Corrosion Monitoring Research Articles

Corrosion Monitoring in Humidity-Controlled Environment Simulating Gamma Ray Irradiation

Corrosion Monitoring in Humidity-Controlled Environment Simulating Gamma Ray Irradiation

Corrosion Monitoring of RC Structures (Assessment and Interpretation)

Reinforced Concrete structure system is more durable and capable from a various adverse environmental condition. Their excellent tensile strength and ductility make them perfect for construction of building structures. Structures are always susceptible to environmental changes. No building will ever be the same once the environmental changes kick in. Out of all the changes, the most serious and devastating in corrosion. Each and every structure needs valuable inspection and proper examination for checking the reinforcement corrosion. There are required assessing and techniques to evaluate and interprets the condition of structures. One can identify the strength of a structure by monitoring techniques and can prevent problem in the structures before it becomes crucial. In this review paper all the non destructive techniques from the point of view of corrosion assessment and application to building and other civil engineering structures are being discussed

Potential step voltammetry: An approach to corrosion rate measurement of reinforcements in concrete

This paper presents a Potentiostatic Step Voltammetry approach to corrosion rate measurement of reinforcements in concrete. We have termed this approach PSV-TE since it is based on the Tafel extrapolation method, but with the added advantage that long and slow potentiodynamic scans are no longer required to obtain the Tafel slopes. In this way, the irreversible polarization of rebars is prevented, so PSV-TE is considered to be a non-destructive method. The Tafel slopes are obtained by fitting the current-time response of the system to a theoretical model which we have outlined and validated previously. In this way, the concrete's electrical resistance and double layer capacity are also obtained. In this study, the optimal PSV-TE design has been established and validated on a range of reinforced concrete specimens. Results show minimal deviation between PSV-TE and reference methods. Therefore, PSV-TE is part of the corrosion monitoring system we have patented.

Stress enhanced intergranular corrosion of friction stir welded AA2024-T3

The paper is aimed at the evaluation of intergranular corrosion of friction stir welded AA2024-T3 joints as a function of manufacturing parameters and loading conditions. Tests for intergranular corrosion assessment, long terms exposure tests, corrosion monitoring through electrochemical impedance spectroscopy and microstructural characterization of the corrosion morphologies were performed to evaluate the effect of loading on intergranular corrosion initiation and propagation. Electrochemical impedance spectroscopy spectra were collected during long term exposure tests to determine the onset of the attack and the propagation rate. A slight modification of the impedence modulus was observed during the exposure as a function of the process parameters. On the contrary, relevant effect of loading condition on intergranular corrosion initiation and propagation mechanisms was noticed. Although no stress corrosion cracking phenomena were evidenced, stress enhanced intergranular attack was observed on loaded specimens at the nugget, where coalescence of sub-micrometric and continuous copper-rich precipitates at the grain boundary occurred. These phenomena are mainly attributable to the thermo-mechanical action of the welding process. Intergranular attacks were not observed in the heat-affected zone and in the base metal, where grain recrystallization does not occur.

Application of Ag/AgCl Sensor for Chloride Monitoring of Mortar under Dry-Wet Cycles.

An Ag/AgCl electrode used as a corrosion sensor in a reinforced concrete structure is considered as having good application prospect. However, its performance under complex conditions, such as dry-wet cycle condition, is not affirmed. In the current study, the performance of Ag/AgCl as chloride selective electrode in mortar exposed to dry-wet cycle condition was investigated. A simple Ag/AgCl electrode was prepared and fabricated by electrochemical anodization. These Ag/AgCl electrodes were embedded into a mortar specimen with temperature sensors, humidity sensors and anode ladder monitoring system (ALS). After 28 d curing time, the upper surface of mortar specimen was wetted (with 5% NaCl solution) and dried regularly. The obtained results indicate that Ag/AgCl electrode responds to the ingress of chloride ion, sensitively. The chloride ion concentration variation can be reflected by the potential trend. Furthermore, the balance potential of Ag/AgCl electrodes is influenced by dry-wet cycles. Compared with ALS, it demonstrates that Ag/AgCl electrodes are more sensitive to chloride. The research provides the key element for the specific application of Ag/AgCl electrode for corrosion monitoring in the future.

