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Corrosion & Erosion
Natural objects, such as granite, and man-made structures, such as bridges, cars, ships,
refineries, and aircraft, are all subject to the same environmental stresses. Light, temperature
changes, water, and gases in the air all play a role in the breakdown of materials.
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Impact of Corrosion
The negative effects of corrosion and erosion cost the oil
& gas and power generation industries billions of dollars
every year in unscheduled plant or pipeline shutdowns,
inefficient or lost production, high maintenance repair
costs or imposed fines. According to the WCO – The World
Corrosion Organization - the estimated cost of corrosion
to all the world’s economies is $2.2 trillion USD annually.
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Corrosion Monitoring
Think of the industrial infrastructure of a plant, mill, refinery or manufacturing facility as a human body; the metal pipes and vessels are the circulatory system and organs. Pipes transport water, processed chemicals, and raw materials such as crude oil and waste products.
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Corrosion Detection
Accurate and adequate inspection plays a crucial role in asset integrity. Due to constant innovation there are several nondestructive techniques available to detect corrosion defects.
Remote Visual Inspection
is a cost-effective inspection technique used to capture real-time views and images from inside voids such as tubes, pipes, rotating machinery, engines, heat exchangers, tray towers, refractory-lined vessels and enclosed structures. RVI can be a perfect complementary technique to other NDT disciplines and is frequently used as the primary or initial inspection screening method to find localized corrosion and erosion.
Eddy current
is a fast, accurate and cost-effective electro-magnetic method for detection of surface or near-surface flaws such as metal loss due to corrosion or erosion. It is commonly used for the inspection of heat exchanger tubing and piping, shell-side components such as support plates and rotating equipment such as turbine blades.
Corrosion Monitoring and Pit Detection Using Phased Array Ultrasound
Regularly scheduled inspections can validate corrosion rates and allow to better plan for maintenance situations. While ultrasound thickness (UT) readings do not provide enough precision with the collection of manual thickness readings to adequately determine wall thickness losses from corrosion. Pitting cannot be reliably detected by conventional UT methods simply because the size of the defect is small compared to the area inspected. Phased array ultrasound (PAUT) techniques can be used to approach the needed precision and get great coverage quickly.
Digital radiography (DR)
is one of the better tools to detect corrosion under insulation and flow accelerated corrosion. It is fast (reduces inspection times by more than 95%) and does not require the insulation to be removed and replaced. Digital radiography also makes it easier to manage large volumes of inspection data using DICONDE-compliant digital reporting tools.
Types of Corrosion
Predictable
If a given material is passing through a given pipe, tube, tank or vessel, at a given set of temperatures and
pressures, general corrosion is expected and predictable. Materials in this category are most often under a
comprehensive maintenance and inspection program.
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Unpredictable, but expected
Certain conditions may give rise to localized corrosion environments, such as: Corrosion under insulation (CUI).
In the process of transforming raw materials to products, temperature is often a major control requirement
meaning that pipes or vessels are insulated.
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Unpredictable
An example of unpredictable corrosion would be in the production of crude oil. If a well picks up significant
sand or other abrasive material, it can cause very fast-acting corrosion.
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