Corrosion coupons

The simplest, and longest-established, method of

estimating corrosion losses in plant and equipment
is weight loss analysis. A weighed sample
(coupon) of the metal or alloy under consideration
is introduced into the process, and later removed
after a reasonable time interval. The coupon is
then cleaned of all corrosion product and is
reweighed. The weight loss is converted to a total
thickness loss, or average corrosion rate using
proper conversion equations .
Electrical Resistance (ER)
The electrical resistance technique is one of the most widely used
methods for measuring material loss occurring in the interior of plant and
pipelines. This technique operates by measuring the change in electrical
resistance of a metallic element immersed in a product media relative to a
reference element sealed within the probe body. Since temperature
changes effect the resistance of both the exposed and protected element
equally, measuring the resistance ratio minimizes the influence of changes
in the ambient temperature. Therefore, any net change in the resistance
ratio is solely attributable to metal loss from the exposed element once
temperature equilibrium is established .
If the corrosion occurring in the vessel under study is roughly uniform, a
change in resistance is proportional to an increment of corrosion. Although
universally applicable, the ER method is uniquely suited to corrosive
environments having either poor or non-continuous electrolytes such as
vapors, gases, soils, "wet" hydro-carbons, and non aqueous liquids .
Linear Polarization Resistance
Polarization resistance is particularly useful as a method to rapidly identify
corrosion upsets and initiate remedial action, thereby prolonging plant life
and minimizing unscheduled downtime. The technique is utilized to
maximum effect, when installed as a continuous monitoring system. This
technique has been used successfully for over thirty years, in almost all
types of water-based, corrosive environments. Some of the more common
applications are :

1. Cooling water systems

2. Secondary recovery system
3. Potable water treatment and distribution systems
4. Amine sweetening
5. Waste water treatment systems
6. Pickling and mineral extraction processes
7. Pulp and paper manufacturing
8. Hydrocarbon production with free water
The measurement of polarization resistance has very similar requirements
to the measurement of full polarization curves. There are essentially four
different methods of making the measurement according to whether the
current or the potential is controlled and whether the current (or potential)
is swept smoothly from one value to another, or simply switched between
two values. In addition the measurement may be made between two
nominally identical electrodes (a two-electrode system), or a conventional
three-electrode system (working, reference and counter) may be used .
Galvanic probes
Galvanic probes are used in water
injection systems to monitor small
amounts of oxygen which often cause
corrosion. This is achieved by measuring
the galvanic current in the circuit
between a steel and a brass electrode,
which has been found to be particularly
sensitive to the amount of oxygen in the
water.
Although the galvanic current, within
certain restrictions, is proportional to the
oxygen concentration in a system, it may
not replace an oxygen sensor. Other
parameters affecting the galvanic current
are temperature, product flow rate, and
not least the amount and quality of
coatings and corrosion products forming
on the electrode surfaces.
This also explains why galvanic
currents may be relatively high
initially after installation of a
probe when the electrodes are
clean. Gradually, as deposits
build up on the electrodes the
galvanic current drops off until a
steady state is chieved. If
calibrations of the
probe readings versus oxygen
concentrations are attempted,
this should be done after such
steady-state conditions have
been obtained.
Stress corrosion cracking probes
Sacrificial Anodes
When two metals are electrically connected to each other in a
electrolyte e.g. seawater, electrons will flow from the more active metal
to the other, due to the difference in the electrical potential, the so
called' driving force .'When the most active metal) anode (supplies
current, it will gradually dissolve into ions in the electrolyte, and at the
same time produce electrons, which the least active) cathode (will
receive through the metallic connection with the anode. The result is
that the cathode will be negatively polarized and hence be protected
against corrosion. To calculate the rates at which these processes
occur, one has to understand the electrochemical kinetics associated
with the complex sets of reactions that can all happen simultaneously
on these metals .
Cathodic Protection
The basic principle of all CP techniques is that the
unwanted anodic corrosion reactions are suppressed by
the application of an opposing current forcing the local
anodes to be polarized to the potential of the local cathodes
therefore stifling corrosion cells. If less than this amount of
cathodic current is supplied some corrosion would still occur,
but the level of corrosion would be less than that without
any CP. From a thermodynamics point of view, the
application of a CP current basically reduces the corrosion
rate of a metallic structure by reducing its corrosion potential
towards its immune state as shown for iron and steel or for
aluminum and its alloys .
Impressed Current Cathodic Protection (ICCP)
Impressed current cathodic protection is applied by coupling the metal to be
protected to the negative pole of a direct current (DC) source ,while the positive
pole is coupled to an auxiliary anode. Since the driving voltage is provided by the
DC source there is no need for the anode to be more active than the structure to
be protected .
Materials Selection

The choice of a material is the result of several

compromises. For example, the technical appraisal of an
alloy will generally be a compromise between corrosion
resistance and some other properties such as strength
and weld ability. And the final selection will be a
compromise between technical competence and
economic factors. In specifying a material, the task usually
requires three stages:
•Listing the requirements
•Selecting and evaluating the candidate material
•Choosing the most economical material
Corrosion Inhibitors
Inhibitors are chemicals that react with a metallic surface, or
the environment this surface is exposed to, giving the surface
a certain level of protection.Inhibitors often work by
adsorbing themselves on the metallic surface, protecting the
metallic surface by forming a film. Inhibitors are normally
distributed from a solution or dispersion. Some are included
in a protective coating formulation. Inhibitors slow corrosion
processes by either:
•Increasing the anodic or cathodic polarization behavior
(Tafel slopes)
•Reducing the movement or diffusion of ions to the metallic
surface
•Increasing the electrical resistance of the metallic surface
Protective Coatings
Many coatings contain as many as 15 to 20 ingredients with their own
range of functionality. Some of the main variables used to design
corrosion protective coatings are :
Impermeability :The ideal impermeable coating should be completely
unaffected by the specific environment it is designed to block, be it most
commonly humidity, water or any other corrosive agent such as gases, ions
or electrons. The ideal impermeable coating should have a high dielectric
constant and also have perfect adhesion to the underlying surface in order
to avoid any entrapment of corrosive agents .

Inhibition :In contrast with coatings developed on the basis of

impermeability, inhibitive coatings function by reacting with a certain
environment to provide a protective film or barrier on the metallic surface.
The concept of adding an inhibitor to a primer has been applied to coatings
of steel vessels since these vessels have been first constructed. Such
coatings were originally oil based and heavily loaded with red lead .
Cathodically protective pigments :As with inhibition ,
cathodic protection in coatings is mostly provided by
additives in the primer. The main function of these additives
is to shift the potential of the environment to a less corrosive
cathodic potential. Inorganic zinc based primers are good
examples of this concept .