Inspection Procedure 19 June 2022
00-SAIP-74
Inspection of Corrosion under Insulation and Fireproofing
Document Responsibility: Inspection Engineering Standards Committee
Previous Issue: 20 September 2018 Next Planned Update: 19 June 2027
Revised paragraphs are indicated in the right margin Page 1 of 18
Contact: Mohamed Attia (attiama) on phone +966-13-8801843
©Saudi Aramco 2022. All rights reserved.
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Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-74
Issue Date: 19 June 2022
Next Planned Update: 19 June 2027 Inspection of Corrosion under Insulation and Fireproofing
Contents:
Summary of Changes............................................................................................... 3
1 Scope .............................................................................................................. 4
2 Conflicts and Deviations .................................................................................. 4
3 References ...................................................................................................... 4
3.1 Saudi Aramco References .............................................................................. 4
3.2 Industry Codes and Standards ........................................................................ 5
4 Definitions ....................................................................................................... 5
5 Responsibilities ............................................................................................... 6
5.1 The Inspection Unit Supervisor ....................................................................... 6
5.2 The Inspection Field Supervisor ...................................................................... 7
5.3 The Area Inspector .......................................................................................... 7
5.4 The Plant Corrosion Engineer ......................................................................... 7
5.5 The Process Engineer ..................................................................................... 7
6 Susceptible Systems to CUI ............................................................................ 8
7 Common Suspect Locations of CUI in Susceptible Systems .......................... 9
8 Guidelines for Inspection Program of CUI ..................................................... 10
9 Inspection for Corrosion Under Fireproofing (CUF) ....................................... 13
Document History ................................................................................................... 15
Appendix A – Available Inspection Technologies For Detecting Cui And Cuf ........ 16
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Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-74
Issue Date: 19 June 2022
Next Planned Update: 19 June 2027 Inspection of Corrosion under Insulation and Fireproofing
Summary of Changes
Paragraph Number Change Type
Previous Current (Addition, Technical Change(s)
Modification,
Revision Revision Deletion, New)
(7 March 2018) (19 June 2022)
3 3 Modification Updated and added new references.
Seven (7) new definitions were added:
Condition Monitoring Locations, Direct
Inspection Methods, External Chloride Stress
4 4 Addition
Corrosion Cracking, Indirect Inspection
Methods, Qualitative NDE methods, Semi-
quantitative methods, and Transition points.
Added responsibilities for Inspection Field
5 5 Addition Supervisor (para. 5.2) and Process Engineer
(para. 5.5).
Aligned with International Standards, including
duplex stainless steel (para. 6.3). Examples
6 6 Modification
were added as well as previsions in the case
of Mothballing (new para. 6.11).
More examples of common suspect locations
of CUI damage were added (From 7.1.11 to
7 7 Addition
7.1.15 were added, as well as from 7.2.4 to
7.2.6).
More questions were added and references
8.1 8.1 Addition
for the MOC process in the commentary note.
Enhancing the clarity of write-up and
specifying the inspection interval for each kind
of inspection. Table 1 was modified and
8.2 8.2 Modification
included as a recommendation, instead of
mandatory. Clarification for the kind of NDE
for indirect and direct inspection methods.
Considerations for systems operating below
8 8.4 New
0°C were added.
Added some indications of CUF and the
hammer testing technique in para 9.1.
9 9 A requirement was added for the most critical
applications, such as LPG Spheres legs (para
9.3) and new para 9.4.
New Appendix was added listing all Available
- Appendix A New Inspection Technologies for detecting CUI and
CUF and their limitations.
All sections have undergone editorial and
All All Modification
language checks to ensure clarity.
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Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-74
Issue Date: 19 June 2022
Next Planned Update: 19 June 2027 Inspection of Corrosion under Insulation and Fireproofing
1 Scope
This SAIP 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.
2 Conflicts and Deviations
Any conflicts between this document and other applicable Mandatory Saudi
Aramco Engineering Requirements (MSAERs) or industry standards, codes,
and forms shall be resolved in writing through the Chairman, Inspection
Engineering Standards Committee of Saudi Aramco.
