Excellence Integrity Management

One of the most dangerous corrosion mechanisms in Oil & Gas is also one of the hardest to detect.

Because you can't see it.

A pipe may appear perfectly healthy on the outside while losing significant wall thickness beneath the insulation.

No visible leak.

No obvious warning.

No indication of the risk developing underneath.

This hidden threat is known as Corrosion Under Insulation (CUI).

Industry studies have shown that CUI accounts for a significant percentage of piping maintenance costs and integrity-related failures across operating facilities.

The most common mistake?

Waiting for visible signs before taking action.

By then, the damage is often already severe.

High-risk locations include:

• Pipe supports
• Insulation terminations
• Valves and flanges
• Vessel nozzles
• Dead legs
• Areas exposed to water ingress

The best integrity programs don't inspect everything.

They identify where CUI is most likely to occur and focus resources accordingly.

Question for integrity and inspection professionals:

Where have you found the most severe CUI damage?
A. Pipe Supports
B. Valves & Flanges
C. Vessel Nozzles
D. Dead Legs
E. Insulation Terminations

Comment your answer below.

We're covering CUI mechanisms, inspection techniques, assessment methods, and mitigation strategies during our upcoming 4-Day Live Online Training on Corrosion Under Insulation (22–25 June 2026).

Details available in the comments.

Equipment failures rarely happen without warning.

The warning signs are usually there:

• Corrosion progressing unnoticed
• Damage mechanisms not properly identified
• PSV performance degradation
• CUI hidden beneath insulation
• Tank and pipeline integrity issues developing over time
• Maintenance strategies focused on repairs instead of prevention

The challenge isn't a lack of data.

It's having professionals who can recognize the risks early, understand the mechanisms involved, and make the right decisions before failures impact safety, reliability, and production.

That's why organizations across the Oil & Gas industry continue investing in workforce competency.

Strong technical knowledge in areas such as:
- API 571 Damage Mechanisms
- Risk-Based Inspection (RBI)
- Pressure Safety Valves (PSV)
- Storage Tank Integrity (API 653)
- Pipeline Integrity Management
- Corrosion Under Insulation (CUI)
- Heat Exchanger Inspection & Maintenance
- Rotating Equipment Reliability
- Welding Inspection & Repair
- QA/QC Systems

helps teams move from reactive maintenance to proactive asset management.

The most reliable facilities are not necessarily the ones with the newest equipment.

They are the ones with people who understand how equipment fails, how risks develop, and how integrity can be maintained throughout the asset lifecycle.

At Excellence Integrity Management (EIM), we support organizations through specialized corporate training programs focused on inspection, integrity, reliability, maintenance, corrosion management, and asset performance improvement.

Our programs are delivered by industry professionals and built around practical applications, real-world case studies, and operational challenges faced by today's Oil & Gas workforce.

If your organization is looking to strengthen technical competency and improve asset reliability, let's connect.

Which technical competency do you believe delivers the greatest impact on asset reliability: Inspection, Corrosion Management, RBI, Maintenance, or Process Safety?