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Materials Today: Proceedings xxx (xxxx) xxx

Contents lists available at ScienceDirect

Materials Today: Proceedings


journal homepage: www.elsevier.com/locate/matpr

Pipeline corrosion assessment using electromechanical impedance


technique
Amit Thoriya ⇑, Tarak Vora, Pius Nyanzi
Department of Civil Engineering, Marwadi University, Rajkot 360003, India

a r t i c l e i n f o a b s t r a c t

Article history: Pipelines which transport and distribute petroleum products, oil, and gas, chemical substances, water,
Available online xxxx steam are vital to the economy. And these vital assets’ health is adversely affected significantly by corro-
sion. Moreover, the corrosion of pipelines leads to periodical maintenance which often results in shut-
Keywords: down of operation and even leads to catastrophic failure of pipelines. Hence, an adequate monitoring
Pipelines system is required to detect and monitor corrosion in the pipelines. The Electromechanical Impedance
Accelerated corrosion Based method has emerged as the most promising non-destructive technique because of its ability to
Electromechanical impedance
detect damage at an incipient level. This research work presents corrosion monitoring of mild steel
Lead zirconate titanate (PZT) patch
Corrosion
pipelines using the Electromechanical Impedance Method (EMI). The corrosion monitoring was carried
out for full surface corrosion and strip corrosion in mild steel specimens by simulating corrosion through
the accelerated corrosion test. The variation in the conductance signature is used for the qualitative and
quantitative evaluation of corrosion damage. The conductance of specimens is acquired using the LCR
meter at regular intervals of time. Results indicate that the magnitude of conductance signature is
decreased with an increase in the degree of corrosion. The quantification of corrosion amount is evalu-
ated through Root Mean Square Deviation (RMSD), Moving Absolute Percent Deviation (MAPD), and
Correlation Coefficient Deviation (CCD). All three matrices increase with the increase of the corrosion
degree. The RMSD and CCD are consistent with the degree of corrosion. Among the three metrics, the
MAPD has the most pronounced values and showed the highest sensitivity. The results from the study
show promising development in SHM and illustrate the capability to quantify imminent corrosion in
pipelines using damage indices.
Copyright Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Confer-
ence on Applied Research and Engineering 2021

1. Introduction alone for pipeline corrosion. However, the use of currently avail-
able corrosion monitoring techniques can reduce the cost of corro-
The pipelines are considered as one of the essential parts of civil sion by 15% to 35%, i.e., between US$375 and $875 billion globally
infrastructure, which carries natural oil and gases, water, haz- [3]. Hence, there is a need for structural health monitoring or con-
ardous materials, and other substances. The length of pipelines ditional monitoring for pipelines that can identify and detect the
all over the world is approximated as 2,175,000 miles [1]. Further- corrosion at the incipient level so further deterioration can be pre-
more, the length of oil and gas pipelines globally is expected to be vented by corrosion mitigation techniques, which reduces the cost
increased by the rate of 7.2% [2]. Hence, pipeline facilities are one of corrosion. The polymer adhesive also used to prevent the corro-
of the most critical elements for the economic growth of any sion behaviour of pipelines [4,5].
nation. But, unfortunately, corrosion is one of the most critical fac- The non-destructive testing of pipelines is carried out by mag-
tors which endangers the health and reliability of these critical netic flux leakage, guided waves, electrochemical impedance spec-
assets. As per the NACE 2013, the global cost of corrosion is troscopy, linear polarization technique, optical fibre-based
approximately estimated as USD 2.5 trillion and USD 276 billion techniques. These methods provide valuable health monitoring
data, but they failed to provide real-time data due to automation
[6]. Hence, this research focuses on real-time health monitoring
⇑ Corresponding author.
of corrosion in pipelines using the Electromechanical Impedance
E-mail address: amitthoriya@gmail.com (A. Thoriya).

https://doi.org/10.1016/j.matpr.2021.12.030
2214-7853/Copyright Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Applied Research and Engineering 2021

