CORROSION MONITORING CORROSION MONITORING –– FACT OR FICTION?FACT OR FICTION?

COLIN BRITTONCOLIN BRITTONINDEPENDENT CONSULTANTINDEPENDENT CONSULTANT

SUMMARY (A)SUMMARY (A)

••

DEFINITIONDEFINITION••

DEVELOPMENT OF METHODSDEVELOPMENT OF METHODS

••

EARLY EQUIPMENT MANUFACTURERSEARLY EQUIPMENT MANUFACTURERS••

USER INDUSTRIESUSER INDUSTRIES

••

SOURCES OF EXPERTISESOURCES OF EXPERTISE••

LITERATURE SOURCESLITERATURE SOURCES

••

STANDARDSSTANDARDS

SUMMARY SUMMARY ––

(B)(B)

••

CONFERENCESCONFERENCES••

SURVEY OF USERSSURVEY OF USERS

••

CASE HISTORIES CASE HISTORIES ––

POSITIVEPOSITIVE••

CASE HISTORIES CASE HISTORIES ––

NEGATIVENEGATIVE

••

POST SURVEY DEVELOPMENTPOST SURVEY DEVELOPMENT••

FACTORS FOR SUCCESSFACTORS FOR SUCCESS

••

CONCLUSIONSCONCLUSIONS

CORROSION MONITORING - DEFINITION

‘‘The systematic measurement of the The systematic measurement of the corrosion or degradation of an item of corrosion or degradation of an item of equipment, with the objective of assisting equipment, with the objective of assisting understanding of the corrosion process understanding of the corrosion process and/or obtaining information for use in and/or obtaining information for use in controlling corrosion and its consequencescontrolling corrosion and its consequences’’

DEVELOPMENT OF METHODSDEVELOPMENT OF METHODS

••

COUPONSCOUPONS••

HYDROGEN PROBESHYDROGEN PROBES

••

ELECTRICAL RESISTANCE PROBESELECTRICAL RESISTANCE PROBES••

ELECTROCHEMICAL PROBES (LPR ELECTROCHEMICAL PROBES (LPR

AND OTHER)AND OTHER)••

NDT/NDE (METHODS AVAILABLE THAT NDT/NDE (METHODS AVAILABLE THAT HAVE BRIDGED HISTORICAL DIVISION)HAVE BRIDGED HISTORICAL DIVISION)

EARLY EQUIPMENT EARLY EQUIPMENT MANUFACTURERSMANUFACTURERS

••

MAGNA CORPORATION*, USAMAGNA CORPORATION*, USA••

PETROLITE CORPORATION*, USAPETROLITE CORPORATION*, USA

••

GRANT OIL TOOL GRANT OIL TOOL ––COSASCO, USACOSASCO, USA••

CAPROCO, CANADACAPROCO, CANADA

••

SENSORS AND SYSTEMS LTD, UKSENSORS AND SYSTEMS LTD, UK

* Process chemicals supplied* Process chemicals supplied

USER INDUSTRIES (A)USER INDUSTRIES (A)

••

OIL AND GAS OIL AND GAS ––

PRODUCTION AND PRODUCTION AND REFININGREFINING

••

CHEMICAL AND PETROCHEMICAL CHEMICAL AND PETROCHEMICAL --PRODUCTIONPRODUCTION

••

OTHER PROCESS PLANTOTHER PROCESS PLANT

USER INDUSTRIES (B)USER INDUSTRIES (B)

••

POWER PRODUCTION POWER PRODUCTION --

BOILER AND BOILER AND WATER COOLING TREATMENTWATER COOLING TREATMENT

••

OTHER PROCESS PLANTOTHER PROCESS PLANT

••

MISCELLANEOUS (AIRCRAFT/CARS)MISCELLANEOUS (AIRCRAFT/CARS)

