Chapter V:

Corrosion Testing and Monitoring

Introduction:- What does Corrosion Testing mean?
 Corrosion testing refers to the processes conducted by laboratories
in order to solve, prevent or mitigate problems related to corrosion.
 These processes can be applied in industrial materials and
infrastructure products, and are often used in failure analysis.
 All corrosion laboratories are composed of expert failure analysts,
chemists and engineers that are all certified in corrosion testing.
 Such tests can provide useful information in order to make sound
decisions regarding selection of materials, processing and treatment.
 Corrosion laboratories can conduct a broad range of laboratory
tests that are typically focused on areas such as:
• Electrochemical
• Corrosivity
• Heat transfer
• Immersion
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 Testing of various materials used in industrial applications is
required to verify conformation to quality standards.
 One example is immersion testing, which is considered the
most popular and simplest type of corrosion test.
 This test is used to assess different materials that are subjected to
particular conditions.
 It is a very versatile process which can be personalized to meet
specific needs regardless of application.
 In this test, the testing apparatus can expose the specimen to test
solutions and then subject it to different physical or metallurgical
situations, such as crevices and heat treatment.
 Another test is the hot wall test, which is utilized to evaluate
situations where metal vessels are hotter than bulk solutions.
 These are common in external heated vessels where corrosion is
typically impacted by temperature. In this test, elevated
temperatures signify high levels of corrosion activity.
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 There is also a test known as salt spray. This technique is used to
evaluate a coated sample's resistance to corrosion. This test produces
an attack to coated specimens to measure suitability as a protective
coating.
 In addition to these, there are numerous other corrosion testing
techniques available that help prevent loss due to corrosion.
Reasons for conducting corrosion testing?
 To provide an insight into corrosion mechanisms.
 To provide a basis for estimating service life of process equipment.
 To compare the corrosion resistance of one alloy with another under
standard conditions-For example in the development if new alloys
with better corrosion resistance.
 As a quality control test for a given heat of alloy.

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 To conduct corrosion testing, numerous test methods are available.
 The methods can be arranged in the following groups:
1. Laboratory testing, comprising accelerated testing, model
testing, and special tailor-made investigations in research.
 Accelerated test methods give measurable attacks after short time,
which can be obtained by using a more aggressive environment,
higher potential, higher temperature or higher mechanical stress
than under the actual service conditions.
 These methods are suitable only for qualitative comparison and
ranking of various materials with respect to specific properties,
and for routine control and approval of delivered materials.
 Accelerated testing cannot answer questions about lifetime without
knowing the degree of corrosion acceleration.
 Model testing aims at realistic conditions. Possible acceleration
must be limited to avoid change of the corrosion mechanism.
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 The testing takes longer than the accelerated test dealt with above,
and will often require a sensitive measuring technique. For the
extrapolation of results to a realistic service period or lifetime, a
thorough understanding of the corrosion mechanism and the
change of corrosion conditions and rate with time is necessary.
 New measuring techniques contribute to improvements in this
direction.
2. Service (plant) and field testing, including exposure of coupons,
test specimens or components in process environments of
industrial plants as well as in special natural fields (in seawater,
atmospheres, soils etc.)
3. Testing in a pilot plant, which is a true model (up to half scale) of
the actual industrial plant. Pilot plant testing is used as a basis for
appropriate design and selection of materials in cases where the
condition cannot be satisfactorily modelled in laboratory tests.
 Pilot plants for modelling are suitable for relatively expensive
installations, in which the corrosion conditions are complex and
aggressive and the consequences of failure are great. 5
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Immersion testing
 Most frequently conducted test for evaluating the corrosion of metals in
aqueous solutions.
 Immersion tests are conducted to determine the corrosion rates of metals
in a given environment.
 Totally immerse a test specimen in a corrosive solution for a period of
time and then remove the specimen.
 Factors to consider when performing immersion testing :
 Solution composition
 Temperature
 Aeration
 Volume
 Velocity
 Waterline effects
 Specimen surface preparation
 Method of immersion of specimens
 Duration of test
 Method of cleaning specimens at the end of the exposure period. 6
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Total Immersion testing
 Composition of Solution
 Simulated solution as per standards
 Naturally occurring solutions– sea water
 Plant process solutions
 Aeration of Solution
 Aeration or the presence of dissolved oxygen can influence corrosion rates
profoundly.
 Volume of Solution Volume of Solution
 The volume should be large enough to avoid any appreciable change in its
Corrosivity during the test
 Solution-to-specimen area ratio of 200 L/m
 Temperature of Solution
 Temperature is a critical factor in corrosion
 Controlled-temperature water or oil baths
 Evaporation losses
 frequent addition to maintain the original volume within ±1%
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Intermittent Immersion testing
 Alternate immersion and emersion in a corrosive liquid Ž
Practical importance, because they simulate the effects of the
rise and fall of tidal waters and the movements of corrosive
liquids in chemical plants.
 A thin film of the solution, frequently renewed and almost
saturated with oxygen, can be maintained on the test specimen
during most of the period of exposure
 Alternate Immersion in 3.5% NaCl -ASTM G 44 Ž
 1 hour test cycle.
 10 min period of immersion in an aqueous solution of 3.5%
NaCl or a substitute ocean water (without heavy metals) heavy
metals). Ž
 50 min emersion period.
 This 1 hour cycle is continued 24 h/day.
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Specimen Preparation and Duration of Tests
 The type, size, and shape of specimens vary with the purpose
of the test, the nature of the test materials, and the apparatus
used.
 Standard practices for preparing, cleaning, and Standard
practices for preparing, cleaning, and evaluating corrosion test
specimens -ASTM G 1
 Corrosion is a surface phenomenon. Surface condition of
specimens is critical in determining the outcome of tests.
 Proper selection of appropriate lengths of exposure is
important for any corrosion test, and misleading results may
be obtained if the time factor is not considered.
 Planned interval tests involve the accumulated effects of
corrosion at several times under a given set of conditions as
well as the initial rate of corrosion of fresh metal.
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Figure . Type of test coupons that are used for corrosion testing

