&I in lieu of insulation removal or NDT.

9 Guidelines for Inspection Program of CUI

9.1 Insulated equipment and piping systems shall be identified and checked if they
meet any of the criteria stipulated in this procedure for vulnerability to corrosion
under insulation. All equipment and piping systems susceptible for CUI, as per
section 7 of this procedure shall be inspected frequently through an inspection
program structured as per this procedure.

9.2 CUI/CUF shall be planned by plant inspector for each operating plant in SAIF
system. Defect notifications shall be issued in SAIF if any major findings are
observed during site inspection. The CUI/CUF inspection interval shall be as
below:

 For offshore facilities, CUI/CUF inspection shall be conducted annually.

 For the onshore faciliteis, the maximum inspection interval shall not
exceed 2 years.

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Document Responsibility: Inspection Engineering Standards Committee 00-SAEP-74
Issue Date: March 07, 2018 Inspection of Corrosion
Next Planned Update: March 07, 2021 under Insulation and Fireproofing

 An RBI assessment, which has been validated by ID, may be used to

increase or decrease the inspection frequency and scope of CUI/CUF
inspections. Guidance on RBI assessment can be found in API 580, API
581, and SAEP-343.

9.4 Piping classification shall be defined as per section 6.3.4 of API-570 (4th
edition, 2016). All vessels and tanks are to be classified as class 1.

9.5 Susceptible systems shall be thoroughly inspected visually. Visual inspection

shall be perfomed in such a manner trying to locate potential CUI damage
through any indication that can be observed externally, such as damaged
jacketing, exposed insulation, wicking of insulation, discoloration of jacketing
due to rust, bulge of insulated system, or any other sign of CUI damage.

9.6 Locations of damaged insulation found through visual inspection of the system
shall be inspected by either NDT or insulation removal. If external visual
inspection reveals good condition of insulation (i.e. no damage in representative
locations) and the inspector believes no hidden CUI damages exists then no
further action is required. If external visual inspection reveals any sign of CUI
damage, then proper NDE method, as specified in API RP 583, should be
utilized to detect CUI damage. If NDE result gives indication of CUI damage,
then appropriate percentage of insulation in susceptable locations shall be
removed as per table 1 for inspector’s further inspection and analysis.

Commentary Note:

It should be noted that CUI might take place without any sign of it on the
external surface of the insulation. NDT may be used in lieu of insulation
removal provided the method and extent of NDT is approved by Inspection
Department.

9.6 If the inspected locations found significant corrosion under insulation, then the
percentage of location selection should be increased. If the system is known to
have a good coating system, or if the system has a good history from previous
inspections for corrosion under insulation, then the percentage of locations
selected can be decreased 50% of the amounts given in Table 1.

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Document Responsibility: Inspection Engineering Standards Committee 00-SAEP-74
Issue Date: March 07, 2018 Inspection of Corrosion
Next Planned Update: March 07, 2021 under Insulation and Fireproofing

Table 1: Recommended Extent of CUI Inspection Following Visual Inspection for

Susceptible Piping.
At Damaged Insulation At Non-Damaged Insulation
Locations Locations
Approximate Amount of Approximate Amount of CUI
Class
Examination with NDE or Inspection with NDE or Insulation
Insulation Removal at Areas Removal at Areas without
with Damaged Insulation Damaged Insulation
1 75% 50%
2 50% 33%
3 25% 10%
4 Optional Optional

10 Inspection for Corrosion Under Fireproofing (CUF)

Fireproofing on static equipment and piping systems shall be considered as insulation.

Equipment furnished with fireproofing shall be inspected for corrosion under
fireproofing as per the guidelines of sections 7, 8, and 9 of this procedure.

10.1 For Static Equipment Skirts, Saddles and Elevated pipe Supports

Thorough visual inspection shall be performed. Areas near moisture and water
entry points shall be given more attention during inspection. Any crack in the
fireproofing shall be studied to find out if it is indicating any sign of corrosion.
Inspection windows might be made to verify any external sign of corrosion
under fireproofing. If corrosion is found then the fireproofing shall be removed
to expose all corroded area.

10.2 For Structures and Pipe Racks

Visual inspection shall be performed to find out any external sign of corrosion
under fireproofing. Inspection windows in form of horizontal stripes should be
made if deemed necessary. They should intersect cracks at random locations. If
corrosion is found, then all corroded area shall be exposed.

10.3 If any NDT can be applied to inspect the equipment under fireproofing for
corrosion, then inspection windows or stripes should not be made.

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Document Responsibility: Inspection Engineering Standards Committee 00-SAEP-74
Issue Date: March 07, 2018 Inspection of Corrosion
Next Planned Update: March 07, 2021 under Insulation and Fireproofing

Revision Summary

1 August 2009 Editorial revision to change the Primary Contact.

7 March 2018 This revision is to change the Primary Contact, alignment with international standards
API571 API 583, requirements of inspection planning through SAIF system and adopt RBI
methodology for instpection interval determination.

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