SOURCE OF EXPERTISESOURCE OF EXPERTISE

••

LARGER CHEMICAL COMPANIES (ICI)LARGER CHEMICAL COMPANIES (ICI)••

LARGER OIL COMPANIESLARGER OIL COMPANIES

••

DEFENCE (ADMIRALTY IN UK)DEFENCE (ADMIRALTY IN UK)••

UNIVERSITY INPUTUNIVERSITY INPUT

••

OFFICE OF SALINE WATER (US)OFFICE OF SALINE WATER (US)••

NUCLEAR INDUSTRYNUCLEAR INDUSTRY

LITERATURE SOURCESLITERATURE SOURCES

••

INDUSTRIAL CORROSION MONITORING INDUSTRIAL CORROSION MONITORING (D. OF INDUSTRY(D. OF INDUSTRY--

COMMITTEE OF COMMITTEE OF

CORROSION CORROSION --

J G HINES/ P J MORELAND/ J G HINES/ P J MORELAND/ G P ROTHWELL/ J C ROWLANDS/ W R G P ROTHWELL/ J C ROWLANDS/ W R MORGAN, 1978, 60 p, 47 REFERENCESMORGAN, 1978, 60 p, 47 REFERENCES

••

NACE, PROBES (E/R AND LPR), Document NACE, PROBES (E/R AND LPR), Document 3D170 3D170

STANDARDSSTANDARDS

••

NACE NACE ––

3D170 3D170 ––

PROBES (E/R AND LPR)PROBES (E/R AND LPR)••

NACE NACE --

1C187 1C187 ––

GALVANIC PROBESGALVANIC PROBES

••

NACE NACE --

1C184 1C184 ––

HYDROGEN PROBESHYDROGEN PROBES••

ASTM G4 ASTM G4 ––

COUPONS (PLANT)COUPONS (PLANT)

••

NACE NACE ––

RPO189 RPO189 ––

COOLING WATERSCOOLING WATERS••

NACE NACE ––

RPO192 RPO192 ––

OIL AND GAS (IRON OIL AND GAS (IRON

COUNTS)COUNTS)

CONFRENCESCONFRENCES

••

ONON--LINE SURVEILLANCE AND MONITORING OF LINE SURVEILLANCE AND MONITORING OF PLANT PLANT ––

SCI (UK)1977SCI (UK)1977

••

C.M. IN THE OIL, PETROCHEM. AND PROCESS C.M. IN THE OIL, PETROCHEM. AND PROCESS INDUSTRIES INDUSTRIES ––

OYEZ (UK) 1980OYEZ (UK) 1980

••

C.M. AND INSPECTION IN PROCESS C.M. AND INSPECTION IN PROCESS INDUSTRIES INDUSTRIES ––

OYEZ, (UK) 1984OYEZ, (UK) 1984

••

CONDITION M. REFINERIES ETC CONDITION M. REFINERIES ETC ––

BRINTEX BRINTEX (UK) 1992(UK) 1992

COMPUTER DATA BASECOMPUTER DATA BASE

••

CORROSION MONITORING CORROSION MONITORING ––

A A RESOURCE DIGEST FOR THE ACHILLES RESOURCE DIGEST FOR THE ACHILLES EXPERT SYSTEM PROJECT *EXPERT SYSTEM PROJECT *CONTENTSCONTENTS ––

INTRODUCTION/ INTRODUCTION/

JUSTIFICATION/ STATEGY/ CORROSION JUSTIFICATION/ STATEGY/ CORROSION TYPES/ TECHNIQUES/ TYPES/ TECHNIQUES/ INSPECTION INSPECTION AND PLANT MONITORINGAND PLANT MONITORING/ / APPENDICES/ BIBLIOGRAPHYAPPENDICES/ BIBLIOGRAPHY