Please cite this article as: A. Thoriya, T. Vora and P. Nyanzi, Pipeline corrosion assessment using electromechanical impedance technique, Materials Today:
Proceedings, https://doi.org/10.1016/j.matpr.2021.12.030
A. Thoriya, T. Vora and P. Nyanzi Materials Today: Proceedings xxx (xxxx) xxx

technique (EMI). The current corrosion monitoring technique has nique for damage detection in structures. However, a limited num-
several deficiencies, including high time requirements, the shut- ber of research works have been reported for corrosion detection
down of operation during test time, absence of automation, chal- and especially in pipeline structures. This paper presents a corro-
lenging test procedures requiring massive data management. sion detection assessment of mild steel pipelines using the EMI
However, the EMI technique can provide a practical and easy-to- technique by considering the real part of admittance under the full
use conditional assessment when combined with PZT (Lead Zir- surface and the strip surface corrosion. First, the qualitative assess-
conate Titanate) sensors. ment of corrosion is discussed based on the magnitude of conduc-
The EMI technique has emerged as one of the most prominent tance signature. Then, the quantitative assessment of corrosion is
techniques for damage detection using PZT transducers bonded carried out based on statistical indices like RMSD, MAPD, and CCD.
to the host structure due to its ability to detect damage at an incip-
ient level. The EMI method is based on the concept of variation in 2. Theoretical background & methodology of EMI technique
mechanical impedance of structure due to change of properties of
structures caused by the damage. After the first proof of concept of 2.1. Theoretical background of electromechanical impedance
the EMI proposed by Liang et al. [7] in 1994, many research works technique
have been reported in the last two decades. G. Park et al. [8] were
first to check the suitability of the impedance-based method for A PZT is a piezoelectric material and works on the principle of
the integrity of bolted civil pipeline structure based on the varia- piezoelectricity. The electromechanical-impedance technique used
tion of structural impedance for damage detection. S. Park et al. the PZT patches as sensor as well as actuator. The PZT patch used
[9] proposed the wireless impedance measurement device for cor- the electro-mechanical coupling between PZT and structure based
rosion detection in metallic structures. The variation in resonant on direct and converse effect. Whenever a PZT patch is subjected to
frequency shift was used to quantify the corrosion in the metallic stress or strain it produces the electric charge which is known as
beam & it was observed that with the increase in corrosion in direct effect and produce a stress or strain whenever subjected to
the beam, the resonant frequency shift also increased. The quantifi- electric field which is known as the converse effect. Hence, PZT
cation of corrosion using extracted equivalent structural parame- materials can be used as a sensor (based on direct effect) as well
ters for reinforced concrete was investigated by V. Talakokula as actuator (based on converse effect). The PZT patch attached or
et al. [10]. They carried out a series of experiments under the accel- embedded into structure excited by an impedance analyzer at a
erated corrosion test to detect and quantify corrosion for rein- very higher frequency range and the electric impedance signature
forced concrete elements for surface bonded and embedded are measured which shows the interaction between the PZT and
piezo patches [11]. The extracted equivalent structural parameters, the host structure known as electromechanical impedance.
i.e., PZT identified mass and stiffness losses, were in good agree- The first theoretical proof of concept of the EMI technique was
ment with the actual mass and stiffness losses of the host struc- proposed by Liang et al. [7]. Fig. 1 shows a schematic diagram of a
ture. The rate of corrosion measured from the PZT-identified one-dimensional electromechanical impedance system, which is
mass loss was also in the range of an actual mass loss of the host modelled as a PZT patch attached to the mechanical impedance
structure. The equivalent parameters extracted from the admit- of the host structure. A PZT, when subjected to an alternating volt-
tance signature were also used for the diagnosis of carbonation- age in direction 3, behaves as a one-dimensional thin bar undergo-
induced corrosion [12]. Martowicz et al. [13] used the EMI tech- ing axial vibration in direction 1. The electromechanical impedance
nique to detect the loosened bolt in bolted pipeline connections of coupled system shown in Fig. 1 in terms of admittance which is
using the point frequency response function and transferring fre- inverse of impedance was introduced by Liang et al. [7] is given in
quency response function with outlier analysis to quantify the Eq. (1)
damage. Zhu et al. [14] used the Structural Mechanical Impedance
wl    Z  
tankl

