Author: Ph.D. Yolanda Reyes, November 15, 2023.
Introduction
Pipeline corrosion is some of the major challenges in the oil and gas process industries, causing unplanned shutdowns and limiting operational performance. It is important that operators monitor the risk of corrosion and erosion and its impact on the condition of assets.
Currently, companies offer a wide variety of cutting-edge equipment for measuring corrosion and erosion, in order to offer the best data for a comprehensive understanding of the risks of these phenomena. Operators use this data to make more informed decisions, thereby maximizing plant performance, safety and profitability.
It is a considerable industrial problem, because it can cause accidents (breakage of a piece) and, in addition, represents a relevant cost. Furthermore, it is estimated that every second five tons of steel are dissolved in the world, coming from a few nanometers or picometers, invisible in each piece, but which, multiplied by the amount of steel that exists in the world, constitutes a significant amount.
In this context, the most innovative technologies for monitoring corrosion in pipes in the industry will be addressed.
Technological innovations in pipe corrosion monitoring
1.-High sensitivity ultrasonic technology
En el mundo de la integridad de la corrosión, es comprensible que la clave para un control efectivo de la corrosión no solo reside en el monitoreo, sino también en el mantenimiento constante de los equipos que suministran datos importantes para salvaguardar personas y activos. En este sentido, los equipos de monitoreo de corrosión interna, desarrollado por AXESS, se ha ganado el reconocimiento global como el estándar por excelencia en el control de la corrosión interna.
AXESS, a world leader in corrosion monitoring technology, offers the revolutionary SONOWALL 70 (Figure 1), or its equivalent, which employs highly sensitive ultrasonic technology. This non-intrusive instrument provides continuous corrosion and erosion monitoring, setting the standard in precision and reliability 1
The versatility of the system allows the connection of several transducers from a single point, facilitating periodic measurements of wall thickness with the corresponding date and time, or for more critical applications. Additionally, the ability to automatically collect and store continuous measurements from a single transducer ensures detailed and effective monitoring.
Featured Corrosion Monitoring Products from AXESS:
- Environmental Corrosion Monitors: Designed to evaluate and record changes in environmental conditions that could affect corrosion.
- Corrosion rate probes: Provide accurate measurements of corrosion rate, allowing proactive intervention.
- Test tubes for measurement and abrasion of Fluids: Equipped to evaluate corrosion in environments with aggressive and abrasive fluids.
- Ultrasonic Thickness Measurement System: Uses advanced technology to accurately measure wall thickness, vital for corrosion assessment.
With a regular maintenance plan and consistent utilization of components and spare parts supplied by leaders in the field, internal corrosion monitoring equipment can be kept in operation for extended periods without interruptions in production. This approach not only ensures equipment durability, but promotes safer, more secure operations.
Advanced technology ensures a continued commitment to asset security and integrity. Research and innovation in corrosion monitoring advances towards a future where protection against corrosion becomes a solid guarantee.
2.-Advanced corrosion measurement methods
In today’s industry, the importance of minimizing downtime and costs associated with repairs due to corrosion. For this reason, a complete line of specialized corrosion monitoring equipment, designed for a variety of materials and dimensions, is necessary.
This comprehensive range of instrumentation not only provides timely alerts on potential structural damage, but also enables detailed analysis of system corrosivity, identifying changes in process parameters and their effects on corrosive conditions 2 .
Video YouTube sobre monitoreo de la corrosión en tuberías cortesía de Morken Group2.
Electrical resistance test tubes (Microcor) and retractable coupons:
They are used depending on the time of measurement of the corrosion rate 3 .
- Long-term corrosion: Using coupon weight loss method, adapting to various materials and dimensions according to specific needs. will give a corrosion rate value (MPY), based on the
La técnica de pérdida de peso es la más simple y la más conocida de todos los métodos de monitoreo de corrosión. Esta técnica se basa en la exposición por un tiempo determinado de una muestra (cupón) del mismo material de la estructura supervisada, en el mismo ambiente corrosivo al que la estructura está expuesta. La medición obtenida de los cupones al analizarse es la pérdida de peso que ocurre en la muestra durante el período de tiempo al que ha sido expuesto, expresada como tasa de corrosión.
simplicidad de esta medición es tal, que la técnica de monitoreo con cupones es el método básico utilizado en muchos programas de inspección de la corrosión. Esta técnica es extremadamente versátil, debido a que los cupones de pérdida de peso pueden ser fabricados en cualquier aleación comercial disponible. Además, utilizando el diseño geométrico apropiado, una amplia variedad de fenómenos corrosivos pueden ser estudiados
Corrosión a corto plazo o instantánea: Empleo de probetas de resistencia eléctrica o de polarización lineal para evaluar corrosión a corto plazo, brindando resultados instantáneos para acciones rápidas.