ANALYSIS OF THE USE OF ULTRASONIC TESTING METHODS IN THE FRAMEWORK OF CORROSION MONITORING OF INTERNAL CORROSION AT GAS PRODUCTION FACILITIES IN THE PRESENCE OF CARBON DIOXIDE

The use of various intrusive and non-intrusive methods of corrosion monitoring makes it possible to assess the corrosion situation and the effectiveness of the applied corrosion protection agents in conditions of internal corrosion at gas production facilities due to the presence of aggressive gases. The analysis of the application of ultrasonic testing methods as part of corrosion monitoring of internal corrosion at gas production facilities in the presence of corrosive components is carried out. Ultrasonic thickness measurement is widely used as a non-intrusive method for monitoring internal corrosion and detecting corrosion defects in promising gas fields. Many gas fields (Bovanenkovskoye oil and gas condensate field, Urengoy oil and gas field and others) revealed corrosion defects due to cases of internal corrosion due to the presence of increased amounts of carbon dioxide in the produced hydrocarbons. Under conditions of corrosion in the presence of carbon dioxide, ultrasonic methods for measuring the thickness of a metal have certain limitations associated with the unpredictable local nature of carbon dioxide corrosion, which should be considered when used in gas facilities. The main method for measuring thickness under operational conditions is ultrasonic thickness measurement, which is used in conjunction with radiographic monitoring. Using these two main non-intrusive methods, corrosion monitoring monitors the thinning of the metal, the size and depth of local defects and the dynamics of their change over time. Based on the results of measuring the residual wall thickness of the pipe and equipment, the possibility of their further work is determined, and recommendations are made on extending the safe life of gas facilities. The authors analyzed the literature data on new options and technical solutions for the use of ultrasonic methods in the measurement of the thickness of a metal surface.

Photo-Electrochemical Application of ZnOG Thin Film for in situ Monitoring of Steel Sour Corrosion

Further to traditional corrosion monitoring techniques for rated deteriorations, nowadays modern electrochemical monitoring methods are promising for the control of non-rated damage mechanisms. Considering carbon steel as the most commonly used alloy in the oil and gas industry, there are special grades under NACE MR0175 standard which are immune to sour corrosion. However, according to the industry reports, their immunity can be terminated by upset conditions or on site repairs. This issue will impose either a high operational risk or exorbitant maintenance and inspection costs. Hence, in this paper, a new monitoring technology framework is discussed to lessen a catastrophic failure risk for carbon steel under wet H2S corrosion. In this regard, the application of a developed hybridized ZnO-graphene micro-electrode (ZnOG) with a mix band gap of 1.17 eV is studied. Under hydrogen sulfide attack and when ZnOG hybrids are excited by UV illumination, their photo-electrochemical responses are analyzed. ZnOG hybrids emanate informative impedance signals in a response to the formation of ZnO(1 – x)Sx nano-crystals.

Combined application of novel electromagnetic sensors and acoustic emission apparatus to monitor corrosion process of reinforced bars in concrete

Reinforced bar corrosion is a primary reason for performance deterioration of reinforced concrete (RC) structures. Corrosion monitoring of reinforced bars in concrete is a key point to evaluate the durability and the remaining service life of structures, especially in marine environments. Non-destructive tests (NDTs) have been developed as critical methods to assess damage levels inside concrete without external damage based on physical characterization (e.g., electromagnetic response, acoustic signals, etc.). This paper provides a novel idea where home-made electromagnetic (EM) sensors and an acoustic emission (AE) apparatus are combined in order to monitor the entire corrosion process of reinforced concrete beams; meanwhile, a home-made electromagnetic sensor is also upgraded and introduced in this paper. The result shows that it is an excellent option to jointly utilize two kinds of monitoring apparatus to monitor signals from corrosion initiation and subsequent cracking, respectively, based on their own physical performances. Moreover, the reliability of monitoring signals is also highlighted in this paper.

Corrosion monitoring of the reinforced concrete by using the embedded annular piezoelectric transducer

It is an important issue to ensure the long-term reliable service of the reinforced concrete structures by developing effective online monitoring techniques. In this paper, three different accelerated corrosion experiments were conducted by using the electrochemical method, and the ultrasonic pitch-catch and the electrochemical impedance spectroscopy methods were employed to discuss the corrosion phenomena by using the embedded annular piezoelectric ultrasonic transducer. The results show that the capacitance arc length in the high frequency zone of the electrochemical impedance spectra increases gradually with increasing the corrosion rate. When the corrosion rate is larger than 3%, obvious corrosion products can be found on surface of the reinforced concrete, and there exist two capacitance arcs in the corresponding electrochemical impedance spectra. The ultrasonic analysis results show that there is an obvious longitudinal mode wave packet in the time domain spectra, and the peak-peak value shows a linear decreasing trend with increasing the corrosion time. The dominant frequency peak value also decreases with increasing the corrosion time accompanying with the appearances of the new peaks in the low frequency zone. The wavelet transform method was also employed for the ultrasonic time-frequency domain analysis. Based on variations of the acoustic energy and dominant frequency components of the ultrasonic wave, the corrosion extent of the reinforced concrete can be qualitatively evaluated.

