Active Mitigation, Micro-Environmental Diagnostics, and Real-Time IoT Telemetry

Manufactured by: Wenzhou Leakage Corrosion Hardware Products Co., Ltd. (LCH)
Official Portal: leakcorrosion.com

1. System Engineering Architecture

The LCH Integrated CUI Control System is an active, multi-barrier protection network engineered to eliminate Corrosion Under Insulation (CUI) on high-temperature piping, chemical towers, and complex valve manifolds. The system seamlessly unifies proactive chemical passivation, non-metallic physical fluidics, and real-time electronic sensors into a single, closed-loop diagnostic framework.

                  ┌──────────────────────────────────────────────┐
                  │   VCI POWER Compressed Dry Air/N₂ Manifold   │
                  │      (0.01-0.05 MPa | Flow: 500 L/min)       │
                  └──────────────────────┬───────────────────────┘
                                         │ (Forced Convection Purge)
                                         ▼
┌─────────────────────────────────────────────────────────────────────────────────┐
│            Slotted Support Spacers & Perforated PTFE Insertion Tubes            │
│  (Secures routing paths and distributes passivating VCI vapors along the shell) │
└────────────────────────────────────────┬────────────────────────────────────────┘
                                         │
                                         ▼
┌─────────────────────────────────────────────────────────────────────────────────┐
│                  Multi-Substrate Flexible ER Corrosion Sensors                  │
│   (0.02mm to 0.3mm low-profile matrix tracking real-time micron thickness loss) │
└────────────────────────────────────────┬────────────────────────────────────────┘
                                         │
                                         ▼
┌─────────────────────────────────────────────────────────────────────────────────┐
│            Removable Insulation Blankets with Integrated Snap Drain Plugs      │
│  (In-house OEM fabric, one-way gravity drainage check-valve, & venting holes)  │
└─────────────────────────────────────────────────────────────────────────────────┘

2. Core System Components

2.1 Removable Insulation Blankets with Integrated Snap Drain Plugs

Direct OEM Integration: As a direct source manufacturer, LCH designs and manufactures both the premium removable insulation blankets and the companion drainage systems in-house. PPS drain plugs are pre-installed and seamlessly sewn/integrated into the blanket layout prior to delivery, ensuring turnkey field installation.
Efficient Gravity Drainage: Positioned at the lowest gravitational boundaries to allow trapped condensation and external rainwater tracking to escape freely.
Adjustable Thickness Adaptability: Features an innovative mechanical profile with an adjustable silicone duckbill valve length. This adjustable architecture enables the assembly to seamlessly fit, telescope, and firmly clamp onto varying blanket thicknesses without creating crushed air gaps or bypassing loose fits.
Flame-Resistant Construction: Manufactured from high-strength engineering Polyphenylsulfone (PPS), which is inherently flame-resistant and non-combustible.

2.2 Multi-Substrate Flexible ER Corrosion Sensors

Ultra-Thin Conformability: Sacrificial sensor tracks are engineered at ultra-low thicknesses (0.02 mm to 0.3 mm), allowing the sensor strip grid to wrap flawlessly around tight-radius pipe elbows, vessel heads, and curved structural surfaces.
Substrate & Alloy Customization: Backing profiles can be laminated on varying substrates, including Polyimide (PI), PTFE, or reinforced Silicone Rubber to suit specific process temperatures. The metal electrode chemistry is matched precisely to site metals (Carbon Steel, 316L Stainless Steel, or specific alloy coatings) to deliver micro-ampere level realism for corrosion rate calculations.
Plug-and-Play Field Replacement: The modular gold-finger edge connector matches an integrated toolless quick-swap socket for zero-downtime field probe replacements once the sacrificial life is depleted.

2.3 Active VCI Silicone Autolysis / Self-Fusing Tape

Physical Boundary Layer: Wounds tightly over bare metal substrates with a mandatory 50% overlap profile, cross-linking within 24 hours to form a highly resilient, water-tight physical shield.
Vapor-Phase Passivation: The integrated Volatile Corrosion Inhibitor (VCI) compound volatilizes under process heat, saturating the micro-voids between the pipe wall and the insulation with a molecular protective layer that halts oxidation even during electrolyte ingress.

2.4 VCI POWER Multi-Stage Dry Air / N₂ Injection Manifold

Precision Pneumatics: Operates under safe, controlled micro-positive pressures of 0.01 to 0.05 MPa with a high continuous rated output flow rate of 500 L/min (engineered to inject Dry Air or N₂ gaseous media).
Parallel Distribution: Accommodates a dual-head layout pushing ten individual 10mm distribution lines concurrently to clean up moisture traps up to 3 meters per span.
Forced Convection Drying: Blends physical moisture stripping with gaseous VCI delivery, turning wet insulation matrices into actively dried, vapor-passivated environments.