(SMI) derived from the raw conductance for corrosion detection
Y ¼ xj b eT33  d31 Y E þ d31 Y E
2 a 2
c ð1Þ
and quantification using RMSD and peak frequency shift in the h Zs þ Za kl
steel beam. Wong S.N. [15] used the EMI technique to detect wall
where w, l, and h are the dimensions of the PZT patch, Y E represents
thickness loss for the pipeline. They used the resonant frequency
and root mean square deviation (RMSD) as a damage indicator the young’s modulus of PZT patch under the constant electric field,
for wall thickness reduction. The loos of wall thickness in metallic eT33 represents the complex electric permittivity, d31 denotes the
structure is also investigated using a re-attachable PZT sensor and piezoelectric strain constant, x is the excitation frequency, (tankl/
a probabilistic neural network [16]. Zue et al. [17] proposed the kl) represents the complex tangent ratio, Za and Zs are the effective
modified EMI technique, which considered the influence of bond- mechanical impedance of sensors and structures, respectively.
ing layer between host structure and PZT patch using multiple sen- Any damage alters the mass, stiffness, and damping of the
sors for crack detection in the pipeline. The damage degree and structure, which is responsible for the variation in the value of
location of damage were carried out using the RMSD index. S.N. the mechanical impedance of the host structure. The change in
Khunte [18] used the EMI technique for the erosion identification the mechanical impedance of the host structure can be measured
assessment of steel pipelines. Li et al. [19] suggested a corrosion in terms of the electromechanical admittance through the attached
measuring probe based on the EMI principle, which is manufac- PZT as proposed by Liang et al. using Eq. (1). Typically, an impe-
tured from a circular PZT patch mounted to a metal rod. It was dance analyzer or an LCR meter is used to excite the PZT patch in
noticed that as the quantity of corrosion increased, the peak mag- the high-frequency range of 30 kHz to 400 kHz for the admittance
nitude of the conductance signature decreased. J. Raju et al. [6] signature. Then, damage detection is carried out by comparing the
used the concept of equivalent parameters for corrosion assess- variation of the admittance signature in undamaged and damaged
ment and quantification in reusable non-bonded configuration conditions.
for the pipeline. Reddypogu et al. [20] conducted a numerical
assessment of the EMI signature in pipes with varying degrees of 2.2. Damage quantification
damage. They examined a pipe with varying corrosion lengths cir-
cumferentially and varying corrosion breadth and depth. Any damage in the structure alters the property like stiffness,
From the work mentioned above, it has been observed that mass, damping of the host structure, and mechanical impedance,
many researchers have put their efforts into studying the EMI tech- thus changing its value. This variation of mechanical impedance
2
A. Thoriya, T. Vora and P. Nyanzi Materials Today: Proceedings xxx (xxxx) xxx

Fig. 1. A Schematic illustration of Liang’s single degree of freedom structural impedance.