3 References
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-343 Risk-based Inspection (RBI) for Saudi Aramco Facilities
SAEP-1135 On-Stream Inspection Administration
Saudi Aramco Engineering Standards
SAES-A-133 Internal Corrosion Control Requirements
SAES-A-134 External Corrosion Protection Requirements
SAES-A-135 Establishment of On-stream Inspection (OSI) Program
SAES-B-006 Fireproofing for Plants
SAES-N-001 Basic Criteria, Industrial Insulation
Saudi Aramco General Instruction
GI-6.035 Management of Change (MOC)
Saudi Aramco Inspection Procedures
00-SAIP-01 Dead-legs Inspection and Flushing Requirements
01-SAIP-01 Small Nipple Inspection Program
00-SAIP-72 Inspection Involvement in Management of Change
00-SAIP-75 External Visual Inspection Procedure
00-SAIP-76 Defect Notification Control and Tracking Program
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3.2 Industry Codes and Standards
American Petroleum Institute
API 510 Pressure Vessel Inspection Code: In-Service
Inspection, Rating, Repair, and Alteration. Tenth
Edition, May 2014, Addendum 2, March 2018.
API 570 Piping Inspection Code: In-Service Inspection, Rating,
Repair, and Alteration of Piping Systems. Fourth
Edition, February 2016, Addendum 2, March 2018.
API RP 571 Damage Mechanisms Affecting Fixed Equipment in the
Refining Industry. Third Edition, March 2020.
API RP 572 Inspection Practices for Pressure Vessels. Fourth
Edition, December 2016.
API RP 574 Inspection Practices for Piping System Components.
Fourth Edition, November 2016.
API RP 583 Corrosion under Insulation and Fireproofing. Second
Edition, March 2021.
API STD 653 Tank Inspection, Repair, Alteration, and
Reconstruction. Fifth Edition, November 2014,
Addendum 2, May 2020.
API RP 2218 Fireproofing Practices in Petroleum and Petrochemical
Processing Plants. Third Edition, July 2013,
Reaffirmed, March 2020.
National Association of Corrosion Engineers
NACE SP 0198 Control of Corrosion under Thermal Insulation and
Fireproofing Materials – A System Approach. Revised
2017.
4 Definitions
Condition Monitoring Locations (CML): Designated areas on process
equipment and piping systems where periodic examinations are conducted to
monitor the presence and rate of corrosion. CMLs can be a plane through a
section of piping, a nozzle, or areas of examination points on a piping circuit.
Previously, CMLs were referred to as Thickness Monitoring Locations (TMLs).
Inspection at the CMLs not necessary means removing the insulation, since
semi-quantitative indirect inspection methods can be used.
Corrosion Under Insulation (CUI): CUI is external corrosion that takes place
as a result of 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
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operating conditions are met. It also includes chloride stress corrosion
cracking of austenitic stainless steel under insulation.
Direct Inspection Methods: Inspection methods that are conducted without
the presence of a protective barrier, such as insulation or fireproofing. For
example Visual examination method with complete removal of
insulation/fireproofing and Penetrant Testing (PT).
External Chloride Stress Corrosion Cracking (ECSCC): Surface initiated
cracking in austenitic and duplex stainless steels and some nickel-base alloys
under the combined action of tensile stress, temperature, and an aqueous
chloride environment.
Indirect Inspection Methods: Inspection methods that are conducted in
presence of the protective barrier such as insulation or fireproofing. Indirect
inspection methods can be classified as semi-quantitative methods or
qualitative methods.
Qualitative NDE methods: NDEs that are not designed to quantify the
deterioration caused by CUI directly, but they can be used to detect areas of
wet or damaged insulation on pipes and vessels which may be possible areas
of CUI, such as Infrared Thermography and Neutron Backscatter (see
appendix A para 1.3).
Semi-quantitative methods: Inspection methods that indirectly quantify the
relative degree of surface corrosion that has occurred. Examples are
Radiography Testing (RT), Guided Wave Testing (GWT), and Pulsed Eddy
Current (PEC).
Susceptible Systems for CUI: Equipment and plant facilities that have
greater tendency to become damaged by corrosion under insulation (CUI),
due to their construction materials, process operating parameters, or
geographical location.
Transition points: Protrusions through the insulation system (e.g. vents,
drains, supports, nozzles, instrument connections, etc.) on carbon steel piping
and equipment operating at below ambient or cold service temperatures,
including those operating below -12°C (10°F).
