Name

Jivakumaran A/L Rajasegaran

Shadeeshkumar A/L Visanathan
INDERJEET ADHIRAJSINGH (LEADER)
Chrishenson
Arwin A/L Jayapalan
Rahmani Abderrahmane

ID
1001233428
1001130036
1001233093
1001231143
1001130397
1001333904

Introduction
Corrosion monitoring may be defined as the systematic

measurement of corrosion rate of equipment with the object of

diagnosis and controlling corrosion.
It can also be used for monitoring efficiency of implementation

of corrosion control system.

Why ?
Prevent contamination of product which affect purity

and quality
Loss of valuable product due to leakage from pipeline
and storage tank
Safety purposes, prevent leakage of hazardous
material.
Failed of equipment like pump and valves

Corrosion Monitoring In Petroleum

Industries

Ultrasonic Thickness gauging

Radiographic Examination

Electrical Resistance Probes

Polarization Resistance probes

Hydrogen Probes

Corrosion Coupons

Ultrasonic Thickness gauging

Measures time taken by a pulse of sound to travel from

outside of a piece of metal, bounce off the opposite wall (or

crack, inclusion, etc.) and return to the surface.

Widely used for thickness monitoring of equipment & piping

systems in Refineries.

Systematic thickness recording & comparison with previous

readings for any deterioration and assessment of corrosion rate.

Diagram

Advantages & Disadvantages of

Ultrasonic Thickness Probe
Advantages
Non-destructive technique
Does not require access to both sides of the sample
Can be engineered to cope with coatings, linings, etc.
Disadvantages
Usually requires calibration for each material
Requires good contact with the material

Radiographic Examination
X-rays are beamed through equipment and expose a film on

opposite side of equipment.

Darkness (density) of the developed film in any given area is

proportional to thinness of the metal.

Cannot be used easily on large diameter or thick walled

vessels.

Diagram

Advantages & Disadvantages of

Radiographic Examination
Advantages
Detect surface and internal flaw
Can inspect hidden areas
Minimum part preparation
Disadvantages
Require high degree of skills
Safety hazard very expensive

Electrical Resistance Probes

Metal loss measurements are based on the change in

OHMIC Resistance of test probe elements.

With corrosion, the cross-sectional area of corroding

element reduces, resulting in increase in its electrical
resistance.
The electrical resistance changes are measured using the

wheat stone bridge principle.

ER changes are Time Dependant but results can be

assessed faster than corrosion coupons.

ER Probe remains Installed for its Operational life

Can be Used to Trigger an Alarm

Diagram

Advantages & Disadvantages of

Electrical Probe
Advantages
They are applicable to all working environments gases,
liquids, solids, particulate flows.
Direct corrosion rates can be obtained.
Probe remains installed in-line until operational life
has been exhausted.
They respond quickly to corrosion upsets and can be
used to trigger an alarm.
Disadvantages
Require an experience and high skill to operate

Linear Polarization Resistance (LPR)

Probes
Corrosion Rate indicated / measured Instantaneously

A Small Voltage is Applied to an Electrode in Solution

Measurement of Current indicates the Corrosion Rate
Can only be Used in relatively clean water / liquids /

eletrolytes.
Will not Work in Gases or Water/Oil Mixtures

Diagram

Advantages & Disadvantages of

LPR
Advantages
The measurement of corrosion rate is made
instantaneously.
Disadvantages
It can only be successfully performed in relatively clean
aqueous electrolytic environments.
Not work in gases or water/oil emulsions where fouling of
the electrodes will prevent measurements being made.

Hydrogen Probes

Hydrogen is a by-product of the corrosion reaction in

acidic solutions.

Hydrogen probes detect hydrogen permeating through

the steel an indication of corrosion rate.

Hydrogen probes are surface mounted.

Detects rate of hydrogen penetration / diffusion

through pipe wall.

Diagram

Advantages & Disadvantages of

Hydrogen Probe
Advantages
Provides an indication that corrosion is taking, or has
taken place.
Disadvantages
Hydrogen may be directly absorbed into the fabric of
the plant and produce blistering, embitterment, stress
corrosion.

Corrosion Coupons
Used for detection of corrosion in cooling water system.

The advantages of coupons includes:

Visual interpretation

Deposits can be observed and analyzed and layer effects studied.

Weight loss can be determined.

The degree of localization of corrosion can be observed & measured.

Inhibitor film effects can be observed.

It gives average corrosion rate.

Disadvantages
Only provide integrated corrosion loss data.

Corrosion Monitoring In Chemicals

Industries
Chemical industry includes those manufacturing facilities that

produce bulk or specialty compounds by chemical reactions

between organic and/or inorganic materials.
The design process of a chemical plant should incorporate a

model predicting the probability of corrosion-related failure and

low, moderate, and high corrosion risks.
Such a model allows corrosion engineers to focus on

equipment with a high corrosion risk and to select a cost-effective

corrosion-resistant material.

Challenges facing corrosion

monitoring in the industries
Coupon Technique :

If a corrosion upset occurs, during period of exposure, the

coupon alone cant identify the time of occurrence of the upset,

Depending upon the peak value of the upset and its duration,

may not even register a statistically significant increased

weight loss.

Challenges facing corrosion

monitoring in the industries
Corrosion under insulation

The development of Nondestructive

testing(NDT)/Nondestructive examination(NDE) technologies

- science and industry to evaluate the properties of a material,
component or system without causing damage.
New measuring techniques for the early detection of CUI in

onshore, offshore, subsea and pipelines.

Challenges facing corrosion

monitoring in the industries
Wide-area corrosion monitoring

Corrosion monitoring is restricted to single point

measurements.
Corrosion in piping and pressure vessels is rarely uniform and

can be underestimated or missed when using localised

detection methods.
There is no open protocol for how the data is manipulated in

order to display results and it is not possible to cross check

Conclusion

Corrosion monitoring offers an answer to the question of

whether more corrosion is occurring today as compared to

yesterday !
It is possible to qualify the cause of corrosion and quantify its
effect.
Corrosion monitoring remains a valuable weapon in the fight
against corrosion.

Thank you