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A 2020 inspection at a coastal petrochemical complex revealed severe CUI — with tower sections having lost 40% of their thickness. Pyrogel® XTE compressed the remediation window and recovered lost production revenue.
Severe CUI threatened a major unplanned downtime event.
A scheduled inspection revealed corrosion that had been progressing for years under intact-looking insulation.
- Severe CUI discovered. 40%+ wall-thickness loss on tower sections, identified during a 2020 inspection.
- Reduced selectivity, then metal loss. Process performance had been off-baseline, prompting the inspection.
- High risk of major downtime. Without an accelerated remediation plan, the unit faced weeks of unscheduled shutdown.
Pyrogel® XTE mitigated future CUI and recovered the schedule.
Pyrogel® XTE’s faster application compressed the metal-remediation window and accelerated restart.
- Mitigated future CUI events. Hydrophobic blanket eliminates the moisture pathway that drove the original failure.
- Recovered metal-remediation time. Faster insulation application freed schedule used for additional metal work.
- Completion 20 days ahead. Integrated remediation + re-insulation closed out faster than the original plan.
- Captured lost downtime revenue. Earlier restart converted directly into revenue that would otherwise have been lost.
8× return on investment from accelerated restart.
The operator captured an 8× return on investment — recovered production days dwarfed the material premium over traditional insulation. The site recorded the project as a downtime-rescue case and added Pyrogel® XTE to the spec for future CUI work.
Discovered CUI on a critical tower?
Talk to an Aspen engineer about a Pyrogel® XTE remediation plan that fits your turnaround window.