Vulnerable Locations for CUI: 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 CUI shall monitor these locations which will represent the general
condition of the insulated facility.
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, tracked in SAIF,
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and all susceptible systems for corrosion under insulation are
inspected and monitored.
5.1.2 Ensure issuing of defect notification (DN) in SAIF system for any non-
conformances related to CUI and CUF.
5.1.3 Periodically review of CUI & CUF program in SAIF.
5.2 The Inspection Field Supervisor shall:
5.2.1 Ensure all susceptible systems for CUI/CUF are identified, monitored,
and inspected according to this procedure.
5.2.2 Ensure adequate closure of DN as per 00-SAIP-76.
5.2.3 Verify that appropriate inspection methods are used for CUI/CUF
inspections (see Appendix A).
5.3 The Area Inspector shall:
5.3.1 Establish and track the CUI and CUF inspection program through
SAIF system for plant insulated piping and equipment and fireproofed
assets.
5.3.2 Ensure all susceptible systems for CUI/CUF are identified, monitored,
and inspected according to this procedure.
5.3.3 Inspect vulnerable locations for CUI/CUF as per the inspection
interval in this procedure.
5.3.4 Perform visual inspection as per external inspection guidelines in
SAEP-20 and 00-SAIP-75. The reports are to be captured in SAIF.
5.3.5 Issue a defect notification in SAIF system for any non-conforming
findings.
5.3.6 Track the closure of issued defect notifications.
5.3.7 Communicate the inspection anomalies to the Corrosion Engineer
and/or Engineering Unit for further evaluation.
5.4 The Plant Corrosion Engineer shall:
5.4.1 Identify all susceptible and vulnerable locations for corrosion under
insulation and fireproofing.
5.4.2 Review all repair procedures and make sure that factors promoting
corrosion under insulation are eliminated if possible.
5.4.3 Review and analyze the inspection results to determine the required
control and/or mitigation measures.
5.5 The Process Engineer shall:
5.5.1 Make sure that all drawings (P&IDs) are updated to reflect the latest
modification done on insulations in the field.
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5.5.2 Work with the corrosion engineer and the plant engineer to identify all
CUI susceptible systems.
5.5.3 Verify that all existing insulation on piping or equipment is needed
either for energy conservation or personnel protection as per SAES-
A-134 Para 7 & 8. All unneeded insulation should be removed and
related drawings and documents should be updated.
5.5.4 Notify the inspector of any occasion where the damage to the
insulation system may have occurred, such as showering, washing,
etc.
Commentary Note:
Insulation shall not be used for personal protection unless there is no other
method, as established in SAES-A-134 para 7.4. Consider the use of
insulating paints or protective cages.
6 Susceptible Systems to CUI
For piping systems and insulated drums, vessels, and other static equipment
the key factor for CUI damage to occur is that a corrosive aqueous layer is
present on the insulated metal surface during any operating period or during
downtime. Insulated piping systems and equipment shall be included in an
inspection program for CUI if any of the followings conditions apply:
6.1 Piping systems/equipment made of carbon and low alloy steel and
operating temperature as indicated in API RP 571/583.
6.2 Piping systems/equipment in cyclic condition or intermittent service
made of carbon and low alloy steel, even operating at a temperature
above 175ºC (350ºF) or below -12ºC (10ºF).
6.3 Piping systems / equipment made of austenitic and duplex stainless
steel and operating between temperatures indicated in API RP
571/583, where ECSCC is a concern.
6.4 Piping systems/equipment located in coastal/marine areas, cooling
tower overspray, or local external water source exposure (deluge
systems, steam vents, dripping steam condensate, or any source of
saltwater).
6.5 Piping systems/equipment subject to process spills, ingress of
moistures, or acid vapors.
6.6 Areas of protrusions through insulation/jacketing for piping/
equipment, such as transition points.
6.7 Deadlegs, attachments, and protrusions from insulted piping that
operates at different temperatures than the operating temperature of
the active line.
6.8 Vibrating piping/equipment that may inflict damage to the insulation
jacketing causing a path for water ingress.
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6.9 Steam traced piping systems/equipment that may experience tracing
leaks, especially at tubing fittings beneath the insulation.
