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Techniques for corrosion monitoring
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Related titles:
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(ISBN 978-1 84569-181-3) The cold spray process produces extremely dense, oxide-free coatings that make it ideal in diverse applications such as metal repair, electronics and the control of corrosion and wear. This important book reviews both the principles of the process and its practical uses. The fi rst part of the book reviews its advantages and dis- davantages compared with thermal spray coating. Part II discusses the role of parameters such as powders, nozzle design, particle temperature and velocity and particle-substrate interaction. The fi nal part of the book analyses applications in such areas as improved wear and corrosion protection as well as repair of com- ponents and shielding from electromagnetic interference. Innovative pre-treatment techniques to prevent corrosion of metallic surfaces (ISBN 978-1-84569-365-7) There has long been a need for effective pre-treatment techniques to prevent cor- rosion of metallic surfaces. This important volume discusses coating and preparation methods for aluminium alloys such as silane fi lms, sol-gel coatings and magnesium- rich primers. It also reviews pre-treatments for steel, copper, zinc and magnesium alloys. Other chapters consider electrochemical and other techniques to monitor the effectiveness of pre-treatments in preventing corrosion together with methods for monitoring dissolution-precipitation mechanisms of a range of pre-treatments. Details of these and other Woodhead Publishing books, as well as books from
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• visiting www.woodheadpublishing.com • contacting Customer Services (e-mail: sales@woodhead-publishing.com fax: +44 (0) 1223 893694; tel.: +44 (0) 1223 891358 ext. 130; address: Woodhead Publishing Ltd, Abington Hall, Abington, Cambridge CB21 6AH, England) If you would like to receive information on forthcoming titles, please send your address details to: Francis Dodds (address, tel. and fax as above; e-mail: francisd@woodhead-publishing.com ). Please confi rm which subject areas you are interested in. Maney currently publishes 16 peer-reviewed materials science and engineering journals. For further information visit www.maney.co.uk/journals
© 2008, Woodhead Publishing Limited
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Techniques for
corrosion monitoring
Edited by
Lietai Yang
Woodhead Publishing and Maney Publishing
on behalf of
The Institute of Materials, Minerals & Mining
CRC Press
Boca Raton Boston New York Washington, DC
Cambridge England
SOUTHWEST RESEARCH INSTITUTE
© 2008, Woodhead Publishing Limited
XXX JSBO NBWBE DPN Woodhead Publishing Limited and Maney Publishing Limited on behalf of
The Institute of Materials, Minerals & Mining
Woodhead Publishing Limited, Abington Hall, Abington
Cambridge CB21 6AH, England
www.woodheadpublishing.com Published in North America by CRC Press LLC, 6000 Broken Sound Parkway,
NW, Suite 300, Boca Raton, FL 33487, USA
First published 2008, Woodhead Publishing Limited and CRC Press LLC
© 2008, Woodhead Publishing Limited
The authors have asserted their moral rights.
This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. Reasonable efforts have been made to publish reliable data and information, but the authors and the publishers cannot assume responsibility for the validity of all materials. Neither the authors nor the publishers, nor anyone else associated with this publication, shall be liable for any loss, damage or liability directly or indirectly caused or alleged to be caused by this book. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microÞ lming and recording, or by any information storage or retrieval system, without permission in writing from Woodhead Publishing Limited. The consent of Woodhead Publishing Limited does not extend to copying for general distribution, for promotion, for creating new works, or for resale. SpeciÞ c permission must be obtained in writing from Woodhead Publishing Limited for such copying. Trademark notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identiÞ cation and explanation, without intent to infringe.
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library. Library of Congress Cataloging in Publication Data A catalog record for this book is available from the Library of Congress.
