Erosion-Corrosion and its Monitoring

Sambhav Jaina, Lavanya Mb*

a
Department of Biotechnology, Manipal Institute of Technology, Manipal Academy of
Higher Education, Karnataka.
Email: sambhav.jain1@learner.manipal.edu
b
Department of Chemical Engineering, Manipal Institute of Technology, Manipal Academy
of Higher Education, Karnataka.
Email: lavanya.m@manipal.edu
*Corresponding author’s email: lavanya.m@manipal.edu

Abstract

Corrosion caused due to the flow of a corrosive fluid over the surface of a material is known
as erosion-corrosion. The movement of the fluid causes erosion of the surface, while the fluid
itself corrodes the exposed layer. The study of this form of corrosion is important, especially
in the oil industry, where pipes are used to transport fluids over large distances. Erosion-
corrosion can lead to loss of efficiency in such industries.

Keywords:

Erosion, Corrosion, Slurry,

1. Introduction

Erosion-corrosion involves the acceleration of the rate of attack on a material due to relative
movement between a corrosive fluid and the material surface [1]. It results in the thinning of
the material over time, as layers from the surface are stripped away. The movement of the
fluid is generally rapid and causes mechanical wear and abrasion as well. The erosion aspect
of this form of corrosion involves the disturbance of the protective surface coating by the
high velocity fluid. This disturbance allows the corrosive elements in the fluid to strip the
protective coating, resulting in corrosion [2]. Ions from the surface of the material dissolve

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into the corroding fluid, which are then swept away by the flow of the liquid. Due to this
flow, corrosion of the material usually exhibits a directional pattern [3].

2. Test rigs

Test rigs are experimental set ups that enable us to design and test the various components
used in a system or machine. The role of the test rig is to assess the tolerance of the parts to
erosion due to various predetermined parameters, such as angle of attack, speed and force of
impingement, media etc. [4]. For the testing of erosion-corrosion, 2 types of test rigs are
generally used: the jet type and the rotating type. Some of the most common test rigs from
these 2 types are discussed below.

2.1 Jet type test rigs

As the name suggests, these types of rigs involve the use of a jet. The jet delivers the fluid
media at desired speed, angle, and force, towards the sample to be tested. The sample can be
either fixed in place or rotating, allowing us to test more parameters [5].

Stationary jet rigs have the sample immobilized and the nozzle continuously sending
impacting slurry at the sample [6]. These types of rigs are further differentiated depending on
when the erodent is added to the slurry. In some rigs the erodent is mixed beforehand and
then pumped through the nozzle; in others, it is added just before the slurry exits the nozzle.

In rotational jet rigs, the sample is repeatedly impacted by the slurry by the action of
rotational motion. The sample is fixed to a rotating disc or arm, with the nozzle attached
perpendicularly to the rotating part. The frequency of impaction can be increased or
decreased by changing the rotational speed of the disc [5].

Jet impingement rigs can also be distinguished between on the basis of recirculation of the
slurry. Rigs which recirculate the slurry are easier to design, construct and operate. Rigs
which do not recirculate the slurry, on the other hand, allows for a more uniform
concentration of particles in the slurry.

2.2 Rotational test rigs

The most common types of rotational test rigs are the slurry pot, Coriolis erosion device, and
the whirling arm device.

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First designed and fabricated in 1992 [7], the slurry pot remains as one of the most popular
test rigs to date. The specimens are mounted parallel to the main shaft, with the flow of the
slurry directed perpendicularly to the axis of the specimen. While in operation, the pot is
completely closed, with the slurry being drained out at the end of the test period. This test rig
has difficulty in controlling some parameters such as slurry temperature, density of impacting
particles etc. However, its ease of operation and manufacturing, and its ability to control the
slurry velocity, particle impact angle, etc. makes it a popular choice [8]. Further, its ability to
compare and test 4 different samples of different materials makes it a versatile rig.

The Coriolis erosion tester was introduced in 1984 by Tuzson [9] and further improved and
modified by Clark et al. in 1999 [10] to enable the testing of flat samples. The two specimens
are placed on a diametrical channel equidistant from the centre. As the rotation speed
increases, centrifugal forces force the slurry outwards from the centre. Coriolis forces
increase the interaction of the slurry particles with the specimen surface, and the high rotation
speed decreases the test time [8].

The whirling arm rig was developed to test specific erosion conditions rather than developing
an erosion model. It is a combination of a slurry pot and a jet, wherein the rotating specimens
are impinged by slurry fed through a jet [8]. The samples can be tilted as required to obtain
the test impingement angle. It was developed by Lin and Shao [11].

3. Measurement of Corrosion

While test rigs allows us to study the effect of erosion on materials, other techniques and
instruments are required to analyse corrosion and its effects. Some of these techniques are
studied below.

Developed in the 1950s, the Rotating Cylinder Electrode (RCE) is used to determine the
corrosion rate of materials in the presence of flowing fluids. It offers a good mass transport
control, which is dependent on the rotation speed. It operates in turbulent flow, is versatile in
the type of specimens that can be used and allows for the use of multiple electrodes where
required [12].

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7. Conclusions

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