6.10 Piping systems/equipment with deteriorated insulation, coating and
wrapping, and damaged insulation cladding, e.g. bulges and stains in
the insulation or cladding.
6.11 Piping systems and equipment during extended shutdown or long-
term mothball. In case of mothballing, the corrosion engineer needs
to evaluate the potential CUI damage during the expected idle period
and shall study the cost-benefit of removing the insulation to avoid
CUI damages or keep the insulation.
Commentary Note:
API 510, 570, RP 572, RP 574, RP 583, and NACE SP-0198 may provide
additional guidance in identifying CUI susceptible locations and acceptable
methodologies for inspection. These should be used for general guidance.
7 Common Suspect Locations of CUI in Susceptible Systems
7.1 Piping systems susceptible to CUI may have specific locations, which will be
more vulnerable to CUI than the rest of the piping systems.
7.1.1 All penetrations or breaches in the insulation jacketing such as
deadlegs, vents, drains, nozzles, instrument tapping, pipe hangers,
and supports, steam tracing tubing penetrations and similar items.
7.1.2 Irregular insulation surfaces such as valves and fittings.
7.1.3 Terminations of insulation at flanges and other piping components,
and termination of insulation in vertical piping.
7.1.4 Damaged or wet insulation, damaged or missing insulation jacketing,
vapor barriers, or when the seams of the insulating jacketing are
located on the top of horizontal piping or improperly lapped or sealed.
7.1.5 Bolted-on shoes.
7.1.6 Caulking that has hardened, has separated, or is missing.
7.1.7 Bulges or staining of insulation or jacketing.
7.1.8 Low points in piping systems that have a known breach in the
insulation system, including low points in long unsupported piping
runs.
7.1.9 Carbon or low-alloy steel flanges, bolting, and other components
under insulation used with high-alloy piping systems.
7.1.10 UT measurement windows in the insulation jacketing.
7.1.11 Damage and leaking steam tracing.
7.1.12 Where the coating beneath the insulation has been deteriorated or
damaged.
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7.1.13 Areas downwind of cooling towers exposed to cooling tower mist.
7.1.14 Areas where banding on the jacket is missing.
7.1.15 Areas where smaller branch connections intersect with larger
diameter lines.
7.2 Insulated vessels, tanks, and other static equipment that are susceptible to
CUI have locations that are more prone to CUI. Examples of highly suspect
areas include, but are not limited to the following:
7.2.1 Stiffening rings and insulation support rings.
7.2.2 Areas around nozzles, flanges, manways, and saddles.
7.2.3 Areas around protrusions; like lifting lugs, ladder brackets, and piping
and platforms’ supports.
7.2.4 Top heads of vertical vessels.
7.2.5 Bottom of horizontal vessels (i.e. lower third to half of a vessel)
7.2.6 Insulated leg supports or insulated zone at skirt weld.
Commentary Note:
If practical, these locations can be inspected internally by thickness
measurements during equipment T&I in lieu of insulation removal or non-
intrusive NDT.
8 Guidelines for Inspection Program of CUI
8.1 Insulated equipment and piping systems shall be identified and checked if they
meet any of the criteria stipulated in this procedure for susceptibility to CUI.
The purpose of insulation should be well understood before performing CUI
inspections to determine hazards associated with insulation removal. The
following questions should be asked prior to executing CUI inspections or
insulation removal:
• Is equipment/piping currently out-of-service?
• Is equipment/piping in intermittent or cyclic service? If yes, what is the
frequency of operation and duration of maximum temperature?
• Can the insulation be removed for CUI inspection and remediation while
the equipment/piping is in service without adversely affecting process
control, product quality, and safety?
• Is insulation installed for the sole purpose of personnel protection,
>60°C (140°F)? If yes, can metal cages or ceramic coatings be used
instead of insulation?
• Does the heat conservation economics dictate this insulation requirement,
usually considered at >95°C (200°F)?
• Does the equipment/piping contain fluids that may freeze resulting in an
interruption of service(s)?
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• Does the equipment/piping require insulation to reduce condensation?
• Does the equipment/piping require heat tracing? If yes, is the heat tracing
used continuously or only if certain conditions exist?
• How long has the equipment been in service since last insulated?
• Is piping or equipment coated?
• What are the consequences of a leak?