Woodhead Publishing ISBN 978-1-84569-187-5 (book)
Woodhead Publishing ISBN 978-1-84569-405-0 (e-book)
CRC Press ISBN 978-1-4200-7089-7
CRC Press order number WP7089
The publishersÕ policy is to use permanent paper from mills that operate a sustainable forestry policy, and which has been manufactured from pulp which is processed using acid-free and elementary chlorine-free practices. Furthermore, the publishers ensure that the text paper and cover board used have met acceptable environmental accreditation standards. Typeset by SNP Best-set Typesetter Ltd., Hong Kong Printed by TJ International Limited, Padstow, Cornwall, England
© 2008, Woodhead Publishing Limited
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Contributor contact details xv
1 Introduction 1
L Yang, Southwest Research Institute, USA
1.1 Defi nition of corrosion 1
1.2 Corrosion cost 1
1.3 Corrosion monitoring and its importance
in corrosion prevention and control 2
1.4 Organization of the book 3
1.5 References 5
2 Corrosion fundamentals and
characterization techniques 6
G A Cragnolino, Southwest Research Institute, USA
2.1 Introduction 6
2.2 General corrosion 7
2.3 Passivity and localized corrosion 9
2.4 Microbially infl uenced corrosion 24
2.5 Flow-assisted corrosion and erosion corrosion 26
2.6 Stress corrosion cracking 28
2.7 Corrosion fatigue 33
2.8 Hydrogen embrittlement 36
2.9 Characterization techniques 37
2.10 References 40
Part I Electrochemical techniques for
corrosion monitoring 47
3 Electrochemical polarization techniques
for corrosion monitoring 49
S Papavinasam, CANMET Materials Technology
Laboratory, Canada
3.1 Introduction 49
Contents
v
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3.2 Electrochemical nature of corrosion 49
3.3 EnergyÐpotentialÐcurrent relationship 51
3.4 Electrochemical polarization techniques for
determining corrosion rates 57
3.5 Conversion of I
corr into the corrosion rate 69
3.6 Measurement of corrosion rate by polarization
methods in the laboratory 71
3.7 Measurement of corrosion rate by polarization
methods in the Þ eld 77
3.8 General limitations of polarization methods of
determining the corrosion rate 79
3.9 Applications of polarization methods in the Þ eld 81
3.10 Future trends 81
3.11 Further information 83
3.12 References 83
4 Electrochemical noise for corrosion monitoring 86
R Cottis, University of Manchester, UK
4.1 Introduction to electrochemical noise 86
4.2 Measurement of EN 87
4.3 Alternative EN measurement methods 92
4.4 Interpretation of EN 95
4.5 Comparison of EN and polarization resistance
for the estimation of corrosion rate 103
4.6 Practical applications 105
4.7 Harmonic distortion analysis 106
4.8 Electrochemical frequency modulation 108
4.9 References 109
5 Zero resistance ammetry and galvanic sensors 111
R D Klassen and P R Roberge, Royal Military
College of Canada, Canada
5.1 Introduction 111
5.2 Galvanic current 112
5.3 ZRA measurement circuitry 114
5.4 Applications 115
5.5 Future trends 124
5.6 References 124vi Contents
© 2008, Woodhead Publishing Limited
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6 Differential ß ow through cell technique 127
B Yang, Honeywell, USA
6.1 Introduction 127
6.2 Principles of the differential fl ow cell (DFC)
method 127
6.3 Data interpretation and use 141
6.4 Applications 153
6.5 Future trends and additional information 153
6.6 References 153
7 Thermodynamics of corrosion and
potentiometric methods for measuring localised corrosion 156
P Shukla, Southwest Research Institute, USA
7.1 Introduction 156
7.2 Thermodynamics of corrosion 156
7.3 Galvanic series of alloys 172
7.4 Potentiometric methods for measuring
localized corrosion 174
7.5 Summary 182
7.6 References 183
8 Multielectrode systems 187
L Yang, Southwest Research Institute, USA
8.1 Introduction 187
8.2 Earlier multielectrode systems for high
throughput corrosion studies 188
8.3 Uncoupled multielectrode arrays 190
8.4 Coupled multielectrode systems for corrosion
detection 191
8.5 Coupled multielectrode arrays for spatiotemporal
corrosion and electrochemical studies 194
8.6 Coupled multielectrode arrays for spatiotemporal