in terms of admittance is used as the damage indicator in the EMI 3. Experimental setup
approach. The quantification of damage severity can be estimated
by the difference between undamaged and damaged state impe- As shown in Fig. 2(b), The three mild steel pipes, with 155 mm
dance signature. The emergence of a new peak and the lateral length, 90 mm outer diameter, and 5 mm thickness, were chosen
and vertical movement of the conductance signature’s peaks are for the full surface corrosion experimental work. While studying
often the leading signs of structural deterioration. the strip corrosion, a mild steel specimen of 450 mm length,
Statistical indices are used as a damage indicator based on dif- 280 mm outer diameter, and 5 mm thickness was chosen, as
ference between pristine and damaged (in present context shown in Fig. 2(c). Before the experiments, pipe specimens were
between uncorroded and corroded states) conductance signatures. cleaned with a brush and washed with water before bonding PZT
Many researchers have used various statistical techniques like patches. Then, the pipe surface was smoothened with sandpaper,
RMSD (root Mean Square Deviation), MAPD (Mean Absolute Per- and a portion (10  10 mm) of it flattened with a grinder to allow
cent Deviation), and Correlation Coefficient Deviation (CCD). These for easy and levelled bonding of the PZT sensors using epoxy adhe-
indices serve as an indication of damage based on its presence & sive. To allow easy connection of electrical wires for accelerated
severity of damage. The difference between conductance signa- corrosion test a 6 mm diameter holes were drilled close to the
tures can be quantified by using the RMSD, which shows the differ- top of the specimens, and the initial mass was recorded. PZT 5H
ence of square root of between undamaged and damaged states. piezoelectric ceramics produced by Central Electronics Limited
The MAPD presents the average of the deviation at discrete data (CEL) India, was used for the test because of their excellent sensi-
points of the conductance signature. The CCD measures the linear tivity over a more comprehensive temperature range (10o-210oC).
relationships between individual data points of two damage states. The PZT size was 10 mm  10 mm  0.2 mm, as shown in Fig. 2(a).
The various damage indices show the greater values when there is Its physical properties, dielectric properties, electromechanical
a larger difference between base line and damaged state conduc- data, and frequency constants are presented in Table 1 below.
tance signature due to change in properties of structures caused Typically, corrosion is a prolonged process, and the accumula-
by damage. Hence, calculated damage indices values reveal the tion of corrosion takes several days to years, depending upon the
health state of structure subjected to damage. exposure conditions. Hence, to complete the study within a rea-
sonable time, an accelerated corrosion test was used for the cur-
vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi rent study. The specimens were placed in a water container
uP n
u ðG  G Þ containing distilled water and 3% NaCl solution. As shown in
u id iud
ui¼1 Fig. 3(a), the corrosion was initiated by applying a constant current
RMSDð%Þ ¼ u n  100 ð2Þ
t P of 300 (mA/cm2) through the D.C. power supply. The conductance
ðGiud Þ2
i¼1 signature for different specimens was acquired for the 2nd, 7th,
21st, 45th, and 60th days. Simultaneously, the mass loss was also
reported, and the degree of corrosion was calculated as the per-
N   centage of mass loss. The mass loss due to corrosion can be found
1 X  Gid  Giud 
MAPDð%Þ ¼  100 ð3Þ by Faraday’s law by Eq (5), and the observed mass loss of different
N I¼1  Giud  specimens is found to be consistent with the same.

X MIt
1 N
  Dm ¼ ð5Þ
CCDð%Þ ¼ 1  Giud  Giud Gid  Gid  100 ð4Þ ZF
NrO r1 I¼1

where, M = Atomic weight of metal 56 g for Fe, I = Applied current


where; Giud and Gid represent the pre-damage and post damage Amperes, Z = ionic charge 2 for Fe, F = Faraday’s constant = 96,500 A/
conductance signature, respectively. Giud and Gid Indicate the mean s, t = time duration (s). The EMI signatures of the raw and corroded
values of pre and post-damage conductance values. rO and r1 rep- pipe specimens were obtained and analyzed using the Keysight
resent the standard deviation of pre and post-damage conductance E4980AL precision LCR meter (Keysight Technologies, USA) con-
signature, and N represents the number of data points. nected to a computer, as shown in Fig. 3(b).
3
A. Thoriya, T. Vora and P. Nyanzi Materials Today: Proceedings xxx (xxxx) xxx

Fig. 2. (a) PZT Patch, (b) Mild Steel Pipe Specimens for the full surface corrosion, (c) Mild Steel Specimen for Strip Corrosion.

Table 1
Properties of PZT 5H.