Commentary Note:
Management of change (MOC) process should be used when considering
modification or removal of any insulation or fireproofing, as per GI-6.035,
00-SAIP-72 and Operational Excellence (OE) Process ID OE-10.1.
8.2 Inspection plan shall be set up by the plant inspector in SAIF system. Defect
notifications shall be issued in SAIF if any non-conforming findings are
observed during the inspection, as per 00-SAIP-76. The CUI inspection plan
shall be established as follows:
8.2.1 External Visual Inspection without insulation removal (Screening of the
insulation system).
The maximum inspection interval shall be as indicated in the External
Visual Inspection Procedure 00-SAIP-75 for Onshore and Offshore
facilities.
Insulated piping and equipment shall be thoroughly inspected visually.
Visual inspection shall be performed in such a manner trying to locate
potential CUI through any indication that can be observed externally,
such as damaged jacketing, exposed insulation, wicking of insulation,
discoloration of jacketing due to rust, stain marks, bulge, dents, or
distortion of the insulated system, gaps around penetration or any other
sign of damage in the insulation system.
Commentary Note:
Qualitative NDE for screening of insulation such as Neutron
Backscatter and Infrared Thermography (see Appendix A) can be used
to complement the visual inspection and detect susceptible locations to
CUI due to damaged/wet insulation.
As a result of the inspection, some suspect areas detected may require
further inspections as per para. 8.2.2.
In case of detecting damage in the insulation system, a DN shall be
created with the required actions such as determining the required
amount of additional inspection and the repair of the insulation system
as per the requirements of 00-SAIP-76.
8.2.2 Direct Inspection Methods (i.e. partial insulation removal) or Indirect
Inspection Methods (i.e. semi-quantitative NDE)
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This kind of inspection shall be conducted at the CMLs established in
the OSI program, as well as in the areas found with deficiencies or
suspected of having CUI identified in para 8.2.1.
In the case of Dead-legs and Small Nipples, the inspection interval
established by 00-SAIP-01 and 01-SAIP-01 respectively must be
followed, and this inspection is a good opportunity to at the same time
inspect for CUI.
Commentary Note:
CMLs established for monitoring internal corrosion may also be used
to inspect for CUI. However, Corrosion Specialists should be consulted
to determine if additional CMLs are required to monitor CUI at
susceptible areas, as defined in sections 6 and 7.
If insulation is removed, Visual Inspection and ultrasonic thickness
measurement reading shall be performed. Alternatively, semi-
quantitative indirect inspection methods as specified in API RP 583 and
approved by Inspection Department (see Appendix A) can be used to
avoid the insulation removal.
If significant corrosion is revealed, then inspection coverage shall be
extended. The area inspector shall determine the amount of this
additional examination through insulation removal or special NDE
(semi-quantitative indirect inspection methods mentioned in Appendix
A) until the extension of the affected area is determined. Table 1 guides
the definition of the extension of inspection coverage.
For Pressure Vessels made of carbon and low alloy steel, if the
insulation jacket is in good condition and there is no reason to suspect
underneath corrosion, insulation removal can be evaded, by taking
shell thickness measurements during the T&I internal inspection, but
the inspector should be aware that CUI damage is often highly localized
and therefore a proper inspection technique for localized corrosion
shall be implemented. These thickness measurement readings shall
be saved in SAIF system as per SAEP-1135.
Inspection for External Chloride Stress Corrosion Cracking (ECSCC)
should be made of susceptible austenitic and duplex stainless-steel
piping or equipment unless otherwise approved in the Corrosion
Control Document (CCD). In this case Penetrant Testing (PT) or Eddy
Current Testing (ECT) can be used, when the piping or equipment is
removed from service.
Commentary Note:
Inspection for ECSCC shall not be performed from inside the pressure
vessels.
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Table 1 - Recommended Extent of CUI Inspection at Suspect
Areas.
Extent of Examination with NDE b
Class a
or Insulation Removal c
1 75%
2 50%
3 25%
4 Optional
(a) API 570 Piping Service Class.
(b) Semi-quantitative Indirect Inspection Methods (without
insulation removal), refer to Appendix A Para. 1.2
(c) Percentage of the total area of the piping spool/shell course
for pressure vessels.
