KAEFER Australia transformed its Corrosion Under Insulation (CUI) inspection process by adopting digital radiography, enabling faster inspections, reduced costs, and eliminating the need for insulation removal.
What is Corrosion Under Insulation (CUI)?
Corrosion Under Insulation (CUI) is a hidden form of corrosion that develops on insulated pipes and equipment when moisture becomes trapped beneath insulation.
Because corrosion occurs out of sight, it is particularly difficult to detect and often leads to:
- unexpected failures
- costly maintenance operations
- safety risks in industrial environments
Why CUI is difficult to inspect?
Detecting CUI is complex because traditional inspection methods often require:
- removing insulation
- stopping operations
- accessing hard-to-reach areas
As a result, inspections are typically:
- time-consuming
- expensive
- partially incomplete
Interview with Chris Rawlinson, Lead CUI Inspector at KAEFER Australia
To better understand how digital radiography improves CUI inspections, we spoke with Chris Rawlinson, Lead CUI Inspector at KAEFER Australia.
What was your inspection process before using digital radiography?
Chris Rawlinson:
“Prior to adopting RTR (Real-Time Radiography) for CUI inspections, our process relied heavily on physical insulation removal to visually inspect potential corrosion sites — an invasive, time consuming, and costly method.”
What were the main challenges with this approach?
Chris Rawlinson:
“The major challenges included:
• High labor and material costs associated with insulation removal and reinstallation.
• Time inefficiencies.
• Limited access to some piping systems due to location or operational constraints.”
Operator using our Go-Scan C-View to detect CUI © Kaefer Australia
Why KAEFER needed a new CUI inspection solution
KAEFER was looking for a solution that could:
- detect corrosion without removing insulation
- improve inspection speed
- maintain high accuracy and reliability
What were you looking for in a solution?
Chris Rawlinson:
“We needed a fast, reliable, and truly non-destructive inspection method that could deliver accurate results without dismantling insulation.”
How did you first hear about our products?
Chris Rawlinson:
“We discovered the product through targeted research into advanced inspection solutions and upcoming innovations in radiographic technology.”
What features of our product was most appealing?
Chris Rawlinson:
“We were particularly drawn to:
• The high image quality and reliability.
• Ease of use in various field environments.
• The availability of uniquely adapted X-ray systems, especially those developed for the security sector, which translated well into industrial applications.”
Images taken aboard FPSO in WA waters © Kaefer Australia
The solution: Digital Radiography for CUI Inspection
KAEFER adopted digital radiography using Teledyne ICM’s solutions.
Why real-time radiography is effective for CUI?
- Enables inspection without removing insulation
- Provides real-time imaging
- Improves inspection speed and coverage
- Works in complex and constrained environments
Implementation in the field
How did you introduce our solution?
Chris Rawlinson:
“To build confidence with clients, we conducted both in-house and on-site trials. These demonstrations showcased the product’s capabilities and helped drive adoption.”
Results: Improved efficiency and cost savings
How does our product help your company achieve its objectives?
Chris Rawlinson:
“The system has:
• Provided consistent and reliable inspection results.
• Enabled efficient service delivery.
• Demonstrated flexibility in adapting to our unique operational requirements.”
Has this solution saved money and/or increased productivity?
Chris Rawlinson:
“Absolutely. The equipment has saved our clients significant time and costs by reducing the need for insulation removal and allowing for more flexible inspection planning.”
Key benefits observed
- Reduced inspection time
- Lower labor and material costs
- No insulation removal required
- Improved accessibility to complex areas
- Reliable and repeatable inspection results
Adoption over time
How long have you been using our product?
Chris Rawlinson:
“We have used the C-Arm system (Go-Scan C-View, ed.) since 2019, and added the CP160B & Go-Scan 4335 digital panel in 2020.”
What plans do you have to use our product in the future?
Chris Rawlinson:
“We aim to automate parts of the scanning process, allowing us to inspect larger diameters more quickly and further streamline workflows.”
What is your advice for other teams or companies who are tackling problems like those you had before you purchased our product?
Chris Rawlinson:
“Invest in the right technology and ensure your team receives thorough training. The upfront effort pays off in long-term efficiency and reliability.”
Operators installing our battery-operated portable X-ray generator, the CP160B, and our X-ray digital detector, the Go-Scan 4335, to perform an inspection. © Kaefer Australia
Conclusion: Transforming CUI inspection with Digital Radiography
KAEFER Australia’s experience highlights how digital radiography is transforming CUI inspection by improving efficiency, reducing costs, and enabling non-destructive inspection.
For companies facing corrosion challenges, this approach offers a more efficient and scalable alternative to traditional methods.
About Kaefer
KAEFER is a well-established provider of construction, maintenance and shutdown services. In 2018, KAEFER expanded its portfolio by introducing Corrosion Under Insulation (CUI) inspection services, aligning with industry demand for more proactive asset integrity solutions.
You want to share your experience with our products?
Contact us:
Eva Libert — Marketing & Communication Manager
eva.libert@teledyne.com
+32 87 60 71 33
