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As facilities in the oil and gas industry age with time, corrosion mitigation and control become more important. Failure of processing equipment is likely to entail production loss, loss of containment, environmental impact, and/or human risk. Internal corrosion failures represent one of the major risks to process equipment and piping.
With the new development in the fields of corrosion and condition monitoring for equipment and piping, multiple new technologies have been introduced. While there is an overlap between corrosion monitoring and condition monitoring, there are critical distinctions that are often overlooked. Corrosion monitoring technologies include corrosion coupons and online corrosion sensors; both provide data on the corrosivity of process fluids. Coupons provide one corrosion rate reading over a long interval (usually one data point every quarter), but provide much more data on active damage mechanisms and the scale/corrosion products. Online corrosion sensors (commonly known as corrosion probes), on the other hand, provide online live data of the system corrosivity. One of the latest developments in the field of condition monitoring technologies is online permanent UT sensors, which will be the focus of this paper. They are installed in locations where a high corrosion rate is expected to directly measure the remaining thickness of the pipe/equipment. Corrosion monitoring and condition monitoring technologies provide different types of data that have different uses to manage the integrity of piping and equipment. Relying only on one of them is not sufficient. As such, this paper explores the differences between corrosion and condition monitoring, their pros, and cons, and how to get the most out of their installation.
The corrosion is a spontaneous chemical reaction connected to heat exchangers and pipelines that degrades the strength and quality of utilized steel. The aggressive environment, which is ongoing, intense, and frequently difficult to totally prevent, is the key factor contributing to the metal's deterioration. Additionally, it demonstrates a serious economic problem that causes industrial operational assets to require expensive repairs, ruining the public space.
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One of the most common ways of protecting steel assets and structures is by organic protective coating systems. The performance of such protective coating systems is assessed based on results after accelerated laboratory exposure testing, where one attempts to mimic the conditions the coatings will be exposed to under in-service conditions in a significantly shorter time frame. Such testing is also how coating systems are qualified for certain corrosivity classes and durabilities, being formalized in standards and specifications such as ISO 12944-6 and NORSOK M-501 ed. 7.
Atmospheric corrosion monitoring has traditionally been a lengthy and costly discipline. Visual inspection and weight loss testing is commonly applied, and this requires years of testing and on-site inspections with regular intervals. Furthermore, inspections and surveys in marine environments are troublesome, expensive and sometimes dangerous.