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A corrosion monitoring program provides comprehensive monitoring of all critical components of industrial objects, assets, facilities and plants for signs of corrosion. For reliable operation it is important to identify the location, rate, and underlying causes of corrosion. A corrosion monitoring program identifies any non-conforming alloy components, as these are generally susceptible to accelerated corrosion and can give relatively frequent cause for catastrophic failure. Corrosion Monitoring can provide significant advantages when integrated into both preventative maintenance and the processes inherent to safety management programs. Based on the results of the Corrosion Monitoring program, informed decisions can be made, not only regarding the remaining life of the object affected by corrosion but also regarding life extension strategies, prospective material selection, and cost-effective methods for remedy of corrosion issues and problems.
An effective corrosion monitoring program includes a wide range of activities:
- Identification of all critical components
- Identification of component alloy composition
- Measurement of the location and extent of corrosion
- Prediction of remaining life
- Identification of failure mechanisms
- Determination of fitness for service condition
- Inspection scheduling
- Development of recommendations for remedy and correction of problems
- Development of corrosion prevention strategies
Why monitor corrosion
Corrosion is a major problem in many industries, particularly in the petrochemical industry. Corrosion is one of the most serious ageing mechanisms impacting the equipment and assets of refineries and plants. Uncontrolled corrosion can cause leaks and component failures, bringing about a reduction in both the performance and reliability of important equipment. In extreme cases, corrosion can lead to unexpected failures that can be costly in terms of repair costs, environmental damage and potential harm to humans.
Corrosion Monitoring uses a wide range of measurement techniques. non-destructive testing (NDT) methods are the most effective and broadly applied testing methods. Suitable NDT methods for the monitoring of corrosion include:
The selection of the appropriate method as well as the detection and monitoring of corrosion requires knowledgeable and experienced personnel.