CORROSION AND NDT

ASHLEY JOLLEY
What is Corrosion?
 Corrosion

All metals that do not exist in the natural state corrode while those that do exist in the natural
state, the so-called noble metals such as gold and platinum, do not.

All non-noble metals exist naturally as oxides, carbonates, silicates, sulphides and other
compounds.

Corrosion is the process by which these metals revert to their natural state.
The Corrosion Triangle

Cathode Electrolyte

Anode
Corrosion Cell

Corrosion in a metal object, such as a pipe for example.

A negative area of metal (Cathode) is connected to a positive area
(Anode) by the pipe wall itself. As a result, electrons can flow from
the anode to the cathode.
The Galvanic List

MATERIAL POTENTIAL
Graphite +0.25v
Titanium -0.00v
Silver -0.10v
Nickel -0.15v
Copper -0.30v
Millscale -0.40v
Mild Steel -0.70v
Aluminium Alloys -0.90v
Zinc -1.00v
Magnesium -1.60v
Corrosion in Pipes

Methods
• Direct
Types • Electrochemical
• General (wet)
• Localised
• Crevice
• Pitting Factors
• Stress • Atmosphere
• Hydrogen • Contents
• Temp/Press
• Material
Prevention • Geometry
• Surface Coatings
• Paints
• Cathodic Protection Monitoring
(CP) • Visual
• Inhibitors • Radiography
• Electro Magnetics
• Ultrasonic
Corrosion Summary
CORROSION PROCESSES ARE CHEMICAL REACTIONS TAKING PLACE
AT THE SURFACE OF THE METAL (EXTERNAL OR INTERNAL).

THEY OBEY WELL ESTABLISHED CHEMICAL LAWS – WHICH IS FINE IF

YOU KNOW THEM!

WE DO NOT NEED TO KNOW THESE BECAUSE WE ARE DEALING WITH

THE DETECTION OF CORROSION AND NOT THE PREVENTION OF
CORROSION.

REFER TO SECTION 1.13 TO 1.15 OF THE COURSE NOTES FOR

FURTHER INFORMATION ON MODES OF CORROSION.
Non Destructive Testing (NDT)

Non-Destructive Testing (NDT) covers a range of physical methods for detecting flaws and
discontinuities in materials, structures, fabrications and components.

NDT is therefore a tool that can be used in quality control during manufacture and condition monitoring
during service.
 Principle NDT Methods

The principle NDT methods are:

Penetrants (Dye-Pen)

Magnetic Particle Inspection (MPI)

Magnetic-flux leakage (MFL)

Eddy-current Testing (ET)

Radiography (X-Ray, Gamma)

Ultrasonic (UT, AUT, PA, TOFD, GWT)

Guided Wave Testing (GWT)

GUIDED WAVE TESTING IS A RELATIVELY NEW

ULTRASONIC TECHNIQUE. THE EQUIPMENT USED IN
THIS COURSE HAS BEEN DEVELOPED SPECIFICALLY
FOR DETECTING CORROSION IN PIPES, PIPELINES
AND STRUCTURAL TUBULARS.
GWT Offers:

• Rapid SCREENING for in-service degradation.

• Detection of internal and external damage.

• Avoidance of removal / reinstatement of insulation or

coating (except at location of transducer tool).

• The ability to inspect inaccessible areas (clamps,

cased sections, etc).

• The ability to scan large lengths of pipeline from a

single test point.

• Results in reduced inspection costs.

Corrosion detected with GWT

Detection of external corrosion at a girth

weld on a buried pipeline.
Corrosion detected with GWT

Corrosion identified at a girth weld on an

elevated insulated pipeline. Water ingress on
insulated lines can get trapped by the girth weld
caps, which, can lead to external corrosion at the
weld location.
Corrosion detected with GWT

External corrosion identified on a buried gas

pipeline.
Corrosion detected with GWT

External corrosion identified on a partially

buried pipeline. It was noted whilst
investigating the signal produced by this wall
loss that there was plant life at the area of
the corrosion. Obviously a plant requires
water to survive, so a high risk area for a
pipeline! This type of thing should be noted
during a visual inspection and added to the
final report.
Corrosion detected with GWT

External corrosion on a vertical pipeline. Located at a circumferential insulation clamp.

Corrosion detected with GWT

Through wall corrosion identified at the 180°

position. This pipeline had leaked crude oil
but had resealed itself. Evidence of the leak
was still visible below the pipeline.
Corrosion detected with GWT

External CUI (Corrosion Under Insulation).

When inspecting insulated pipelines look for
evidence of water ingress by paying attention
to the external condition of the insulation
jacket, looking for signs of rust or openings in
the outer jacket!
Corrosion detected with GWT

Localised external CUI ~ 4mm wall loss.

Corrosion detected with GWT
Corrosion detected with GWT
Summary

NDT IS USED IN A VARIETY OF SETTINGS FOR THE DETECTION OF

MANUFACTURING FLAWS AND MORE COMMONLY IN-SERVICE DEGRADATION.

NEW NDT METHODS AND APPLICATIONS ARE BEING CONTINUOUSLY

DEVELOPED, GWT BEING ONE SUCH EXAMPLE.

GWT IS A PROVEN NDT TECHNIQUE FOR THE DETECTION OF CORROSION IN

PIPES, PIPELINES AND STRUCTURAL TUBULARS.