3. Targeted Solutions for High-Risk Complex Geometries

Irregular profiles represent the absolute highest-risk areas for CUI due to thermal expansion gaps, structural stress concentration, and gravitational water pooling.

3.1 Pipe Elbows & Tees (弯头与三通)

Risk Profile: Natural gravitational accumulation zones where outer weatherproof cladding seams routinely warp over time, leading to heavy gravity-fed rainwater ingress.
Targeted Layout: VCI autolysis tape and flexible sensors are spiraled along the external radius and flanks of the curved surface. The insulation jacket sleeve is punched at the exact lowest dead-center coordinate of the turn to host the one-way PPS/silicone drainage check valve.
Engineering Impact: Trapped liquid cannot accumulate into a stagnant pool, preventing severe structural thinning on critical directional pipe changes.

3.2 Process Valves & Flanges (阀门与法兰)

Risk Profile: Highly susceptible to packing gland weeping, flange gasket failure, and intensive condensation collection driven by heavy thermal cycling.
Targeted Layout: A flexible sensor strip grid (PI or PTFE base) is wrapped beneath the body and lower bonnet assembly. The custom removable jacket features an integrated one-way snap drain plug directly underneath the main valve belly.
Engineering Impact: Any internal media leak or rainwater tracking immediately migrates to the lowest collection zone, triggering an instant alert while discharging liquid out via gravity.

3.3 Pipe Supports (管支架)

Risk Profile: Non-insulated structural pipe hangers, shoes, and support anchors create narrow crevices. Continuous rubbing action from thermal movement strips standard coatings, allowing capillary action to suck in water and cause aggressive galvanic corrosion.
Targeted Layout: Multiple layers of heavy-duty VCI silicone autolysis tape are wrapped directly over the support-pipe interface zone, extending at least 150 mm beyond the metallic contact crevice to break the electrical contact between the dissimilar metals.
Engineering Impact: Completely isolates bare steel from mechanical friction and metal-to-metal galvanic coupling, while the localized VCI vapor passivates the tightest crevice dead zones.

3.4 Equipment Nozzles (设备接管口)

Risk Profile: Protruding nozzles on pressure vessels create vertical stress interfaces. Weatherproof silicones around the nozzle collar dry out, crack, and channel massive amounts of downward-flowing rainwater straight into the vessel's internal matrix.
Targeted Layout: A multi-layered collar wrap using VCI self-fusing bands seals the nozzle-to-shell radius intersection. A dedicated collar-profile removable jacket covers the area, integrating a compressed gas sniffer/injection port on the upper quadrant and a duckbill snap drain plug on the lower edge.
Engineering Impact: Blocks rainwater running down the vertical vessel wall from entering the shell boundary, allowing the interior of the nozzle base to remain continuously monitored, dry, and protected.

4. Localized Telemetry & Intelligent IoT Dashboard

The physical thickness loss of the flexible ER sensor grid is continuously tracked by the localized edge processor and uploaded directly via MQTT to the cloud interface

4.1 On-Site Sensor Display Diagnostics

The module is equipped with a high-contrast localized micro OLED screen providing rapid field validation:

T: 32.5C (Temperature): Localized under-insulation temperature for real-time tracking and automatic thermal resistance compensation math.
H: 52.1% (Humidity): Relative micro-environmental humidity; functions as an early-warning predictor for fluidic ingress.
CR: 0.000 mm/y (Corrosion Rate): Annualized material corrosion rate derived from active track resistance drift (\(PCB\_R - R_0\)).
Rate: 0.0 % (Thickness Loss Rate): Accumulated thickness loss rate of the sacrificial tracking grid.
P: OK (Status Check): Power loop, reference electrode baseline (0.868 V), and communication hardware verified as healthy.
Life: 100% (Sensor Remaining Useful Life): Remaining thickness percentage gauge.

[底层传感器物理电阻微变] ──(JSON 封装)──> [MQTT 边缘网关] ──(无线/以太网)──> [云端大数据引擎] ──> [可视化趋势与剩余寿命预警]

4.2 Proactive Closed-Loop Operations

Early Ingress Alert: Moisture or condensation accumulates in the insulation profile. The Flexible ER sensor registers thickness loss, instantly flashing a remote alert to the Customizable CUI Web Portal / Mobile App via the LCH COR 20 logger.
Active Purging Process: Operations review the peak corrosion velocity spike (up to 99.07 mm/y) and activate the VCI POWER system. Compressed dry air or N₂ (0.01-0.05 MPa) is driven through Perforated PTFE tubes slotted into the non-metallic support spacers.
Complete Dehydration: The forced convective gas flow drives liquid water downward, venting it out of the Snap-fit one-way silicone drain plugs while exhausting humid vapors out of the air holes until the entire internal matrix is dried, stabilized, and passivated.