About Our Corrosion Engineering Insulation and Fireproofing Material Course

Time Training Center’s 5-day, 30-hour Corrosion Engineering Insulation and Fireproofing Material Course equips participants with an in-depth understanding of corrosion under insulation (CUI) and corrosion under fireproofing (CUF), two of the most persistent and costly integrity challenges in industrial settings. The course focuses on the mechanisms, contributing factors, and consequences of hidden corrosion in oil & gas, petrochemical, refining, and power sectors.

Participants learn how water ingress, insulation materials, temperature ranges, and system design influence corrosion risks. The program emphasizes detection methods, risk-based inspection (RBI) strategies, and modern approaches to insulation selection, coating systems, and design optimization.

Through a combination of theory and real-world case studies, attendees gain practical skills to assess risks, implement preventive measures, and apply best practices in design, maintenance, and mitigation to manage CUI and CUF effectively, ensuring equipment reliability, process safety, and regulatory compliance.

Corrosion Engineering, Insulation, and Fireproofing Material Course Objectives

Upon successful completion of this Corrosion Engineering Insulation and Fireproofing Material course, participants will be able to:

• Understand the basic principles and terminology related to corrosion under insulation and fireproofing
• Identify and analyze the root causes and contributing factors leading to CUI and CUF
• Recognize the different forms of corrosion commonly found under insulation, such as pitting, crevice, and chloride stress corrosion cracking
• Evaluate the corrosion behavior of common industrial alloys under insulation and fireproofing conditions
• Assess critical plant areas susceptible to CUI and CUF damage and understand how different components, such as vessels, piping, and tanks, are affected
• Select appropriate insulation and fireproofing materials, jacketing systems, and coatings to minimize corrosion risks
• Utilize inspection methods and non-destructive testing (NDT) techniques for effective detection of hidden corrosion
• Apply risk-based inspection (RBI) methodologies to prioritize inspection and maintenance activities
• Implement design practices and maintenance strategies that prevent and mitigate corrosion in both existing systems and new installations
• Analyze real-world case studies to understand the application of detection, prevention, and repair strategies in industrial environments

Who Should Attend Our Corrosion Engineering Insulation and Fireproofing Material Course?

This course is highly beneficial for professionals involved in corrosion control, inspection, insulation design, and maintenance in industries where CUI and CUF are critical concerns, including:

• Corrosion Engineers
• Inspection and QA/QC Personnel
• Maintenance Engineers and Supervisors
• Mechanical and Process Engineers
• Asset Integrity Engineers
• Plant Designers and Project Engineers
• Coating and Fireproofing Specialists
• Operations and HSE Professionals

Corrosion Engineering Insulation and Fireproofing Material Course Training Methodology

We employ a comprehensive and applied learning strategy, integrating theory with real-world implementation:

• 30% Conceptual Learning: Expert-led sessions on catalytic theory and engineering principles
• 20% Interactive Workshops: Group exercises, presentations, and technical discussion forums
• 30% Case-Based Learning: Industry-specific examples and troubleshooting scenarios
• 20% Technology Integration: Digital tools, simulations, and catalyst modeling applications

Note: Instructors may adjust the training approach to fit technical requirements or participant engagement levels.

Corrosion Engineering Insulation and Fireproofing Material Course Instructor

Our courses are delivered by highly qualified instructors with extensive experience in both industry and academia. With decades of hands-on expertise across a wide range of technical disciplines, our instructors are dedicated to providing high-quality, impactful training that equips participants with practical knowledge and skills they can immediately apply. Full instructor profiles are available upon request.

Corrosion Engineering Insulation and Fireproofing Material Course Fees

The course fee includes the following:

• Course Materials: Comprehensive participant materials, including lecture notes, slides, and case study documents. (Tablet or IPAD)
• Coffee/Tea: Provided on arrival and during morning and afternoon breaks to keep participants refreshed.
• Buffet Lunch: Served daily to ensure participants have an opportunity to network and recharge during lunch breaks.

