Asset Life Extension Through Deployment of Corrosion and Inspection Technologies: Corrosion Monitoring Vs. Condition Monitoring

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As facilities in the oil and gas industry age with time, corrosion mitigation and control become more important. Failure of processing equipment is likely to entail production loss, loss of containment, environmental impact, and/or human risk. Internal corrosion failures represent one of the major risks to process equipment and piping.

Product Number: 51323-19279-SG

Author: Faisal M. Al-Mutahhar, Rakan A. Al-Shebil, Ayman A. Alabdullatif

Publication Date: 2023

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With the new development in the fields of corrosion and condition monitoring for equipment and piping, multiple new technologies have been introduced. While there is an overlap between corrosion monitoring and condition monitoring, there are critical distinctions that are often overlooked. Corrosion monitoring technologies include corrosion coupons and online corrosion sensors; both provide data on the corrosivity of process fluids. Coupons provide one corrosion rate reading over a long interval (usually one data point every quarter), but provide much more data on active damage mechanisms and the scale/corrosion products. Online corrosion sensors (commonly known as corrosion probes), on the other hand, provide online live data of the system corrosivity. One of the latest developments in the field of condition monitoring technologies is online permanent UT sensors, which will be the focus of this paper. They are installed in locations where a high corrosion rate is expected to directly measure the remaining thickness of the pipe/equipment. Corrosion monitoring and condition monitoring technologies provide different types of data that have different uses to manage the integrity of piping and equipment. Relying only on one of them is not sufficient. As such, this paper explores the differences between corrosion and condition monitoring, their pros, and cons, and how to get the most out of their installation.