PHYSICAL PROPERTIES PZT-5H PHYSICAL PROPERTIES PZT-5H


Density gm/cc 7.4 Coupling co-efficient KP 0.56
Curie Temperature 210C K31 0.34
Dielectric Constant at 1 kHz K3t 3250 K33 0.68
Dissipation factor at 1 kHz 0.02 Piezoelectric Charge constant (C/NX1012) D33 580
Thickness Mode (Hz-meter) 1950 Piezoelectric Voltage constant (103 volts-meter/ Newton) g33 20

4. Results and discussions comparing the damage level signature to its baseline signature of
the respective PZT patch.
The selection of frequency range is an essential aspect of dam- From Fig. 4, it can be observed that the increase in corrosion
age detection in the EMI technique. Hence, first of all, the conduc- amount leads to a decrease in the magnitude of conductance signa-
tance signatures were taken over a wide range of frequencies to ture, which results in flattened and smoothed curves for all three
identify the sensitivity and peaks of the signature. As shown in specimens. Hence all the specimens have shown the same ten-
Fig. 4, most peaks with large amplitudes are present in a frequency dency. The sudden decrease in the magnitude of the conductance
range of 1 kHz to 300 kHz. Hence, the frequency range of 1 kHz to signature even at 2 days corrosion shows the capacity of the EMI
300 kHz is selected for corrosion detection. In addition, the real technique to detect the incipient level of corrosion. The change
part of admittance, i.e., conductance, was selected for corrosion in mass, stiffness, and damping of pipe specimens due to corrosion
detection as it is proven that conductance is more sensitive than are responsible for the conductance signature variation over the
other parameters of the EMI technique. corrosion exposure period. Hence, corrosion monitoring is possible
The corrosion was initiated in mild steel specimens under two by observing the variation in the conductance signature. The over-
different conditions. First, three mild steel specimens are subjected all tendency of the three specimens is comparable at varying levels
to full surface corrosion, where the whole specimens were sub- of corrosion, demonstrating the constancy of the EMI corrosion
jected to accelerated corrosion. In the second case, the strip corro- monitoring approach. However, the degree of change in the con-
sion was applied where only 75 mm strip of the specimen was ductance signature varies across specimens. Because of the under
subjected to accelerated corrosion test. impressed current, all the specimens are not subjected to uniform
mass loss as in ideal condition, and Fig. 3(c) shows the corroded
specimens where different specimens show different amounts of
corrosion.
4.1. The full surface corrosion
The shift in peak frequency could also indicate damage due to a
change in structural stiffness [21,22]. However, in the present
Fig. 4 shows specimens A, B, and C’s conductance signature for
study, the peak frequency shift is not consistent and not conclu-
the different corrosion amounts under the full surface corrosion. It
sive. Many parameters are responsible for this kind of behaviour,
is important to note here that the conductance signatures of all the
and one important reason is the increase in damping, which leads
specimens are not the same due to various reasons like the slight
to a flattened and smoothened curve, as discussed by Li et al. [19].
variation in the properties of the PZT patch, the thickness of the
Hence, in this study, the corrosion assessment is done based on the
epoxy layer, and the variation of properties of different specimens.
variation of the conductance signature using statistical indices.
Therefore, in the EMI technique, damage detection is carried out by

Fig. 3. (a) Accelerated Corrosion Test (b) Pipe Specimen Connected to LCR meter for Impedance Measurement (c) Corroded Specimens Under Full Surface Corrosion.

4
A. Thoriya, T. Vora and P. Nyanzi Materials Today: Proceedings xxx (xxxx) xxx

Fig. 4. Conductance Signature of (a) Specimen-A (b) Specimen-B, and (c) Specimen-C for Different Corrosion Amount.

Fig. 5. RMSD Index for (a) Specimen A, (b) Specimen B, and (c) Specimen C under the full surface corrosion.

