en.Wedoany.com Reported - The joint industrial project led by SIRRIS, a Belgian non-profit technology research and innovation center, is addressing one of the most complex and costly corrosion challenges in the oil, gas, and petrochemical industries—corrosion under insulation (CUI)—by combining accelerated coating testing with long-term slow aging exposure tests. The project aims to develop new testing methods to better understand coating degradation and evaluate what actionable data CUI humidity sensors can provide, thereby improving how the industry manages CUI.
The first phase of the project employed a design that combined accelerated laboratory methods with long-term "slow aging" exposure tests to more accurately reflect coating performance under actual operating conditions. Tests were conducted under repeated wet-dry cycling conditions between 80°C and 140°C. The study also explored the potential of using electrochemical impedance spectroscopy (EIS) to assess coating degradation. Although EIS measurement data added significant value, experts at the meeting noted that further optimization of measurement methods and data processing is needed to account for common localized failure issues.
Jeroen Tacq of SIRRIS stated that maintaining the integrity of steel under insulation requires closer interdisciplinary collaboration, linking material properties, exposure conditions, and inspection insights. Peter Janssen, head of corrosion and materials expert company EbertHera and advisor to Saudi Basic Industries Corporation (SABIC), pointed out that continuous monitoring of humidity in the insulation layer is a key goal for controlling CUI. The project's actual test rig revealed how humidity monitoring methods depend on system design and insulation type.
Jenny Manvik, R&D Manager for Special Coatings at Jotun, stated that collaboration fosters deeper technical understanding and trust, helping to clarify assumptions and understand the scope of the problem. Ingrid Vee, Global Category Manager at Jotun, noted that participating in the project closely aligns with the company's strategic goal of being a trusted partner and technology leader in CUI prevention. According to data from DNV, CUI accounts for approximately half of all hydrocarbon leaks in the oil and gas industry, making its resolution critical for steel integrity, safety, and sustainability.
Based on the outcomes of the first phase, the second phase of the project will launch this summer. This phase will further study coating degradation mechanisms, refine testing methods, and improve EIS and visual analysis approaches, while evaluating the potential for inclusion in future testing standards with industrial partners. The work will also extend beyond epoxy technologies to include multi-polymer coating systems and investigate how different exposure conditions affect long-term and accelerated test performance. The project's long-term goal is to achieve on-site estimation of remaining coating life by combining laboratory tests with CUI humidity monitoring data. The first phase of the project brought together operators such as Shell, Equinor, BP, Chevron, SABIC, Dow, and Gassco, as well as coating manufacturers including AkzoNobel, Carboline, and Jotun.
