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Corrosion Monitoring in Petroleum Refineries: K.R. Soni, Saga Global Consultants
Corrosion Monitoring in Petroleum Refineries: K.R. Soni, Saga Global Consultants
Petroleum Refineries
K.R. SONI,
SAGA GLOBAL CONSULTANTS
CORROSION MONITORING
Corrosion monitoring may be defined as the
systematic measurement of corrosion rate of
equipment with the object of diagnosis and
controlling corrosion.
o Knowing the speed of sound through the metal, the thickness of the metal can
be calculated.
Ultrasonic inspection involves transmission of very
high frequency sound waves through the metal whose
thickness is required
Piezoelectric crystals are used for generation of
ultrasonics sound waves
Detection of reflected sound pulses from the front
and back faces of metal is done with equipment
electronic circuitary.
The time taken for the sound to travels the thickness
of metal and returned to the probe is given as digital
output in terms of thickness of metal
ULTRASONIC INSPECTION
Widely used for thickness monitoring of equipment &
piping systems in Refineries.
Systematic thickness recording & comparison with
previous readings for any deterioration and
assessment of corrosion rate.
Advantage - Access to one side of object is sufficient
for thickness measurement.
Disadvantage - Not suitable for pitted or rough
surfaces.
High temperature can destroy piezoelectric properties
of the probe.
Fig. 12 The priciple of time of flight measurement
Fig. 13 Block diagram: Pulse Echo Method
Fig. 18 Backwall echo at the 8th scale graduation
CORROSION MAPPING
Fig. 58b
vessels.
RADIOGRAPHY INSPECTION
Radiography Technique depends on the opacity of
material to either gamma or X-rays and the passage of
radiation through the component reaching on the
photographic film.
The density of the image produced on the film is
related to the thickness and density of the material
under examination.
Used in wall thickness measurement / internal
corrosion / deposits assessment.
Disadvantages of this method is radiation hazards &
time required to complete exposure.
Electrical Resistance (ER) probes
Metal loss measurements are based on the change in
OHMIC Resistance of test probe elements.
With corrosion, the cross-sectional area of corroding
element reduces, resulting in increase in its electrical
resistance.
The electrical resistance changes are measured using
the wheat stone bridge principle.
ER changes are Time Dependant but results can be
assessed faster than corrosion coupons.
ER Probe remains Installed for its Operational life
Can be Used to Trigger an Alarm
ELECTRIC RESISTANCE METHOD
• Gives integrated corrosion rate.
• Corrosion rate measurement in liquid & vapour phase.
• Corrosion measurement made without removal of test
sample.
• Suitable for measurement of uniform corrosion.
• Can detect low corrosion rates.
• Not suitable when pitting or stress corrosion attack are
likely.
• Errors introduced in measurement with metallurgical
condition of probe element & temperature changes.
Electrical Resistance (ER) Probes
• Variety of probes available
• Probes measure change in electrical resistance of a metal specimen
and convert into a corrosion rate.
• The probes are available in a variety of metallurgies and corrosion
sensitivities.
• ER probes give essentially instantaneous corrosion rate
measurements.
• Meaningful data can be obtained in a few days if corrosion is severe
or the probe is sensitive to corrosion.
• Probes show corrosion at the location of the probe.
Electrical Resistance (ER) probes
R = low R = high
• Wire loop probes are very sensitive to pitting corrosion.
R = low R = high
HAC INHIBITOR PROGRAM MONITORING
Electronics
for
measuring
resistance
Probe Fittings
Fixed (Threaded)
Removable (Under Pressure)
• Special High Pressure Access System used
Corrosion Monitoring Probes
Monitoring with ER Probes
Linear Polarization Resistance (LPR) Probes
This technique is based on the measurement of apparent
“resistance” of a test cell when it is polarized by a small
voltage of the order of 5 to 20 mV.
K
Rp =
Icorr
Icorr is the corrosion current (amp/m2) which is readily
converted to metal loss (mm/year).
This method gives instantaneous corrosion rate.
Portable Meters
Data Loggers
Continuous Single Channel
Continuous Multi-channel
Remote Monitoring Units
Installation of probes
Types of coupons
• Strip Coupons
• Disc Coupons
• Rod Coupons
• Coupons with applied stress
• Coupons with residual stress
CORROSION COUPON METHOD
The advantages of coupons includes:
Visual interpretation
Deposits can be observed and analyzed and layer effects
studied.
Weight loss can be determined.
The degree of localization of corrosion can be observed &
measured.
Inhibitor film effects can be observed.
It gives average corrosion rate.
Used for detection of corrosion in gas / oil pipelines, vessels,
tanks & cooling water system.
CORROSION COUPONS
CORROSION COUPONS
Corrosion Coupon Racks At Inlet Header Of Cooling Towers
CORROSION MONITORING - Conclusions