The change in the conductance signature is the qualitative indi- fully. However, for specimen B, RMSD and CCD indices show a
cator for corrosion detection and monitor. However, quantifying decreasing trend after 2nd-day corrosion and indicate an increas-
corrosion damage severity at different amounts of corrosion is also ing trend afterward.
calculated by statistical indicators like RMSD, MAPD, and CCD. The general trend of the RMSD and CCD is increasing in propor-
Figs. 5 to 7 shows the values of RMSD, MAPD, and CCD indices tion to the degree of corrosion. The MAPD has shown the greatest
for the different amounts of corrosion. From Figs. 5 to 7, it is sensitivity and accuracy out of the three measures. As a result, all
observed that the increase in corrosion increases the damage three of these damage indices may be used to monitor the corro-
indices in most of the cases. The RMSD values are between 7.21% sion process. These findings established the viability of the sug-
and 75.89%, The MAPD values are between 8.74% and 531.80%, gested corrosion-measuring technique.
and The CCD values are between 0.81% and 22.32%. As shown in The trend of the conductance profiles of these three specimens
Figs. 8 to 10, RMSD and CCD values based on conductance signa- is highly similar. However, the degree of change in signatures var-
ture for Specimens A and C show a consistently increasing trend, ies across different specimens. There are mainly two reasons, first
which indicates that corrosion damage has been captured success- is the variation of the properties of the PZT patch. The second sig-

5
A. Thoriya, T. Vora and P. Nyanzi Materials Today: Proceedings xxx (xxxx) xxx

Fig. 6. MAPD Index for (a) Specimen A, (b) Specimen B, and (c) Specimen C under the full surface corrosion.

Fig. 7. CCD Index for (a) Specimen A, (b) Specimen B, and (c) Specimen C under the full surface corrosion.

Base depicts the morphology of corroded specimens. Hence, corrosion


2 Days assessment was made by comparing corroded state signature to
7 Days the baseline signature of the respective specimen. Hence, the value
0.006 21 Days of damage indices is not the same for different specimens at the
45 Days same applied degree of corrosion.
0.005 60 Days
Conductance (G)

0.004
4.2. The strip corrosion

0.003
In real-life conditions, pipelines may not be subjected to full
surface corrosion as studied above and may also be subjected to
0.002
local corrosion. However, it’s challenging to generate local corro-
sion in the laboratory, as found in a real-life case. Hence to simu-
0.001
late the local corrosion, the mild steel specimen D was subjected
to corrosion in only a 75 mm strip. Specimen D’s outer surface
0.000
was painted as a bare strip of 75 mm across the pipe length and
0 100 200 300 400 then subjected to a 75 mm wide corrosion strip in the corrosion
Freq (Hz) bath. The conductance signature was acquired on the 2nd, 7th,
21st, 45th, and 60th days in the frequency range of 1 kHz to
Fig. 8. Conductance Signature of Specimen-D for Different Corrosion Amount under 400 kHz. Fig. 8 shows the conductance signature for specimen D
The Strip Corrosion.
under the strip corrosion.
Fig. 9 shows the RMSD, MAPD, and CCD indices values for strip
corrosion of specimen D. The RMSD values are between 25.0% and
nificant reason for this is that the corrosion morphology of each 87.56%, The MAPD values are between 5.93% and 247.25%, and The
specimen might vary during accelerated corrosion testing. In an CCD values are between 2.76% and 22.51%. From the results, it can
ideal condition, the material loss of the mild steel pipeline is uni- be seen that all indices show the increasing trend with the increase
form across all exposed surfaces when an impressed current is of corrosion amount. Again, MAPD is found to be most sensitive as
applied. However, in practice, such regularity is seldom achieved compared to RMSD and CCD values. Hence, the strip or local corro-
owing to material imperfections, as depicted in Fig. 7, which sion can be captured by the EMI technique.
6
A. Thoriya, T. Vora and P. Nyanzi Materials Today: Proceedings xxx (xxxx) xxx

Fig. 9. Damage Index for the Specimen-D under the Strip Corrosion (a) RMSD, (b) MAPD, and (c) CCD.

5. Conclusion References

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