Case Study

Making every cent spent on plant maintenance count

Risk-based analysis of corrosion under insulation, (CUI) maximising multi-million dollars of maintenance


Operator, North America


Plant equipment and piping


Maintenance costs spread effectively over five years

Client challenge

Corrosion under insulation (CUI) has presented a major threat to asset integrity for many years. Implementing an effective management programme here, particularly for piping, can be a major undertaking. We were asked by a US plant operator to assign all its insulated equipment and piping to a managed CUI programme and prioritise the inspection and maintenance plan.

How we helped

Our experts collected the appropriate data and predicted the risk of CUI damage, based on design and inspection information. We carried out both visual and non-destructive examination (NDE) inspections, updating the risk profile based on the findings.

Alongside establishing a manageable CUI programme, we developed a 10-year inspection plan with the client. The current and future risk informed our prioritised list of items requiring future inspections.

Business benefits

As a result of the project, our client could spread its multi-million dollar maintenance costs over a five-year period, with maintained or reduced risk levels. All of our objectives were met within six months.

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