Study on embedded system in monitoring of intelligent city pipeline network

The construction of an intelligent city needs healthy operation in all aspects. The monitoring of the intelligent city’s pipeline network in the paper is studied to ensure its healthy development. The surveillance and management system of urban underground pipeline network can improve the efficiency of network resource management, shorten the maintenance time of pipeline network, reduce the cost of resource consumption, resource management cost, and ensure the healthy operation of society. The pipeline network monitoring system is based on an embedded system, which can realize functions such as viewing, historical data query, trend analysis, alarm record query, data export, report generation, etc. The operation condition monitoring module mainly implements real-time monitoring and alarming functions for the state parameters, for example, temperature drop, pressure drop and flow velocity of each pipe section in the pipeline network, and integrates the temperature, pressure and flow data of the pipeline network and the customer terminal. The safe operation range of state parameters and alarm upper and lower lines are set by intelligent decision analysis system of pipe network and to judge the damage situation and countermeasures. The system integrates operation condition monitoring, corrosion monitoring, water hammer monitoring and other modules. Meanwhile, the monitoring interface integrates intelligent alarm and pipeline network structure information. After preliminary data processing, the system communicates with host computer data. The system also integrates the local alarm function of fault signal and valve control. Through GPRS technology as a data transmission channel and the interaction between the upper computer in the central control room and the embedded unit in the lower computer of scene. The pipeline operation parameters can be transmitted and the intelligent city pipeline network monitoring system can be realized, which plays an important role in the healthy development of the city.

Electromechanical impedance instrumented circular piezoelectric-metal transducer for corrosion monitoring: modeling and validation

Corrosion induced thickness loss of metallic structures is one of the most common issues across multiple industries. In our previous work, a new type of corrosion sensor based on lead zirconate titanate (PZT) using electromechanical impedance (EMI) technique was proposed. The sensor is fabricated by bonding a PZT patch onto a metal plate. The previous work has demonstrated that the peak frequencies in the conductance signatures decrease linearly with the increase of the corrosion induced thickness loss. However, a theoretical model that fully describe the coupled vibration between piezoelectric element and the metal plate, and the EMI characteristics has not been established. This paper presents the theoretical modeling of the EMI instrumented circular piezoelectric-metal transducer for corrosion monitoring purpose. Based on electro-elastic and Kirchhoff plate theory, the EMI responses of the transducer operated in transverse bending modes with free boundary conditions were modeled. Finite element modeling calculations and experimental measurement were conducted to validate the theoretical results with good agreement.

CORROSION OF WELDED CARBON STEEL PIPES IN OIL PRODUCTION FIELDS IN EGYPT

In oil production fields, corrosion of welded carbon steel pipes frequently occurs in areas near welds. Corrosion in other areas may take place at a lower frequency and with a lower detrimental effect. In this paper, a field survey is conducted of eight oil petroleum fields over a period of seven years. Testing of specimens of carbon steel welded joints is carried out under simulated conditions. This study investigates the predominated corrosion damage mechanisms in welded carbon steel pipes. It examines the critical factors triggering corrosion mechanisms and the techniques for corrosion monitoring and mitigation. Flow-induced corrosion and preferential weld corrosion were found to be the most effective mechanisms compared to pitting and microbiologically induced corrosion. Detrimental factors of corrosion mechanisms include flow rates and changes in process parameters of pH, fluid resistivity, and some anion concentrations. The corrosion mitigation was achieved by increasing the dosage of injected corrosion inhibitors.

Monitoring the Corrosion of Steel in Concrete Exposed to a Marine Environment.

Reinforced concrete structures require continuous monitoring and maintenance to prevent corrosion of the carbon steel reinforcement. In this work, concrete columns with carbon and stainless steel reinforcements were exposed to a real marine environment. In order to monitor the corrosion processes, two types of corrosion probes were embedded in these columns at different height levels. The results from the monitoring of the probes were compared to the actual corrosion damage in the different exposure zones. Electrical resistance (ER) probes and coupled multi-electrodes (CMEs) were shown to be promising methods for long-term corrosion monitoring in concrete. Correlations between the different exposure zones and the corrosion processes of the steel in the concrete were found. Macrocell corrosion properties and the distribution of the separated anodic/cathodic places on the steel in chloride-contaminated concrete were addressed as two of the key issues for understanding the corrosion mechanisms in such environments. The specific advantages and limitations of the tested measuring techniques for long-term corrosion monitoring were also indicated. The results of the measurements and the corrosion damage evaluation clearly confirmed that the tested stainless steels (AISI 304 and AISI 304L) in a chloride-contaminated environment behave significantly better than ordinary carbon steel, with corrosion rates from 110× to 9500× lower in the most severe (tidal) exposure conditions.