corrosion measurements 197
8.7 Coupled multielectrode array sensors with simple
output parameters for corrosion monitoring 198
8.8 Minimizing effects of internal currents,
electronic-conducting deposits and crevices on performance of CMAS probes 217
8.9 Validation of corrosion rate measurement using
coupled multielectrode array sensors 226 Contents vii
© 2008, Woodhead Publishing Limited
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8.10 Applications of coupled multielectrode array
sensor for real-time corrosion monitoring 233
8.11 Limitations of multielectrode systems 233
8.12 Summary 234
8.13 References 235
Part II Other physical or chemical methods
for corrosion monitoring 245
9 Gravimetric techniques 247
K Chiang and T Mintz, Southwest Research
Institute, USA
9.1 Introduction 247
9.2 Thermogravimetric analysis (TGA) technique 247
9.3 Quartz crystal microbalance (QCM) technique 251
9.4 Gravimetric techniques summary 260
9.5 References 263
10 Radioactive tracer methods 265
D C Eberle, Southwest Research Institute, USA
10.1 Principle and history 265
10.2 Assumptions 267
10.3 Labeling methods 268
10.4 Potential isotopes 270
10.5 Calibration and conversion to corrosion units 271
10.6 Applications and limitations 273
10.7 Sources of further information 276
10.8 References 276
11 Electrical resistance techniques 277
C S Brossia, CC Technologies, USA
11.1 Introduction and background 277
11.2 Sensing probe designs 279
11.3 Examples of application and use 281
11.4 Sensing probe electronics and instrumentation 286
11.5 Variations on the ER theme 287
11.6 Advantages and limitations 291
11.7 Summary and conclusions 292
11.8 References 292viii Contents
© 2008, Woodhead Publishing Limited
XXX JSBO NBWBE DPN
12 Nondestructive evaluation technologies for
monitoring corrosion 293
G Light, Southwest Research Institute, USA
12.1 Introduction 293
12.2 NDE methods for corrosion monitoring 294
12.3 Future trends 309
12.4 References 310
13 Hydrogen ß ux measurements in petrochemical
applications 313
F Dean, Ion Science Ltd, UK
13.1 Introduction 313
13.2 Scenarios leading to hydrogen permeation
and detection 313
13.3 A measurement of hydrogen activity based on
fl ux measurement 315
13.4 Comments pertaining to particular fl ux
measurement applications 318
13.5 References 321
14 Rotating cage and jet impingement techniques 322
S Papavinasam, CANMET Materials Technology
Laboratory, Canada
14.1 Introduction 322
14.2 Rotating cage 322
14.3 Jet impingement 331
14.4 Prediction from laboratory test result to fi eld
application 337
14.5 Future trends 340
14.6 Further information 341
14.7 References 341
Part III Corrosion monitoring in particular
environments and other issues 345
15 Corrosion monitoring in microbial environments 347
P Cristiani, Cesiricerca SPA, Italy
15.1 Introduction 347 Contents ix
© 2008, Woodhead Publishing Limited
XXX JSBO NBWBE DPN
15.2 Corrosion monitoring applied to MIC 353
15.3 Electrochemical sensors for the evaluation of
MIC risk 360
15.4 Integrated on-line monitoring systems 369
15.5 Case histories 372
15.6 Summary 382
15.7 References 382
16 Corrosion monitoring in concrete 388
P Schie
§l, Technical University of Munich, Germany
and C Dauberschmidt, Ingenieurbuero Schiessl
Gehlen Sodeikat, Germany
16.1 Introduction 388
16.2 Deterioration mechanisms for corrosion
in concrete 389
16.3 Assessment of corrosion and corrosion risk
in concrete 401
16.4 Sensors for corrosion monitoring 407
16.5 Data evaluation 416
16.6 Applications 417
16.7 Conclusions 421
16.8 References 422
17 Corrosion monitoring in soil 425
N Khan, Saudi Aramco, Saudi Arabia
17.1 Introduction 425
17.2 Types of soil corrosion probes 425
17.3 Electrical resistance probes 426
17.4 Monitoring and data interpretation 432
17.5 Effectiveness criteria 434
17.6 References 434
17.7 Bibliography 435
18 Corrosion monitoring under coatings 436
F Gui and C S Brossia, CC Technologies, USA
18.1 Introduction 436
18.2 Corrosion monitoring methods under coatings 437
18.3 Summary and conclusions 446
18.4 References 446x Contents
© 2008, Woodhead Publishing Limited
