Application of flexible resistometric sensors for real‐time corrosion monitoring under insulation
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Abstract Corrosion under insulation (CUI) is a form of corrosion typically occurring on steel pipes and vessels covered with thermal insulation. CUI is a critical issue in petrochemical and refining industry leading to significant financial losses and severe environmental hazards. State‐of‐the art CUI monitoring system consisting of wireless loggers with flexible resistometric sensors is used to assess the effect of insulation material, position, and presence of a defect on the actual corrosivity toward carbon steel under alternating condensation conditions. All three considered factors together with the climatic parameters and presence of corrosion products are important for the CUI process. Most complex is the role of the insulation material as the properties inhibiting corrosion under intact insulation may be linked to a worse insulating ability. Because of the high sensitivity and immediate response of the sensors, the technique can be applied for timely CUI detection of insulated pipelines in both industrial facilities and laboratory studies.Keywords:
Petrochemical
Corrosion monitoring
Between 1999 and 2001, corrosion-related costs accounted for 3.1% of the Gross Domestic Product (or $276 billion a year) in the US. To minimize the economical loss requires accurately predicting and effectively preventing corrosion. Generally, corrosion is the deterioration of metal by its interaction with a combination of physical and chemical environments. Therefore, corrosion detection can be indirectly achieved by monitoring the accumulation of corrosion products or the physical or chemical changes they cause, e.g. appearance, acoustic and electromagnetic transmission, pH, etc. On the other hand, corrosion can be directly monitored by its electrochemical characteristics such as corrosion current, electrochemical noise, corrosion potential. Each of these corrosion monitoring techniques is worth its own fulfilled discussion. Instead of go through each techniques exhaustively, we will just give a general review of the major corrosion monitoring techniques across different research areas, with the intention of a contribution to the interdisciplinary research of corrosion monitoring techniques. Keywords: Corrosion sensors, corrosion measurement, corrosion monitoring, acoustic sensors, electromagnetic sensors, electrochemical sensors, Acoustic Corrosion, Corrosion Detection, Optical Corrosion Sensors, optical fiber sensors, corroding electrode, corroding anode, electrochemical deterioration process, aluminum alloys, corrosion sensing techniques
Electrochemical noise
Corrosion monitoring
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Metal pipelines buried underground for long time,which are influenced by chemical corrosion and electrochemical corrosion,finally lead to corrosion failure of metal pipelines.In order to reduce the corrosion rate of pipelines and extend the service life of pipelines,the corrosion reasons and main corrosion factors of the buried pipelines were analyzed.Effective anti-corrosion measures were put forward.
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This paper deals with some topical examples of application of corrosion monitoring by electrochemical means to chemical plants, cooling water systems of a nuclear reactor and atmospheric corrosion fields. The corrosion monitoring with the linear polarization resistance method has an advantage in instantaneous measuring of corrosion rates of metals over conventional weight loss measurements. However, this method always requires the correlation between the corrosion rates calculated from the weight losses of immersed test specimens and those obtained from the readings of a corrosion meter.Deviations from the correlation are sometimes found for corrosion occurred in slurry scrubbers equipped in desulfurization plants and for corrosion in plants with processes operated at high pressures and high temperatures. The deviations can often be interpreted in terms of deposits, scales and accumulation of corrosion products formed on the surfaces of monitoring probes.Potential measurements are also useful for a better understanding of specific corrosion phenomena in a cooling water system of a nuclear reactor. The electrodes of stainless steel and platinum used as the corrosion monitoring can detect a large drop in corrosion potential due to the increase in temperature of the water and change in water chemistry.The application of monitoring techniques developed recently to practical fields is also described.
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Corrosion monitoring can be applied to measure the process gas and the state of corrosive liquid flow in the case of normal operation. With the purpose of comprehensive understanding of the oil and gas pipeline corrosion factors and the development of anti-corrosion measures,working principle,the technical characteristic and the monitoring procedures of Microcor corrosion monitoring are described in this paper. Compared with the commonly used corrosion monitoring technology such as the weight loss method,the linear polarization the resistance method,the resistance probe method as well as the application examples of Microcor corrosion monitoring,Microcor corrosion monitoring has the advantages of high sensitivity,wide application,stable performance,fast response and high resolution. Microcor corrosion monitoring corrosion is an ideal test technology of the corrosion process monitoring and the corrosion process control,especially for the inhibitor effect evaluation.