Pipeline corrosion assessment using piezo-sensors in reusable non-bonded configuration

In this paper, a piezoelectric sensor is used in its non-bonded configuration for non-destructive evaluation of a pipeline segment subjected to progressive corrosion damage. A new non-bonded sensor configuration, specially adapted for small diameter pipelines, known as modified non-bonded sensor (MNS), is proposed and evaluated. The new sensor configuration is evaluated for sensitivity in monitoring corrosion induced damage in pipeline segments in controlled laboratory setup through accelerated corrosion tests. The conventional surface-bonded piezo-sensor (SBPS) configuration is used as standard for comparison. Signature analysis using different methods is carried out in the study. Using the principles of the electro-mechanical impedance (EMI) technique, equivalent stiffness, damping and mass parameters are computed from the admittance signatures of both the configurations (MNS & SBPS) and compared. Experimental results show that piezo based a non-dimensional mass parameter from the MNS measurements are very effective in damage detection and quantification. The results are correlated with actual mass loss measurements and consequent corrosion rates are calibrated. The results clearly make case for practical usage of MNS configuration in corrosion detection and health monitoring of pipeline systems. The new MNS configuration proves to be a successful alternative to the conventional bonded piezo configuration.

Understanding environmental impacts on initial atmospheric corrosion based on corrosion monitoring sensors

Atmospheric corrosion monitoring (ACM) sensors were employed to study the initial atmospheric corrosion of carbon steels over a one-month period in six outdoor dynamic atmospheric environments in China. Based on the ∼250,000 corrosion data sets collected, the environmental impacts of relative humidity, temperature and rainfall on the initial corrosion behavior of carbon steels were investigated. The results showed that rainfall was the strongest environmental factor influencing the initial atmospheric corrosion rate. Relative humidity significantly influenced the corrosion of carbon steels in low-precipitation environments and non-rainfall period.

Flaw detection and monitoring over corroded surface through ultrasonic C-scan imaging

Corrosion monitoring is one of the significant areas that is gaining attention in Non-Destructive Evaluation (NDE). In most of the cases, the structures to be monitored will be already corroded and monitoring has to be done on the corroded surface. The corroded surface are not uniform due to the presence of oxides, degraded parts, scaling etc. This non-uniform surface hinders ultrasonic inspection over it. In this work, we investigate the effect of corrosion on ultrasonic parameters. Frequency optimization is done to identify the frequency for perfect inspection. Defect characterization is done through image reconstruction producing more accurate results over normal C-scan images. We exhibit the practicability of non-destructive, ultrasonic C-scan imaging in corrosion monitoring in oil and gas industry.

Real-Time AFM and Impedance Corrosion Monitoring of Environmentally Friendly Ceria Films on AA7075

Cerium-based conversion coatings have emerged as promising green alternatives to the harmful chromium-based ones, but the mechanism of corrosive protection still remains a subject of academic and industrial research. This study focuses at small scale phenomena of corrosion inhibition imparted by ceria (CeO2) to AA7075. Ceria nanoparticles were deposited from diluted and concentrated CeO2 sols by immersion. A multi-analytical approach, combining Atomic Force microscopy (AFM), Scanning Kelvin Probe Force Microscopy, Glow Discharge Optical Emission Spectroscopy, open circuit potential and electrochemical impedance spectroscopy was employed. Deposition of ceria films led to deactivation of cathodic sites, i.e. decreased Volta potential difference, resulting in increased corrosion inhibition. In situ AFM real-time monitoring revealed that during exposure to NaCl electrolyte, the changes in size of deposited ceria aggregates occurred: nanoparticles disintegrated/desorbed and re-deposited at the coating surface. The process was found to be dynamic in nature. Small particles size and inherent reactivity are believed to accelerate this phenomenon. Due to the greater CeO2 reservoir, this phenomenon was more pronounced with a thicker film, imparting longer term protection.

Long-Term Corrosion Monitoring by Titanium Wire Sensor and Vibration-Based Energy Harvester

Long-Term Corrosion Monitoring by Titanium Wire Sensor and Vibration-Based Energy Harvester

Acoustic Emission Technique as a Corrosion Monitoring Technique

Acoustic Emission Technique as a Corrosion Monitoring Technique

Corrosion Strategy in Oil Field System

Crude oil is the main economic supply in many countries. Corrosion has been considered as the first fatal factor destroying the crude oil plants such as crude oil equipment, oil wells, separation vessels, storage tanks, and pipelines. This is the main reason encouraging many companies and researchers to develop new technological methods to manipulate corrosion. In this review, we discuss the types of corrosion, corrosion control methods (chemical and non -chemical methods), corrosion removal methods and corrosion monitoring process (direct and indirect measurement of corrosion). In addition some perspectives on SRB bacteria, types of inhibitors and gases removal methods were provided.