Modelling of Corrosion Under Insulation in Oil Sands

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According to the Petroleum Safety Authority (PSA) in Norway, corrosion under insulation (CUI) caused about 50% of all hydrocarbon leaks at onshore plants. In the case of Alberta’s oil sands, CUI has also been observed in thermal operations in above ground assets carrying emulsions, steam, hot water and/or warm water that are externally insulated to ensure safe and energy efficient operations. CUI has also been observed in oil sands mining operations in various piping systems and in tanks and vessels on structural supports and insulated support rings that are frequently in contact with soil or standing groundwater.

Product Number: 51323-19209-SG

Author: Andrea Marciales, Martin Huard, Kofi Freeman Adane

Publication Date: 2023

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Corrosion Under Insulation (CUI) in Alberta’s oil sands industry has been observed in above ground assets in thermal operations carrying emulsion, steam, hot water and/or warm water that are externally insulated to ensure safe and energy efficient operations. CUI has also been observed in oil sands mining operations in various piping systems, tanks and/or vessels, and structural supports including insulated support rings, which are frequently in contact with soil or standing groundwater. Furthermore, CUI can go easily unnoticed over prolonged periods of time, only detected after an insulation or pressure containment failure occurs. Most of the CUI occurrences are usually found at the 6 o’clock position or lowest collecting point. Therefore, it is important to identify suitable methodologies to predict CUI for Alberta’s oil sands industry. This work, carried out within the Materials and Reliability in Oil Sands (MARIOS) consortium at InnoTech Alberta, explores existing methodologies for CUI prediction reported in the public domain, and provides a preliminary validation of findings using field data collected by the producer members of the MARIOS consortium.