Flexible corrosion rata sensors in CUI
The Corrosion Under Insulation (CUI) monitoring system is a solution designed for autonomous, real-time, and non-destructive monitoring of corrosion beneath insulation layers. The system comprises flexible sensors, compact data loggers, and a user-friendly interface. The corrosion sensors are mounted directly onto the outer wall of the pipe—beneath the insulation—placing them in the same environmental conditions as the pipe itself; this allows for the early detection of rising corrosion activity before structural damage occurs. An integrated alarm system facilitates timely intervention, thereby enhancing operational efficiency, sustainability, environmental protection, and safety.
Flexible sensors—incorporating soft ER elements (designed to monitor both bare metal corrosion and coating degradation)—can be embedded in VCI-impregnated silicone or mounted on flexible polyimide (PI) substrates, allowing them to wrap around curved surfaces.
Flexible sensors can be installed at the following locations:
Pipe supports, brackets, valves, flanges, and elbows: These irregular components make it difficult to achieve a tight fit for the insulation layer; resulting gaps allow water ingress, making them recognized high-risk areas.
Insulation terminations, seams, and damaged areas: Improperly sealed or damaged outer cladding seams and terminations allow rainwater, condensate, and wash water to seep in—moisture that is subsequently difficult to evaporate.
Low points of piping or equipment: Corrosive liquids and condensate tend to accumulate in low-lying areas rather than at the specific point of leakage, creating a high risk of prolonged water exposure in these depressions. Pipelines subject to fluctuating temperatures—alternating between heating and cooling—experience repeated cycles of water vapor condensation and evaporation. This places constant stress on the coating-metal interface, making them more susceptible to corrosion than pipelines operating at constant temperatures.
✓ Continuous, non-intrusive monitoring of Corrosion Under Insulation (CUI)
✓ Data logger installed on the exterior of the insulation system
✓ Wireless data transmission eliminates the need for on-site personnel, enhancing operational safety
✓ High sensitivity enables early detection of CUI, preventing equipment damage on a large scale
✓ Assessment of remaining equipment service life
✓ Simple alert notification system for timely warnings of potential risks
✓ Comprehensive corrosion rate records for professional analysis and assessment
✓ Customizable solutions with full-lifecycle technical support
Applications
❖ Oil & Gas industry
❖ Chemical industry
❖ Pharmaceutical industry
❖ Food processing
❖ Power generation
❖ Geothermal engineering
❖ District heating
❖ Offshore facilities