Commentary Note:
The recommended extent of CUI inspection in Table 1 may be reduced
by 50% of the values included, provided a qualitative nondestructive
screening as per Appendix A is performed to identify wet or damaged
insulation. When moisture or damage in the insulation is detected, the
damage caused by CUI needs to be quantified, either by quantitative
indirect inspection methods or direct inspection methods, and the repair
actions required for the coating/insulation systems need to be
performed.
8.3 RBI assessment conducted as per SAEP-343 may be used to increase or
decrease the inspection frequency and coverage of CUI inspections when
compared to time-based or condition-based inspection planning.
8.4 In systems operating below 0°C (32°F), the removal of insulation during
operation is undesirable, because wet and icy conditions make it difficult to
inspect. It also exposes the insulation to atmospheric water vapor, trapping
more moisture within the insulation prior to re-insulation of the area. In this
case, the primary inspection methods are the Indirect Inspection Methods
mentioned in appendix A. Direct Inspection Methods with the removal of
insulation can be utilized when the piping or equipment is removed from
service.
9 Inspection for Corrosion Under Fireproofing (CUF)
Equipment furnished with fireproofing shall be inspected for corrosion under
fireproofing.
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9.1 For static equipment skirts, saddles, and elevated pipe supports
A thorough visual inspection without fireproofing removal shall be performed
at the same inspection interval as per 8.2.1. Areas near moisture and water
entry points shall be given more attention during the inspection. Any crack,
bulging or rust stain in the fireproofing shall be studied to find out if it is a sign
of underneath corrosion. Loss of bonding between the fireproofing and the
bare metal may be determined by surface bulges or an abnormal sound
through hammer testing.
In case of any external sign of corrosion under fireproofing, inspection
windows shall be made to verify the condition. If corrosion is found, then the
fireproofing shall be removed to determine the whole corroded area. UT
thickness measurements should be made inside the skirt to identify and locate
any CUF, especially when deemed necessary from visual inspection.
If any NDT as per Appendix A can be applied to inspect the equipment under
fireproofing for corrosion; then, inspection windows or stripes may be waived.
When fireproofing is installed over the vessel surface, all components covered
such as shell, head and nozzles are required to be inspected. This can be
done through internal inspection by thickness measurement or through any
approved NDT (as per Appendix A) or direct inspection with selective removal
of small sections of fireproofing to examine conditions at the face of the bare
metal and the surface of reinforcing wire, looking for evidence of corrosion.
Commentary Note:
The inspector shall be aware that CUF can be highly localized and hence
difficult to detect by spot inspection.
9.2 For Structures and Pipe Racks
Visual inspection shall be performed to find out any external signs of CUF.
Inspection windows in form of horizontal stripes should be made if deemed
necessary. The selection of inspection windows location should intersect the
existing cracks in the fireproofing. If corrosion is found; then, all corroded
areas shall be exposed and examined.
9.3 Further inspection through an advance NDT or windows cutting shall be
performed for the critical applications to the structural support integrity. The
Corrosion Engineer and Area Inspector shall identify the extent and frequency
of the inspection based on the condition. Some common examples of these
critical applications can be leg supports for storage spheres, supports for
vessels, towers, columns, process heaters, heat exchangers and offshore
platforms, and associated vessel supports. Details of the inspection and
results shall be documented in the post T&I report and/or equipment files.
9.4 Some fireproofing is covered with a coating that reduces the permeability of
moisture and vapor. This coat needs to be inspected and repaired in case of
damage or excessive thinning.
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Document History
19 June 2022 Major Revision as specified in the summary of changes. Aligned with
international standards and clarifications were made about the different kinds
of inspections for direct and indirect inspection methods, their scope and
inspection interval, as well as the available inspection technologies for CUI and
CUF.
20 September 2018 The revised document is completely aligned with the international requirements
and standards.
7 March 2018 This revision is to change the Primary Contact and align with international
standards API 571 and API 583, requirements of inspection planning through
SAIF system, and adopt RBI methodology for inspection interval determination.
