The Corrosion Monitoring is defined as a step-by-step process that both analyzes and monitors structures, process units, equipment components, and facilities for signs of corrosion. Monitoring programs essentially try to target specific conditions in order to increase the life and the serviceability of assets while maximizing overall safety and significantly reducing any replacement costs. Corrosion monitoring covers any type of corrosion and materials.
- The main benefit to using corrosion monitoring is to find early warning signs of corrosion and to understand certain trends/processing parameters which have sparked an environment that is corrosive. Parameters that have to be changed around include pressure, temperature, pH, etc. In addition, corrosion monitoring is used to help with the effectiveness of corrosion prevention methods to figure out if a Utilized different inspection and/or monitoring techniques should be performed.
- Corrosion can often be considered a serious threat to the petrochemical, oil & gas and other process-intensive industries. It is considered one to blame for countless amounts of financial damage and maintenance costs. Ageing equipment also becomes more susceptible to corrosion and eventually loses its ability to deal with heavy and harsh operating environments (e.g. high temperature and pressure). The overall goal of a powerful corrosion monitor program is to make everything safer, reduce the amount of maintenance that needs to be done and reduce any inspection costs, maximizing efficiency in the grand scheme of things.
How Is This Process Executed?
Corrosion monitoring uses a wide range of different unique strategies. A few of them include controlling, measuring, and mitigating any signs of corrosion. These tactics are often organized into two types of groups: inspection and monitoring.
Types of Monitoring
Once the type of corrosion has been recognized, the measurement methods can be used to find out more information about the overall environment in which the corrosion takes place. This is commonly done with the implementation of probes. These can come in different types, including electrical, mechanical, or electrochemical. The goal of these devices is to monitor change during operation when it comes to corrosivity. Corrosion measurement is also used to provide both indirect and direct information. Common measurements of corrosion are measurements of the pH and analysis of microbiological factors. Strategies that analyze chemistry can provide information on the overall amount of dissolved gas (e.g., O2, CO2, and H2S) and therefore, the oxidation of metal ions (e.g., Fe2+, Fe3+).
– Corrosion monitoring offers measurements that are direct. Common techniques of monitoring include ohm resistance, linear polarization resistance, the utilization of corrosion coupons, and galvanic monitoring. Monitoring methods that tend to be more advanced include ultrasonic thickness monitoring, biological monitoring, and hydrogen penetration monitoring.
Before starting an initial inspection, techniques are applied. It must be known that it is important to document the operating parameters of apparatus. Some of these parameters involve, but are not limited to, pressure, rate of flow, pH, and system temperature. Next, nondestructive testing and inspection methods are done to properly locate and identify the type of corrosion damage that has occurred.
– Risk-based inspection and fitness-for-service assessments are additional methodologies and processes which will complement a monitor program. These methods involve qualitative and quantitative approaches and supply information about the present state of apparatus and supply information about the remaining lifetime of equipment.
Corrosion coupon testing happens to be the most easy/simple when it comes to corrosion monitoring. This method can be used within any and all environments. A coupon could be a piece of a sample that pairs with the fabric of the apparatus. The coupons are put into a unique type of environment and removed after a certain amount of time has gone by. It is then looked into for the overall number of lost mass, the type of corrosion at hand, and the rate of speed of corrosion.
Biological monitoring looks at the overall presence of bacteria that end up consuming sulfate, as well as also generate sulfuric acid (H2SO4). Acid is commonly known as being extremely corrosive to any kind of equipment made of metal.
Linear polarization resistance is a tactic that works by putting a current into an electrode. This in turn measures the corrosion rate almost instantaneously. The main disadvantage to this method is that it can only be done in conductive media, as well as inside a solution.
Electrical resistance probes look at the change in resistivity of a component. It essentially provides information about the overall loss of metal. When you use these probes, they are ready to perform in environments of different types for long durations of time. They’re also able to offer periodic or continuous data about the speed at which the corrosion is taking place.
Galvanic monitoring, also classified as zero resistance ammeter, is another method that calculates galvanic current that passes in between two dissimilar electrodes. The outcome offers details about the overall content of oxygen within the media.
Ultrasonic thickness monitoring is considered a common NDT method. It looks into the wall thickness of a component over a certain amount of time. This technique is very sensitive, and is also capable of scanning over large surface areas using ultrasonic waves.
Hydrogen penetration monitoring uses probes to look at the general amounts of hydrogen that dissolves into things made of steel. Within the oil and gas industry, hydrogen is usually a by-product. It can result in a lot of serious hydrogen induced cracking if left untreated for a long enough amount of time.
At the end of the day, all types of monitoring devices and methods have shown to achieve success in reducing facility shutdown time as well as extending the overall lifetime of the asset, which in turn saves companies from a bunch of impactful costs.
– All of our staff members are chosen carefully, and fully trained to learn about all of the aspects of each project across a wide number of different commercial applications.
– We have the right tools and technologies to properly analyze surface coatings, as well as offer specific details on reports of their overall condition. This enables customers to make fully informed decisions on all things financial, schedule and maintenance related.
– This type of industry is constantly changing, and at a fast pace. Upgrades and products enter the marketplace on a frequent schedule. This happens to make us a beneficial resource which will encourage only the latest and greatest technical and economical choices for your coating projects.