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Figure. Type of test coupons that are used for corrosion testing
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Figure. Flat test coupons that are used for corrosion testing
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Figure. Cylindrical test coupons that are used for corrosion testing

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Figure. Test coupons after subjecting to corrosion testing

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Cleaning Corrosion Test Specimens
 After corrosion testing, specimens should be properly cleaned to
remove bulky deposits and corrosion products but not the metals.
 This must be done as soon as possible, so that the measured
corrosion time interval is accurate.
 Corrosion may be continuing under the damp corrosion products
until they are removed.
 Various mechanical, electrolytic, and chemical cleaning methods
have been developed to clean different metals and alloy.
Calculation of Corrosion Rate
 The average corrosion rate may be obtained as follows:
Corrosion rate = (K × W)/ (A × T × D)
Where : K is a constant (varies with the unit)
T is the time of exposure in hours to the nearest 0.01 h,
A is the area in cm2 to the nearest 0.01 cm2
W is the mass loss in grams to the nearest 1 mg
D is the density in g/cm3 16
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 Several units are used to express corrosion rates.
 Using the above mentioned units for T, A, W, and D, the corrosion
rate can be calculated in a variety of units, with an appropriate
value of K.
Various units used to express corrosion rate

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 Introduction to Corrosion Monitoring
 Corrosion Monitoring is a process that evaluates and
monitors equipment components, structures, process units, and
facilities for signs of corrosion.
 Monitoring programs aim to identify certain conditions in order
to extend the life and serviceability of assets while increasing
safety and reducing replacement costs.
 Corrosion monitoring covers all types of corrosion and
materials.
 The key advantage to implementing corrosion monitoring is to
detect early warning signs of corrosion and to determine trends
and processing parameters that may induce a corrosive
environment. Processing parameters that may need to be altered
include temperature, pressure, pH, etc. Additionally,
corrosion monitoring serves to measure the effectiveness of
corrosion prevention methods in order to determine if different
inspection and/or monitoring techniques should be utilized.
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Why is it Important?
 Corrosion is a major threat to the oil and gas, petrochemical
and other process-intensive industries and is responsible for
countless of dollars in damage and maintenance costs.
 Additionally, ageing equipment becomes more susceptible to
corrosion and loses its ability to withstand harsh operating
environments (e.g. high temperature and pressure).
 The purpose of a strong corrosion monitoring program is to
improve safety, reduce maintenance and inspection costs, and
maximize efficiency.
How is Corrosion Monitoring Performed?
 Corrosion monitoring covers a broad range of techniques that
involve measuring, controlling, and mitigating corrosion.
 These techniques can be broadly classified into two types:
inspection and monitoring.
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Inspection Techniques
 Before inspection techniques are applied, it’s important to
document the operating parameters of equipment that may be
increasing the likelihood of corrosion development. These
parameters include, but are not limited to, pH, flow rate
(velocity), pressure, and temperature of the system.
 Next, nondestructive testing (NDT) and inspection techniques
are performed to locate and identify the type of corrosion
damage. Common NDT methods used to detect corrosion
include ultrasonic testing, radiographic testing, and magnetic
flux leakage.
 Risk-based inspection and fitness-for-service assessments are
additional methodologies and processes that can complement a
monitoring program.
 These methods involve qualitative and quantitative approaches
and provide information about the current state of equipment and
provide information about the remaining life of equipment. 20
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Monitoring Techniques