1 August 2009 Editorial revision to change the Primary Contact.
Saudi Aramco: Company General Use
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Saudi Aramco: Company General Use
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-74
Issue Date: 19 June 2022
Next Planned Update: 19 June 2027 Inspection of Corrosion under Insulation and Fireproofing
Appendix A – Available Inspection Technologies for detecting CUI and CUF
1 Corrosion Under Insulation (CUI):
1.1 Direct Inspection Methods (with insulation removal):
• Visual Inspection (VT).
• Ultrasonic thickness (UT) and pit depth measurement techniques.
1.2 Semi-Quantitative Indirect Inspection Methods (without insulation
removal):
• Radiography Testing (RT).
• Guided Wave Testing (GWT).
• Pulsed Eddy Current Array (PECA).
• Low-Frequency Electromagnetic (LFE).
1.3 Qualitative Indirect Inspection Methods (NDE for Screening of the
Insulation System):
• Infrared Thermography.
• Neutron Backscatter.
1.4 For Austenitic and Duplex Stainless Steel (To detect ECSCC):
Insulation needs to be removed.
• Penetrant Testing (PT).
• Eddy Current Testing (ECT).
2 Corrosion Under Fireproofing (CUF):
• External Visual Inspection without Fireproofing Removal.
• Visual Inspection through Fireproofing Openings/Windows.
• Pulsed Eddy Current Array (PECA).
• Low-Frequency Electromagnetic (LFE).
• Ultrasonic Thickness Measurement (UT) in case of Internal Inspection in
Pressure Vessels with external fireproofing.
Saudi Aramco: Company General Use
Page 16 of 18
Saudi Aramco: Company General Use
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-74
Issue Date: 19 June 2022
Next Planned Update: 19 June 2027 Inspection of Corrosion under Insulation and Fireproofing
AVAILABLE INSPECTION TECHNOLOGIES FOR CUI
Deterioration Detection
Inspection Through Capability Quantitative or Mode of
No. Technology Name NDT Method Comment/Limitations
Coatings General Wall Pitting Qualitative Movement
Corrosion Thick Corrosion
Detection of trapped
Neutron Moisture Neutron
1 Yes No No No Qualitative Manual moisture as an indication of
Detection Backscatter
potential CUI.
Detection of trapped
Infrared Infrared moisture or insulation
2 Yes No No No Qualitative Manual
Thermography Thermography damage as an indication of
potential CUI.
Low-Frequency
Electromagnetic Semi- Insulation thickness less
3 Electromagnetic Yes Yes No No Manual
Testing Quantitative than 2”.
(LFE)
Thickness reading is given
Pulsed Eddy Pulsed Eddy Semi-
4 Yes Yes Yes No Manual as a range of percentage of
Current Array Current Testing Quantitative
metal loss.
Allow testing up to 100 feet
long straight segment of
Guided Wave (Long Guided Wave Semi- pipe with only 8” wide
5 Yes Yes Yes No Manual
Range UT) Testing Quantitative removal of insulation to
attach the sensor ring on
the pipe surface.
Radiography
Testing (through Gamma ray or Semi- Up to 10” pipe diameters.
6 Yes Yes Yes Yes Manual
transmission and X-ray radiation Quantitative
profile radiography)
Semi-
7 OpenVision X-ray radiation Yes Yes No Yes Manual Up to 10” pipe diameters.
Quantitative
Saudi Aramco: Company General Use
Page 17 of 18
Saudi Aramco: Company General Use
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-74
Issue Date: 19 June 2022
Next Planned Update: 19 June 2027 Inspection of Corrosion under Insulation and Fireproofing
AVAILABLE INSPECTION TECHNOLOGIES FOR CUF
Deterioration Detection
Quantitative
Inspection Through Capability Mode of
No. Technology Name NDT Method or Comment/Limitations
Coatings General Wall Pitting Movement
Qualitative
Corrosion Thick Corrosion
Average wall loss, and pitting
corrosion can be missed.
Pulsed Eddy Pulsed Eddy
1 Yes Yes Yes No Quantitative Manual Inaccuracy in quantitative
Current Array Current Testing
measurement. Steel rebars will
reduce sensitivity.
Pitting corrosion can be
Low Frequency
Electromagnetic missed. Insulation thickness
2 Electromagnetic Yes Yes No No Qualitative Manual
Testing less than 2”. Steel rebars will
(LFE)
interfere with inspection.
Saudi Aramco: Company General Use
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Saudi Aramco: Company General Use