Low-Cost Technologies Used in Corrosion Monitoring

Pipeline Elbow Corrosion Simulation for Strain Monitoring with Fiber Bragg Gratings

This study addresses the limitation of traditional non-destructive testing methods in real-time corrosion monitoring of pipe elbows by proposing the utilization of fiber Bragg grating (FBG) strain sensors, renowned for their resilience in harsh environments. However, the current mathematical relationship model for strain representation of elbow corrosion is still lacking. This paper develops a finite element model to scrutinize the strain changes in the elbow due to corrosion under hydrostatic pressure and bending loads. To mitigate temperature loading effects, the corrosion degree is evaluated through the disparity between hoop and axial strains. Simulation outcomes reveal that, under hydrostatic pressure, the strain difference exhibits minimal changes with the increase in corrosion degree, while under bending moment loading, the strain difference escalates proportionally with corrosion progression. Consequently, strain induced by bending moment loading solely characterizes the corrosion degree. Moreover, the optimal placement for FBG sensors is identified at the extrados of the pipe elbow, where strain is most prominent. These insights enhance comprehension of strain-corrosion dynamics in pipe elbows, offering valuable guidance for developing an FBG-based monitoring system for real-time corrosion tracking and predictive maintenance of pipeline infrastructures.

Green Corrosion Inhibitors for Metal and Alloys Protection in Contact with Aqueous Saline

Corrosion is an inevitable and persistent issue that affects various metallic infrastructures, leading to significant economic losses and safety concerns, particularly in areas near or in contact with saline solutions such as seawater. Green corrosion inhibitors are compounds derived from natural sources that are biodegradable in various environments, offering a promising alternative to their conventional counterparts. Despite their potential, green corrosion inhibitors still face several limitations and challenges when exposed to NaCl environments. This comprehensive review delves into these limitations and associated challenges, shedding light on the progress made in addressing these issues and potential future developments as tools in corrosion management. Explicitly the following aspects are covered: (1) attributes of corrosion inhibitors, (2) general corrosion mechanism, (3) mechanism of corrosion inhibition in NaCl, (4) typical electrochemical and surface characterization techniques, (5) theoretical simulations by Density Functional Theory, and (6) corrosion testing standards and general guidelines for corrosion inhibitor selection. This review is expected to advance the knowledge of green corrosion inhibitors and promote further research and applications.

Corrosion Monitoring by Plastic Optic Fiber Sensor Using Bi-Directional Light Transmission

In this paper, a new sensor is proposed to efficiently gather crucial information on corrosion phenomena and their progression within steel components. Fabricated with plastic optical fibers (POF), the sensor can detect corrosion-induced physical changes in the appearance of monitoring points within the steel material. Additionally, the new sensor incorporates an innovative structure that efficiently utilizes bi-directional optical transmission in the POF, simplifying the installation procedure and reducing the total cost of the POF cables by as much as 50% when monitoring multiple points. Furthermore, an extremely compact dummy sensor with the length of 5 mm and a diameter of 2.2 mm for corrosion-depth detection was introduced, and its functionality was validated through experiments. This paper outlines the concept and fundamental structure of the proposed sensor; analyzes the results of various experiments; and discusses its effectiveness, prospects, and economic advantages.

Experimental Investigation for Monitoring Corrosion Using Plastic Optical Fiber Sensors

The timely and cost-effective identification of the onset of corrosion and its progress would be critical for effectively maintaining structural integrity. Consequently, a series of fundamental experiments were conducted to capture the corrosion process on a steel plate using a new type of plastic optical fiber (POF) sensor. Electrolytic corrosion experiments were performed on a 5 mm thick steel plate immersed in an aqueous solution. The POF sensor installed on the upper side of the plate and directed downward detected the upward progression of the corrosion zone that formed on the underside of the plate. The results showed that the POF sensors could detect the onset of the upward-progressing corrosion front as it passed the 1 and 2 mm marks related to the thickness of the corroded zone. The POF sensors were designed to optically identify corrosion; therefore, the data obtained by these sensors could be processed using a newly developed graphic application software for smartphones and also identified by the naked eye. This method offered an easy and cost-effective solution for verifying the corrosion state of structural components.

A Review of Electrochemical Techniques for Corrosion Monitoring - Fundamentals and Research Updates

Interculturally, corrosion has been counted as one of the most expensive factors toward the retrogression of concrete and metallic structures resulting in huge monetary losses and unanticipated loss of life. To a large extent, corrosion-related catastrophes can be avoided by having the ability to monitor corrosion before structural integrity is jeopardized. This paper critically reviews the various accustomed electrochemical techniques utilized for corrosion monitoring in terms of their definition, timeline, experimental set-up, advantages, and shortcomings. Additionally, literature exploiting these techniques as their corrosion detection technique has been focused on here. Furthermore, a comparison between recently reported methods has been made to provide better insights into the research progress in this arena.