* * dtidti

financefinance

NEGATIVE CASE NEGATIVE CASE HISTORIES HISTORIES

••

CHEMICAL PLANT CHEMICAL PLANT ––

PROBE BODIES PROBE BODIES CORRODEDCORRODED

••

GAS PRODUCTION GAS PRODUCTION ––

PROBE LOCATION PROBE LOCATION INCREASED CORROSIONINCREASED CORROSION

••

OIL REFINING OIL REFINING ––

WRONG TECHNIQUE WRONG TECHNIQUE ADOPTEDADOPTED

••

SAFETY ASPECT SAFETY ASPECT ––

PACKING GLANDPACKING GLAND

SURVEY OF USERSSURVEY OF USERS

••

C. BRITTON & B. TOFIELD (1981 & 1984)C. BRITTON & B. TOFIELD (1981 & 1984)••

NACE CONFERENCE EDUCATION LECTURENACE CONFERENCE EDUCATION LECTURE

••

MATERIALS PERFORMANCE, APRIL, 1988, PP MATERIALS PERFORMANCE, APRIL, 1988, PP 4141--

4444

••

M. CLARK 1983, NACEM. CLARK 1983, NACE--ICORR JOINT VENTURE ICORR JOINT VENTURE REPORT, CORROSION MONITORING IN THE REPORT, CORROSION MONITORING IN THE NORTH SEANORTH SEA

SURVEY SURVEY ––

1981 FINDINGS (A)1981 FINDINGS (A)

••

VARIED RESPONSEVARIED RESPONSE••

WIDESPREAD CONCERN WITH THE WIDESPREAD CONCERN WITH THE SIGNIFICANCE OF RESULTSSIGNIFICANCE OF RESULTS

••

RUGGEDNESS AND RELIABILITY RUGGEDNESS AND RELIABILITY PROBLEMSPROBLEMS

••

CONCERN WITH INTRINSIC SAFETYCONCERN WITH INTRINSIC SAFETY

SURVEY SURVEY ––

1981 FINDINGS (B)1981 FINDINGS (B)

••

WHERE WHERE CMCM IS SUCCESSFUL, SEVERAL IS SUCCESSFUL, SEVERAL TECHNIQUES ARE ALMOST IN USETECHNIQUES ARE ALMOST IN USE

••

WIDESPREAD INTEREST IN NEW WIDESPREAD INTEREST IN NEW TECHNIQUESTECHNIQUES

••

UNIVERSAL USE OF NDT (UT AND UNIVERSAL USE OF NDT (UT AND RADIOGRAPHY)RADIOGRAPHY)

SURVEY SURVEY --

1984 FINDINGS (A)1984 FINDINGS (A)

••

INCREASED AWARENESSOF THE NEED INCREASED AWARENESSOF THE NEED FOR FOR CMCM REQUIREMENTS TO BE REQUIREMENTS TO BE CONSIDERED AT THE PLANT DESIGN CONSIDERED AT THE PLANT DESIGN STAGESTAGE

••

EXPANDED USE OF EXPANDED USE OF CMCM IN MANY IN MANY COMPANIESCOMPANIES

••

IMPROVED RELIABILITY OF EQUIPMENT IMPROVED RELIABILITY OF EQUIPMENT BUT MORE TO BE DONEBUT MORE TO BE DONE

SURVEY SURVEY ––

1984 FINDINGS (B) 1984 FINDINGS (B)

••

GREATER APPRECIATION OF THE GREATER APPRECIATION OF THE QUALITATIVE NATURE OF QUALITATIVE NATURE OF CMCM DATA AND DATA AND THE NEED TO LEARN BY EXPERIENCETHE NEED TO LEARN BY EXPERIENCE

