A Complete Guide to Corrosion Monitoring

What is corrosion monitoring and why is it important? Read this guide to learn all about corrosion monitoring, including how drones can help.

Corrosion is a serious threat in industries that handle volatile materials like oil, gas, and petrochemicals. It can significantly reduce the lifespan of critical infrastructure such as boilers, pressure vessels, and pipelines, leading to leaks, failures, and even catastrophic events if left unchecked.

Without regular monitoring, corrosion can cause major damage, resulting in costly repairs, safety hazards, and environmental harm. In fact, in the U.S. alone, the annual cost of carbon steel corrosion is estimated at $276 billion. That's why corrosion monitoring and rust detection are essential for maintaining operational integrity and reducing long-term expenses.

In this article, we'll explore what corrosion monitoring is, why it matters, and how modern technologies like drones are revolutionizing the way we detect and manage corrosion. We’ll also discuss various tools and techniques used in the field, with a special focus on the role of drones in improving efficiency and safety.

What Is Corrosion Monitoring?

Corrosion is the gradual degradation of a material, typically metal, due to chemical or electrochemical reactions with its environment. Monitoring, in this context, refers to the continuous observation and recording of these changes over time.

So, corrosion monitoring involves tracking the progression of material degradation, identifying areas affected by corrosion, and measuring its rate of spread. This helps prevent further damage, ensuring the safety and reliability of industrial assets.

Corrosion often starts as small discolorations or surface irregularities. These signs can be missed during routine checks, which is why regular and detailed monitoring is crucial. By keeping track of these changes, engineers can take timely action before the situation becomes critical.

Monitoring vs. Inspecting

While both monitoring and inspecting are essential, they serve different purposes. Monitoring focuses on specific areas of an asset and is conducted more frequently, while inspecting involves a full review of the entire asset and occurs less often.

For example, if a section of a boiler shows rapid corrosion growth, it may be monitored monthly instead of annually. This allows for more accurate data collection and better decision-making regarding maintenance and repair.

What Exactly Do You Monitor in Corrosion Monitoring?

When conducting corrosion monitoring, the goal is to track the development of existing corrosion and identify any new areas where it may have occurred. This is done using various methods such as visual inspection, ultrasonic testing, and 3D mapping.

Common assets that require corrosion monitoring include:

• Vessels
• Boilers
• Crude oil systems
• Transportation pipelines
• Water systems
• Flowlines
• Vacuum towers
• Cooling systems

Why Is Corrosion Monitoring Important?

There are three main reasons why corrosion monitoring is vital:

• Safety
• Cost Reduction
• Improved Efficiency

Safety

Corrosion can lead to equipment failure, especially in industries handling flammable or hazardous materials. Regular monitoring helps identify potential risks early, preventing accidents and protecting personnel.

Cost Reduction

Replacing damaged equipment due to unmonitored corrosion can be extremely expensive. By extending the life of assets through proper monitoring, companies can save millions in replacement and repair costs.

Improved Efficiency

Effective corrosion monitoring not only prevents failures but also improves operational efficiency. It provides insights into material performance, helps identify cost-effective solutions, and reduces downtime for maintenance.

How Do You Perform Corrosion Monitoring?

The key data points collected during corrosion monitoring include:

• Location and extent of corrosion
• Rate of corrosion
• Underlying causes of corrosion

Inspections typically start with a visual check, followed by more advanced techniques like ultrasonic testing. Other non-destructive testing (NDT) methods include radiographic testing, guided wave testing, and magnetic flux leakage.

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How Drones Can Help with Corrosion Monitoring

Drones have become a game-changer in corrosion monitoring. They provide high-quality visual data, access hard-to-reach areas, and offer precise measurements. This makes them ideal for inspecting tanks, pipelines, and other complex structures.

One of the most advanced drones for this purpose is the Elios 2, which can navigate confined spaces and capture detailed images with centimeter-level accuracy. Its oblique lighting feature enhances visibility, making it easier to spot corrosion in low-light conditions.

Creating an Accurate Visual Record

Drones can collect enough high-quality visual data to create a detailed record of corrosion status over time. This is especially useful for documenting maintenance efforts and ensuring that repairs return assets to their original condition.

3D Models

With advancements in technology, drones can now generate partial 3D models of industrial assets. These models help visualize the location and severity of corrosion, allowing for more informed maintenance decisions.

The latest model, the Elios 3, uses LiDAR to create real-time 3D maps of confined spaces. This capability offers a powerful tool for corrosion monitoring, providing a clear and accurate view of asset conditions.

Watch this 3D fly through created by live footage from the Elios 3 in a decommissioned power plant:

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