 Once corrosion is identified, corrosion measurement techniques may
be used to gather information about the corrosive environment. This
is accomplished by the use of probes, which can be mechanical,
electrical, or electrochemical devices that monitor changes in
corrosivity during operation.
 Furthermore, corrosion measurement techniques can be used to
provide direct and indirect information about a process while on-
stream (i.e. during operation) or off-stream.
 Common corrosion measurements include pH measurements and
microbiological analysis. Analytical chemistry techniques can
provide information about the amount of dissolved gas (e.g., O2,
CO2, and H2S) and the oxidation of metal ions (e.g., Fe2+, Fe3+).
 Corrosion monitoring techniques provide direct measurements while
the process unit is operating. Common monitoring techniques include
the use of corrosion coupons, electrical resistance, linear
polarization resistance, and galvanic monitoring. Advanced
monitoring techniques include biological monitoring, ultrasonic
thickness monitoring, and hydrogen penetration monitoring. 21
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 Corrosion coupon (or mass loss coupon) testing is the simplest form of
corrosion monitoring that can be applied to all environments (e.g. gases,
fluids, and slurries). A coupon is a sample piece that matches the material
of equipment to be monitored. The coupons is placed into a process
environment and removed after a period of time (e.g. weeks or months).
It is then analyzed for: 1) the amount of mass lost, 2) the type of
corrosion, and 3) the rate of corrosion.
 Electrical resistance probes measure the change in electrical resistance
of a component and provide information about metal loss. These probes
are able to perform in all environments for long periods of time.
Furthermore, they are able to provide periodic (e.g. daily, weekly,
monthly) or continuous (e.g. hourly) data about the rate of corrosion.
 Linear polarization resistance is an electrochemical technique that
works by applying current to an electrode and instantaneously measuring
the corrosion rate. The major disadvantage to this techniques is that it can
only be performed in conductive media and in aqueous solution.
 Galvanic monitoring, also called zero resistance ammetry, is another
electrochemical technique that measures galvanic current passing
between two dissimilar electrodes. The results provide information about
the oxygen content in the media. 22
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 Biological monitoring measures the presence of bacteria that
consume sulphate and generate sulphuric acid (H2SO4).
Sulphuric acid is known to be extremely corrosive to metal
equipment.
 Ultrasonic thickness monitoring is a very common NDT
method that measures the wall thickness of a component over
time. This technique is extremely sensitive and is capable of
scanning over large surface areas using ultrasonic waves.
 Hydrogen penetration monitoring uses probes to measure the
amount of hydrogen that dissolves into steel components. In the
oil and gas industry, hydrogen is often a by-product in many
reactions and can lead to hydrogen induced cracking or
hydrogen embrittlement if left untreated.
 Overall, monitoring techniques have proven to be successful in
reducing facility shutdown time, extending the life of the asset,
and saving companies significant costs. It is not uncommon to
apply multiple techniques at the same time.
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When is Corrosion Monitoring Performed?
 Corrosion monitoring plays a vital role throughout the
equipment lifecycle.
 Inspection and monitoring strategies and techniques may change
according to the age and condition of equipment.
 Therefore, inspection and monitoring strategies should be
reviewed at specific intervals at the owner-operator’s discretion.
Where is Corrosion Monitoring Performed?
 Corrosion remains one of the biggest threats to the petroleum
industry.
 Therefore, corrosion prevention is a primary concern especially
in equipment such as flowlines, transportation pipelines, vessels,
water systems, boilers, vacuum towers, cooling systems, amine
systems, and crude oil systems.
 These systems are typically the most susceptible to producing
corrosive environments.
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THE END!!!

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