••

MAINTENANCE COSTS OFTEN TOO HIGHMAINTENANCE COSTS OFTEN TOO HIGH••

DESIRE TO GO MORE AUTOMATIC AND DESIRE TO GO MORE AUTOMATIC AND ONON--LINELINE

SURVEY SURVEY ––

1984 FINDINGS (C)1984 FINDINGS (C)

••

AWARENESS THAT SYSTEM AWARENESS THAT SYSTEM INSTALLATION IS EXPENSIVEINSTALLATION IS EXPENSIVE

••

CONTINUING INTEREST IN NEWCONTINUING INTEREST IN NEWTECHNIQUESTECHNIQUES

••

REPAIRS AND SERVICE REPAIRS AND SERVICE --

USA SOURCEUSA SOURCE

POST SURVEY POST SURVEY ––

POSITIVE CASE POSITIVE CASE HISTORIES HISTORIES

••

CHEMICAL PLANTCHEMICAL PLANT••

OIL AND GAS PRODUCTIONOIL AND GAS PRODUCTION

••

OIL REFININGOIL REFINING••

NUCLEAR REACTOR OPERATIONNUCLEAR REACTOR OPERATION

••

BOILER OPERATIONBOILER OPERATION••

COOLING WATER SYSTEMSCOOLING WATER SYSTEMS

••

PIPELINES PIPELINES ––

IMPROVED IMPROVED ““ILIILI””

SYSTEMSSYSTEMS

INSPECTION INSPECTION ––

NEGATIVESNEGATIVES TRAINING/MANAGEMENTTRAINING/MANAGEMENT

••

SS NORWAY (CRUISE LINER) SS NORWAY (CRUISE LINER) ––

BOILER BOILER EXPLOSION IN DOCK, EIGHT CREW KILLED, SIX EXPLOSION IN DOCK, EIGHT CREW KILLED, SIX SERIOUS INJURIESSERIOUS INJURIES

••

UK UK ––

FAIRGROUND RIDE FAIRGROUND RIDE ––

TWO PERSONS TWO PERSONS KILLED, ONE PERSON SERIOUSLY INJUREDKILLED, ONE PERSON SERIOUSLY INJURED

••

UK UK ––

PLASTICS FACTORY PLASTICS FACTORY ––

EXPLOSION DUE TO EXPLOSION DUE TO CORROSION, NINE WORKERS KILLED, THIRTYCORROSION, NINE WORKERS KILLED, THIRTY--

SEVEN SERIOUS INJURIESSEVEN SERIOUS INJURIES

FACTORS FOR SUCCESS (A)FACTORS FOR SUCCESS (A)

••

OBJECTIVES OF PROGRAMME DEFINEDOBJECTIVES OF PROGRAMME DEFINED••

CONSIDERATION OF CONSIDERATION OF CMCM DESIRABLE AT DESIRABLE AT DESIGN STAGE OF PLANTDESIGN STAGE OF PLANT

••

MORE APPRECIATION OF TECHNIQUES MORE APPRECIATION OF TECHNIQUES AVAILABLE AVAILABLE

FACTORS FOR SUCCESS (B)FACTORS FOR SUCCESS (B)

••

BETTER COBETTER CO--ORDINATION WITH ORDINATION WITH INSPECTION DEPARTMENTINSPECTION DEPARTMENT

••

ANALYSIS OF FLOW DYNAMICSANALYSIS OF FLOW DYNAMICS••

CORRECT LOCATION OF MONITORING CORRECT LOCATION OF MONITORING LOCATIONS LOCATIONS ––

SOURCES OF EXPERTISE?SOURCES OF EXPERTISE?

FACTORS FOR SUCCESS (C)FACTORS FOR SUCCESS (C)

••

DEVELOPMENT IN COMPUTER SYSTEMS DEVELOPMENT IN COMPUTER SYSTEMS FOR HANDLING/PROCESSING DATAFOR HANDLING/PROCESSING DATA

••

MANAGEMENT SYSTEMS FOR OPERATION MANAGEMENT SYSTEMS FOR OPERATION AND REPORTING OF DATA AND REPORTING OF DATA ––

WHO? VIA? WHO? VIA?

