The problem/issue addressed with in this project is inspection technologies for detecting Corrosion under insulation, composite repairs , fireproofing and weather coverings . Corrosion under insulation (CUI) remains a major problem for key process industries in Europe and globally including oil and gas production and refining, petrochemical and bulk chemical production. For outdoor processing where large networks of pipes and vessels operating at 30-120 oC conditions are right for external corrosion in carbon steel pipework, however it is difficult to detect when hidden by thick insulation, weatherproofing and any other obstructions. Standard penetrative inspection techniques, such as ultrasonic inspection, are unable to effectively penetrate these coverings and provide accurate readings of the underlying wall thickness. Other techniques employed such as radiography are cumbersome, slow and difficult to digitalise for modern preventative maintenance strategies. These limitations mean that typically industry still relies on periodic visual inspections, which require removal of covers/insulation. This is very labour and time intensive and increases the risk of additional damage to the coverings leading to further ingress of water and therefore further corrosion.
Hidden corrosion has been estimated to cause 60% of pipework leaks. These failures in key pipework can cause safety, environmental and commercial impacts, meaning detection and management of CUI is highly important for these industries. It has been estimated that the management of CUI accounts for 10% of all maintenance costs in the process industry.
Society would benefit from improvements in detection and management of CUI due to reduction in accidents, reduction in environmental damage due to loss of containment; additionally the reduction in costs for industry will improve competitiveness and improve business resilience.
With a focus on pipework this project aimed to investigate in detail the commercial feasibility of EtherNDE’s PRECISE inspection system which has been developed as a prototype. This technology is based on Pulsed Eddy Current (PEC) inspection technique using Giant Magento-Resistance(GMR) for high sensitivity sensors. The overall objective is to determine if EtherNDE should pursue commercialisation of this technology, based on understanding the size of the market and the targeting of this technology.
Following market surveys, interviews with key industry experts it has been determined that a fast inspection technique that does not require removal of insulation would be particularly beneficial for the management of CUI and there is significant market potential while the industry tries to determine the most cost effective solution for this problem.
Therefore it was conclude that EtherNDE should pursue the commercialisation of the this device.