Development of a novel virtual reality-enabled remote monitoring device for maintenance of cathodic protection systems on oil and gas pipelines

Periodic inspections are required for oil and gas pipelines equipped with cathodic protection systems (CPS) to prevent corrosion. This inspection takes time and requires money, mobilisation of specialised staff, and accessibility of pipeline right of way which is often hindered by security issues, and bad terrain. A novel virtual reality-enabled remote monitoring device, developed using the NACE SP0169 standard, which measures the pipe-to-soil potential (PSP) reading, transmits the measured data to an IoT server, and a virtual environment for analysis and feedback while providing an immersive experience to the user, all in real-time, is presented. The hardware and software components are developed using Sensors, Arduino Mega 2560 board, AWS Sumerian 1.2.0 software, ThingSpeak IoT server, Blender modelling software and AutoCAD. When implemented on real test posts of oil and gas facilities and compared with the traditional methodology, the system showed consistency of data measurement and analysis, with real-time feedback to users, and a Spearman rank's correlation coefficient of 0.998944. The study is significant as it provides the oil industry with an expert, easy-to-understand tool which helps to reduce the rate of oil spillage and losses through corrosion.

Low-Cost Sensors Technologies for Monitoring Sustainability and Safety Issues in Mining Activities: Advances, Gaps, and Future Directions in the Digitalization for Smart Mining

Nowadays, monitoring aspects related to sustainability and safety in mining activities worldwide are a priority, to mitigate socio-environmental impacts, promote efficient use of water, reduce carbon footprint, use renewable energies, reduce mine waste, and minimize the risks of accidents and fatalities. In this context, the implementation of sensor technologies is an attractive alternative for the mining industry in the current digitalization context. To have a digital mine, sensors are essential and form the basis of Industry 4.0, and to allow a more accelerated, reliable, and massive digital transformation, low-cost sensor technology solutions may help to achieve these goals. This article focuses on studying the state of the art of implementing low-cost sensor technologies to monitor sustainability and safety aspects in mining activities, through the review of scientific literature. The methodology applied in this article was carried out by means of the Preferred Reporting Items for Systematic Reviews and Meta-Analyses (PRISMA) guidelines and generating science mapping. For this, a methodological procedure of three steps was implemented: (i) Bibliometric analysis as a quantitative method, (ii) Systematic review of literature as a qualitative method, and (iii) Mixed review as a method to integrate the findings found in (i) and (ii). Finally, according to the results obtained, the main advances, gaps, and future directions in the implementation of low-cost sensor technologies for use in smart mining are exposed. Digital transformation aspects for data measurement with low-cost sensors by real-time monitoring, use of wireless network systems, artificial intelligence, machine learning, digital twins, and the Internet of Things, among other technologies of the Industry 4.0 era are discussed.

Studying the impacts of test condition and nonoptimal positioning of the sensors on the accuracy of the in-situ U-value measurement

The non-destructive thermal characterization of building envelopes relies significantly on various factors such as climate conditions, monitoring devices used, indoor environment, and conditioning systems. In the case of both the temperature-based method (TBM) and heat flux meter (HFM) approaches, U-value is determined considering the ideal condition of steady state. However, it is challenging to accurately define the true thermal condition of buildings when monitoring is affected by inherent uncertainties of the chosen approach and inadequate instrumentation of building envelopes. This paper presents the outcomes of an experimental campaign, that aimed to evaluate the impact of incorrectly positioned exterior sensors, on the precision of U-value measurements. This study simultaneously employed the TBM and HFM approaches. To enhance the accuracy of the results, rigorous outlier detection and statistical analysis were employed on the data collected from three autonomous monitoring systems. The findings of this study revealed that the applied data analysis yielded more satisfactory results for the TBM approach compared to HFM. However, regardless of the approach used, the effectiveness of outlier detection relied heavily on the accuracy of the monitoring systems. When removing an individual outlier, the monitoring systems characterized with higher accuracies provided U-values that were closer to the theoretical values, than less accurate ones.

Alkaloid Extract of Ageratina adenophora Stem as Green Inhibitor for Mild Steel Corrosion in One Molar Sulfuric Acid Solution

Green corrosion inhibitors are of great interest due to their exciting and environmentally friendly behavior in mild steel corrosion control during and after the acid cleaning process. Herein, alkaloids were extracted from the stem of Ageratina adenophora and were ensured by qualitative chemical tests as well as spectroscopic test methods. The corrosion inhibition efficacy of the alkaloids against mild steel corrosion was evaluated by gravimetric, electrochemical and EIS measurement methods. In addition, the adsorption isotherm, free energy of adsorption and thermodynamic parameters of the process were evaluated. The investigations indicated the most promising inhibition efficacy of the alkaloids for mild steel corrosion. The adsorption isotherm study revealed that the adsorption of inhibitor molecules on the MS interface was manifested by dominant physisorption followed by chemisorption. Free energy and thermodynamic parameters are well suited to endothermic processes.