TO?TO?••

ONGOING MONITORING OF PROGRAMMEONGOING MONITORING OF PROGRAMME

CORROSION MONITORING CORROSION MONITORING -- OVERVIEW 2010OVERVIEW 2010

••

WELL ESTABLISHED TECHNOLOGY AND WELL ESTABLISHED TECHNOLOGY AND SCIENCE AMONGST SCIENCE AMONGST ““CORROSION AWARE CORROSION AWARE INDUSTRIESINDUSTRIES””

••

IDENTIFIED IN SEVERAL INTERNATIONAL IDENTIFIED IN SEVERAL INTERNATIONAL STANDARDSSTANDARDS

••

CONSOLIDATION INTO PROCESS CONSOLIDATION INTO PROCESS INSTRUMENTAION (MANUFACTURERS)INSTRUMENTAION (MANUFACTURERS)

EXAMPLE EXAMPLE ––

NACE COMMITTEENACE COMMITTEE --

OIL REFINING REQUIREMENTS OIL REFINING REQUIREMENTS

••

SENSITIVE & RELIABLESENSITIVE & RELIABLE••

FAST RESPONSE TIMEFAST RESPONSE TIME

••

OPERATE IN MOST IF NOT ALL ENVIRONMENTSOPERATE IN MOST IF NOT ALL ENVIRONMENTS••

MUST HAVE ONLINE AND REMOTE DATA MUST HAVE ONLINE AND REMOTE DATA ACCESSACCESS

••

SHOULD BE UNAFFECTED BY IRON SULPHIDESHOULD BE UNAFFECTED BY IRON SULPHIDE••

UNAFFECTED BY NOISE, VIBRATION AND UNAFFECTED BY NOISE, VIBRATION AND TEMPERATURETEMPERATURE

••

COMPATIBLE WITH LOCAL PLANT SERVICESCOMPATIBLE WITH LOCAL PLANT SERVICES

CORROSION CORROSION MONITORING/INSPECTION MONITORING/INSPECTION --

DEVELOPING METHODSDEVELOPING METHODS

••

FIBRE OPTICSFIBRE OPTICS••

MULTISYSTEM SENSORSMULTISYSTEM SENSORS

••

ELECTROCHEMICAL METHODSELECTROCHEMICAL METHODS••

LONG RANGE U/T SYSTEMSLONG RANGE U/T SYSTEMS

••

NONNON--INTRUSIVE SENSING INTRUSIVE SENSING --

FSM/OTHER?FSM/OTHER?

SENSITIVITYSENSITIVITY

(ref: Joosten et al, Materials Performance, April 1995, 44(ref: Joosten et al, Materials Performance, April 1995, 44--48)48)

TECHNIQUETECHNIQUE RESOLUTIONRESOLUTION RESPONSE RESPONSE TIME AT 1 mpyTIME AT 1 mpy

RESP. TIME AT RESP. TIME AT 40 mpy40 mpy

ELECTROELECTRO--CHEMICALCHEMICAL

1.0 1.0 μμAA MINUTESMINUTES MINUTESMINUTES

FSM 25mm (wall FSM 25mm (wall thickness)thickness)

0.025 mm0.025 mm 1 YEAR1 YEAR DAYSDAYS

E/RE/R 0.00025 mm0.00025 mm 4 DAYS4 DAYS MINUTESMINUTES

U/T FIXEDU/T FIXEDPROBEPROBE

0.1 mm0.1 mm 4 YEARS4 YEARS 40 DAYS40 DAYS

COUPONCOUPON 1.0 mg1.0 mg MONTHSMONTHS DAYSDAYS

CORROSION MONITORING CORROSION MONITORING -- PATENTSPATENTS

PATENTS ISSUED AS OF 18PATENTS ISSUED AS OF 18THTH

MARCH 2010MARCH 2010

49,70049,700

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CORROSION MONITORING CORROSION MONITORING ––

FACT FACT OR FICTION?OR FICTION?

FACT FACT –– NO DOUBT NO DOUBT

ABOUT IT!ABOUT IT!