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19 Cathodic protection monitoring 448
A Carlile, Kinder Morgan, USA
19.1 Introduction 448
19.2 Cathodic protection monitoring 448
19.3 Cathodic protection monitoring techniques 454
19.4 Cathodic protection monitoring technology 463
19.5 Effectiveness of corrosion control after installation
and monitoring 465
19.6 Monitoring results and maintenance opportunities 469
19.7 Value of structure increases 469
19.8 Less replacement and maintenance cost for the
company 470
19.9 Cathodic protection monitoring as required by
US government as a minimum requirement and
other considerations 470
19.10 Monitoring frequency helps determine
effectiveness of corrosion program 471
19.11 NACE recommendations 471
19.12 Cathodic protection monitoring relative to
unusual or at-risk environments 472
19.13 Field data to aid in cathodic protection monitoring 473
19.14 Data management 474
19.15 Overview 475
19.16 References 475
20 Remote monitoring and computer applications 476
R Smalling and L Blankenstein, American
Innovations, USA
20.1 Introduction 476
20.2 Data considerations 480
20.3 Communications networks 483
20.4 Application specifi c requirements 490
20.5 NOC and supporting systems 495
20.6 Sources of further information 498
20.7 References 498
21 Models for predicting corrosion 499
N Sridhar, Det Norske Veritas, USA
21.1 Introduction 499
21.2 Examples of empirical models 501 Contents xi
© 2008, Woodhead Publishing Limited
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21.3 Mechanistic (physics-based) models 514
21.4 Future directions 533
21.5 References 534
Part IV Applications and case studies 539
22 Corrosion monitoring in engine exhaust systems 541
M Kass, Oak Ridge National Laboratory, USA
22.1 Introduction 541
22.2 Reciprocating engine combustion and exhaust
chemistry 543
22.3 Formation of corrosive species 546
22.4 Monitoring techniques 549
22.5 Current issues and future needs 555
22.6 References 556
23 Corrosion monitoring in cooling water systems
using differential fl ow cell technique 558
B Yang, Honeywell, USA
23.1 Introduction 558
23.2 Corrosion inhibition program selection
and optimization 558
23.3 Program optimization at a chemical
processing plant 561
23.4 Program optimization using pilot cooling
tower tests 566
23.5 ReÞ nery hydrocarbon leak detection
and control 568
23.6 ReÞ nery leak detection and
program optimization 573
23.7 Admiralty brass corrosion control in cooling water
system using brackish water as make-up 574
23.8 References 582
24 Corrosion monitoring in the pulp and paper industry 584
F Almeraya-CalderÛn, C V Orozco, C Gaona-Tiburcio, T A B orunda , J ChacÛn-Nava, and A MartÌnez- V illafaÒe , Advanced Materials Research Center,
CIMAV, Mexico
24.1 Introduction 584xii Contents
© 2008, Woodhead Publishing Limited
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24.2 Experimental procedures 586
24.3 Results and analysis 591
24.4 Conclusions 598
24.5 Acknowledgements 599
24.6 References 599
25 Advanced corrosion control at chemical plants using
a new corrosion monitoring technique 601 M Miyazawa, Mitsubishi Chemical Corporation, Japan
25.1 Introduction 601
25.2 Investigation 602
25.3 Monitoring and corrosion control 606
25.4 Conclusion 613
25.5 References 613
26 Corrosion monitoring under cathodic protection
conditions using multielectrode array sensors 614
X Sun, Corr Instruments LLC, USA
26.1 Introduction 614
26.2 Corrosion rate measurements for cathodically
protected systems using CMAS probes 615
26.3 Measurements of localized corrosion rates of
carbon steel in simulated seawater 617
26.4 Measurements of localized corrosion rates of
carbon steel in concrete 623
26.5 Measurements of localized corrosion rates of
cathodically protected carbon steel in soil 626
26.6 Measurements of localized corrosion rates of
cathodically protected carbon steel in drinking water 630
26.7 References 636
27 Corrosion measurements with wire beam electrodes
under temporarily protective oil coatings 638
Q Zhong, Shanghai University, China
27.1 Introduction 638
quotesdbs_dbs27.pdfusesText_33
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