Predictive CUI Management with Remote Monitoring – Recent Use Cases (C2026-00354)

Prafull Sharma, Freddie Talbot

Corrosion Under Insulation (CUI) remains a significant integrity threat, particularly in environments with thermal cycling, moisture ingress, deluge systems, and insulation barriers that hinder conventional inspection methods. Often concealed until significant wall loss has occurred, CUI poses risks to safety, reliability, and cost efficiency. Traditional methods—such as insulation removal or localised ultrasonic testing—offer limited coverage and frequency, typically requiring shutdowns or access infrastructure that restrict proactive detection.
This paper examines the deployment of predictive CUI management strategies using remote monitoring technologies. These systems combine long-range electromagnetic sensing with moisture detection to deliver continuous insight into the condition of insulated assets. Drawing from recent use cases across offshore, gas processing, and petrochemical sites, the presentation outlines how these technologies have been implemented in varied operational contexts, and how insulation type, duty cycle, and environment influence sensor performance and corrosion progression. Data is analysed and visualised through a central dashboard, enabling early identification of anomalies, tracking of CUI development, and prioritisation of inspection resources. This supports a shift from reactive, interval-based inspection toward a risk-informed, data-driven maintenance model.