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Abstract A corrosion test system based on the electrical resistance method permits continuous monitoring of corrosion rates in refinery equipment without interrupting normal operations. Corrosion decreases the cross-section, and consequently the electrical conductivity, of a metal specimen exposed to refinery fluids at high temperatures and inaccessible locations. From the decrease in conductivity, or increase in resistance, the amount of corrosion which occurs between measurements can be determined. The system has been used successfully under all conditions of temperature and pressure encountered in a refinery. It has measured corrosion rates in vapor and liquid phases, with both oil and aqueous media. With the aid of the corrosion probe, corrosion rates in operating refinery equipment have been determined quantitatively in a few hours' time, as compared with months required for coupon measurements, water analyses, and unit inspections. Refinery corrosion inhibitors have been compared rapidly in actual use. Effects of changes in unit operating procedures upon corrosion rates have been observed shortly after the changes were made. Sensitive locations where corrosion is expected have been monitored frequently. 2.2.1
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The atmospheric and decompressed facilities for Qingdao petrochemical company mainly suffered two type corrosion,namly sulfur and sulphide high-temperature corrosion and H2S-HCl-H2O low-temperature corrosion.By means of the on-line corrosion monitoring system the apropriate data as reference for the corrosion protection for the above processing facilities can be acquired.The mechanism and function of corrosion monitoring system were analyzed by experiment in this paper which offers effective methods and solutions for the corrosion protection of the facilities refining crude oils with high-acidic and high-sulfur content.
Petrochemical
Corrosion monitoring
Refining (metallurgy)
High-Temperature Corrosion
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Traditionally, for evaluating corrosion resistance of materials used in atmospheric conditions, exposure tests in the actual environment and accelerated corrosion tests in the laboratory have been widely used. Till now, it has been very difficult to estimate in detail corrosion rate variations caused by the change of each environmental factor such as temperature, relative humidity, amount of airborne sea salt during the test periods. Also, it requires a long time period to evaluate the corrosivity in actual corrosive atmospheric environments. For these reasons, an in-situ corrosion monitoring technique is useful. Time variation of corrosion rate has been successfully monitored by using an electrical resistance corrosion sensor, which converts the increase of electrical resistance caused by metal consumption to corrosion loss. Additionally, a new accelerated corrosion test was authorized as ISO 16539 Method B on March 1, 2013. This test has good correlation with corrosion behavior in an actual corrosive atmospheric environment. In this study, the details of the corrosion rate of steel and zinc were evaluated by the accelerated corrosion test (ISO 16539 Method B) and atmospheric exposure test. In addition, the relation between corrosion rate and each environmental factor was analyzed. Two kinds of electrical resistance corrosion sensors, an Fe sensor (250 µm thick) and a Zn sensor (50 µm thick), were used. In the accelerated corrosion test (ISO16539-Method B), the corrosion depth as evaluated by the sensors displayed a good correlation with that of the exposure test samples. The variation in the corrosion rate could be evaluated by the sensors. And also, it was confirmed that the corrosion rate increased during the wet stage and decreased during the dry stage in both sensors. In exposure tests in Okinawa and Kawasaki, the variation of the corrosion rate due to the effects of changeable environmental conditions throughout the year could be evaluated by the sensors. Okinawa is seashore area at the s southern island in Japan, and Kawasaki is industrial area in Japan. The corrosion rate in Okinawa as evaluated by the Fe sensor was greater than that found in Kawasaki. However, the corrosion rate in Okinawa as evaluated by the Zn sensor was almost the same as that in Kawasaki. The corrosion sensors could clarify the difference in corrosion behavior between steel and zinc. Furthermore, the relationship between the corrosion rate and the environmental factors (temperature, relative humidity, amount of airborne sea salt, etc.) was analyzed. The corrosion rate of steel had a positive relation with temperature, relative humidity and airborne sea salt. The dependence of corrosion rate of zinc on environmental factors was also investigated. Comparison of corrosion behavior and its dependence of environmental factors between iron and zinc will be discussed.
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Corrosion monitoring can be used to measure the process gas and the state of corrosive liquid flow in the case of normal operation.The corrosion monitoring technology is a basis about comprehensive understanding corrosion factors of oil and gas field production systems and the establishment of corrosion protection measures.It is corrosion monitoring and evaluates the effectiveness of measures effective means.It can be used to guide the work in accordance with anti-corrosion and play a role in corrosion control of oil and gas production and developments of corrosion.The purpose of this paper in the aspets of corrosion monitoring,significance and technical connotation combines field applicable examples in research on the application of corrosion monitoring technology to the oil and gas fields.
Corrosion monitoring
Natural gas field
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Corrosion monitoring
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This study represents the result of corrosion monitoring on reinforced concrete specimens by means of multi-functional corrosion monitoring sensors. To confirm the effectiveness of the sensors, eight different kinds of condition were adopted. Test factors were corrosion potential, current, corrosion rate, resistivity, and temperature, which were monitored with the sensors. Through this study, judging corrosion of steel in concrete with single corrosion factor such as corrosion potential was difficult, because many other factors can have an influence on the reaction of corrosion. By using three different kinds of sensors, it could enhance the accuracy of corrosion monitoring.
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