Corrosion Engineering Insulation and Fireproofing Material Course Outline

Module 1: Introduction to Corrosion Under Insulation (CUI)

• Pre-test assessment of existing knowledge
• Overview of CUI and CUF mechanisms
• Industrial relevance and economic impact
• Safety, reliability, and environmental concerns

Module 2: Fundamentals of Corrosion and Terminology

• Basic corrosion principles and electrochemical processes
• Key definitions in corrosion engineering
• Classification of corrosion types

Module 3: Root Causes of Corrosion Under Insulation (CUI)

• Corrosivity of water and moisture intrusion
• Sources and ingress paths of water
• Threshold moisture conditions for CUI initiation
• Effects of contaminants on corrosion rates
• Impact of operating temperature on corrosion progression
• Influence of insulation type and physical properties
• Other contributing factors affecting corrosion severity

Module 4: Forms of Corrosion Under Insulation

• General (uniform) corrosion
• Localized corrosion: pitting and crevice mechanisms
• Chloride-induced external stress corrosion cracking (Cl-ESCC)
• Visual indicators and damage morphology

Module 5: CUI Behavior in Common Industrial Alloys

• Susceptibility of carbon and low alloy steels
• Corrosion performance of austenitic and duplex stainless steels
• CUI and CUF concerns in aluminum systems
• Comparative analysis of material resistance

Module 6: Equipment and Areas Susceptible to CUI/CUF Damage

• General high-risk zones in plant infrastructure
• Pressure vessels, piping systems, and headers
• Storage tanks, spheres, and structural supports
• Heat-traced systems and mothballed installations

Module 7: Insulation and Fireproofing System Components

• Selection and properties of insulation materials
• Jacketing and sealing systems: caulking and moisture barriers
• Fireproofing materials: cementitious, intumescent, and subliming compounds
• Use of protective coatings beneath insulation/fireproofing

Module 8: Inspection Methods for CUI and CUF

• Inspection considerations for sub-ambient systems
• Non-destructive examination (NDE) tools and techniques
• Visual inspection and advanced screening methods
• Inspection planning and data interpretation

Module 9: Risk-Based Inspection (RBI) Strategies for CUI

• Principles and benefits of RBI for CUI/CUF
• Development of inspection strategies and prioritization
• Screening and assessment techniques
• Sample RBI plans for critical equipment

Module 10: Engineering Design Practices to Prevent CUI

• Coating systems for hot and cold applications
• Insulation selection for corrosion control
• Jacketing design and installation practices
• Protective design features for heat-traced systems
• Shutdown and mothballing considerations
• QA/QC practices during design and construction

Module 11: Design Guidelines to Minimize CUF

• Dense vs. lightweight concrete applications
• Cementitious fireproofing vs. intumescent coatings
• Subliming compounds and fireproofing technologies
• Protective coatings and sealing systems
• Quality assurance during application and curing

Module 12: Maintenance and Mitigation of CUI/CUF

• Proactive maintenance strategies: condition-based and scheduled
• Execution of inspection and repair programs
• Deluge system challenges and mitigation
• Remediation methods for damaged areas
• Repair technologies and coating reapplication

Module 13: Case Studies and Industry Examples

• Examples of qualitative CUI likelihood assessments
• Insulation techniques tailored to various operating conditions
• Real-world case studies illustrating inspection findings, failures, and remediation

Module 14: Capstone and Assessment

• Review of Core Topics and Key Learnings
• Final Group Discussion and Q&A
• Post-Test Evaluation
• Certificate Presentation

Course Completion Certificate

Upon successfully completing the Corrosion Engineering Insulation and Fireproofing Material Course at Time Training Center, participants will receive an official Course Completion Certificate. This certificate recognizes their knowledge and practical skills in corrosion protection, insulation techniques, and fireproofing materials for industrial applications.