
Three-way coupled physics-first simulator for Corrosion Under Insulation (CUI) on insulated carbon-steel process piping. Couples Fourier heat conduction through the insulation annulus, Philip-de Vries hygrothermal moisture transport driven by capillary and thermal gradients, and Butler-Volmer electrochemical corrosion kinetics at the steel surface. All three fields are advanced together via Strang second-order operator splitting. A DFOS-informed inverse problem recovers moisture source magnitude and location from outer-cladding temperature observations. Anchored to AMPP 2022 (CUI causes ~60% of refinery pipe leaks), API RP 583 critical temperature window (50-175C), and PHMSA Docket 2026-1520 (April 24, 2026). 151 tests, 5 analytical benchmarks.
distributed fiber optic sensing, Philip-de Vries, Fourier conduction, CUI, PHMSA, pipeline integrity, Butler-Volmer, corrosion under insulation, thermohygro-electrochemical, inverse problem, API RP 583, DFOS, Strang splitting
distributed fiber optic sensing, Philip-de Vries, Fourier conduction, CUI, PHMSA, pipeline integrity, Butler-Volmer, corrosion under insulation, thermohygro-electrochemical, inverse problem, API RP 583, DFOS, Strang splitting
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