Las probetas de resistencia eléctrica (ER) pueden ser consideradas como cupones de corrosión “electrónicos”. Al igual que los cupones, las probetas E/R proveen una medición de la pérdida de metal de un elemento expuesto a un ambiente corrosivo, pero a diferencia de los cupones, la magnitud de la pérdida de metal puede ser medido en cualquier momento, a la frecuencia que sea requerida, mientras la probeta se encuentre in-situ y permanentemente expuesto a las condiciones del proceso.
Accurate diagnosis and effective control:
- Identification of specific problems: Detailed diagnosis of particular corrosion problems, identification of underlying causes and determination of control parameters, such as pressure, temperature, pH and flow rate.
- Evaluation of prevention/control techniques: Effective measurement of the effectiveness of the corrosion prevention and control techniques applied to the system.
Wide pressure range:
These systems are configured to cover a wide range of pressures, spanning up to 6000 psi. This capability ensures that the equipment is versatile and able to adapt to a wide range of operating environments, from standard conditions to high pressure applications.
Corrosion monitoring systems not only ensure the prevention of costly damage, but are also ensuring effective asset management, with key information to maintain the integrity of your plant efficiently and cost-effectively to keep facilities in optimal operating condition. .
3.- Online corrosion monitoring equipment
Non-invasive systems to monitor corrosion using software for analysis and interpretation of remote data and solutions (figure 4,a,b,c) 4. “
Online Corrosion Monitoring: Online monitoring systems are designed to deliver your data, it is the simplest and most cost effective method for the needs. Offers an integrated remote process monitoring solution.
Cellular Corrosion Monitoring: For more remote locations, we offer flexible cellular and satellite options. Data can be sent from our range of instruments directly to your networked DCS, a cloud-hosted dashboard, email notifications, SMS and coordinates, GPS.
Database: Software available on the web for storing information or from any device connected to the Internet. For analysis of coupons, test tube data, non-intrusive pressure and temperature sensors and alarm programming by email and SMS
Importance of corrosion monitoring
Corrosion monitoring is essential to provide timely alerts on material degradation, allowing timely implementation of control strategies. This approach not only reduces the costs associated with major repairs, but also contributes to maintaining safe operations, avoiding potential adverse consequences.
Facilita la optimización de los programas de mantenimiento, al permitir intervenciones precisas en función del estado real de los materiales. Esto se traduce en una gestión más eficiente de los recursos y una prolongación significativa de la vida útil de los activos, maximizando la inversión inicial.
Corrosion monitoring is not only an advanced technical practice, but a safeguard for sustainability, safety and efficiency in various industries. Its rigorous implementation not only preserves assets and resources, but also contributes to the development of safer and more sustainable operations in the long term.
Conclusiones
Technologies for monitoring internal corrosion in industrial pipes represent a fundamental pillar in the efficient and safe management of assets in various sectors. These advanced techniques not only offer the ability to accurately detect and evaluate corrosive processes, but also provide advantages by enabling the implementation of preventive strategies.
La implementación de sistemas avanzados, como los medidores de espesores ultrasónicos y el análisis de datos especializado, no solo permite una vigilancia proactiva de posibles daños, sino que también posibilita la planificación eficiente de actividades de mantenimiento, reduciendo así el riesgo de paradas no programadas y optimizando los recursos operativos.
La adopción de tecnologías para el monitoreo de corrosión no solo eleva los estándares de seguridad y confiabilidad en las instalaciones industriales, sino que también contribuye a la eficiencia operativa y sostenibilidad a largo plazo. La capacidad de anticipar y abordar problemas de corrosión de manera oportuna no solo protege las inversiones, sino que también promueve prácticas más responsables y sustentables en el manejo de infraestructuras industriales.
Bibliographic references
- Corrotex, “Internal corrosion monitoring” consulted on November 12, 2023, https://corrotek.cl/service/monitoreo-de-corrosion-y-seguro/
- Morken Group, “Asset monitoring and control” Accessed November 12, 2023, https://morkengroup.com/monitoreo-de-la-corrosion-e-inyectores-quimicos/
- Dichem, “Corrosion monitoring equipment” Accessed November 13, 2023. http://www.oisa.com.ec/equipos-para-monitoreo-de-corrosion.html
- Integral Solutions, “Corrosion Monitoring”, Accessed November 14, 2023, https://vcsolucionesintegrales.com/productos-corrosion/
Sobre el autor:
Ing. Yolanda C Reyes, Ph.D, en Electroquímica y Corrosión, con más de 30 años de experiencia y un amplio y versátil conocimiento en Ciencias de la Corrosión y Tecnología Química a nivel Académico e Industrial. Investigador en el desarrollo de trabajos de investigación en Innovación y desarrollo de Recubrimientos Poliméricos Electroactivos, evaluación de recubrimientos e inhibidores de la corrosión y análisis de fallas de materiales metálicos. Asesor de planes de programas de mantenimiento en la industria en empresas petroleras, al frente de obras de servicios de limpiezas químicas y mecánicas de equipos tales como: Calderas, Intercambiadores de calor, entre otros.
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