Frontiers and Challenges in Electrochemical Corrosion Monitoring; Surface and Downhole Applications

Corrosion sensing is essential to monitor and safeguard the materials’ health and control the maintenance cost of corrosion-prone materials used in various industries. The petroleum industry is a major sufferer of corrosion costs among various industries due to pipelines and downhole applications. This review article encompasses an overview of various technologies used in early detection stages for more reliable corrosion sensing and warnings. This review provides a summary of corrosion types, corrosion causing chemical species, different destructive and non-destructive technologies used in monitoring corrosion and a comprehensive overview of the state-of-the-art of various electrochemical techniques used for surface and downhole corrosion monitoring. Finally, the existing challenges for corrosion monitoring in surface and downhole conditions and prospects are discussed.

[1]  Yi Liu,et al.  Asset Optimization Using Downhole Corrosion Sensor for Electrical Submersible Pumps , 2017 .

[2]  Chao Ma,et al.  Assessing atmospheric corrosion of metals by a novel electrochemical sensor combining with a thin insulating net using electrochemical noise technique , 2017 .

[3]  Pierre R. Roberge,et al.  Handbook of Corrosion Engineering , 1999 .

[4]  Amal Al Ghaferi,et al.  Carbon Nanostructure‐Based Scale Sensors Using Inkjet Printing and Casting Techniques , 2016 .

[5]  Barry Nicholson,et al.  Corrosion in the Oil Industry , 1994 .

[6]  E. W. Brooman,et al.  Economic effects of metallic corrosion in the United States. Appendix B. Part II. A report to NBS by Battelle Columbus Laboratories. Final report , 1978 .

[7]  Da-Hai Xia,et al.  Detection of corrosion-induced metal release from tinplate cans using a novel electrochemical sensor and inductively coupled plasma mass spectrometer , 2012 .

[8]  Joseph L. Rose,et al.  Using ultrasonic guided wave mode cutoff for corrosion detection and classification , 1998, 1998 IEEE Ultrasonics Symposium. Proceedings (Cat. No. 98CH36102).

[9]  Subbiah Karthick,et al.  Long-term relative performance of embedded sensor and surface mounted electrode for corrosion monitoring of steel in concrete structures , 2014 .

[10]  Zulfiqar Ahmad Khan,et al.  Electrochemical corrosion failure analysis of large complex engineering structures by using micro-LPR sensors , 2018, Sensors and Actuators B: Chemical.

[11]  J. Oakey,et al.  High temperature corrosion monitoring by electrochemical noise techniques , 2009 .

[12]  Jeong-Hyo Bae,et al.  Electrochemical studies on the solid embeddable reference sensors for corrosion monitoring in concrete structure , 2006 .

[13]  J. Broomfield Corrosion of Steel in Concrete: Understanding, investigation and repair , 1996 .

[14]  Alberto A. Sagüés,et al.  Characterization of Activated Titanium Solid Reference Electrodes for Corrosion Testing of Steel in Concrete , 1996 .

[15]  Preliminary results of corrosion monitoring studies of carbon steel overpack exposed to supercontainer concrete buffer , 2014 .

[16]  Development and Application of a Downhole Corrosion Prediction Model , 2016 .

[17]  Lietai Yang,et al.  Techniques for Corrosion Monitoring , 2008 .

[18]  Chinedu I. Ossai,et al.  Advances in Asset Management Techniques: An Overview of Corrosion Mechanisms and Mitigation Strategies for Oil and Gas Pipelines , 2012 .

[19]  Karthik Boinapally,et al.  ARMOURED AGAINST CORROSION , 2008 .

[20]  Fabiana Arduini,et al.  A Paper‐Based Potentiometric Sensor for Solid Samples: Corrosion Evaluation of Reinforcements Embedded in Concrete Structures as a Case Study , 2020 .

[21]  Da-Hai Xia,et al.  Corrosion detection of tinplate cans containing coffee using EIS/EN sensor , 2014 .

[22]  Velu Saraswathy,et al.  Electrochemical studies on the performance characteristics of alkaline solid embeddable sensor for concrete environments , 2008 .

[23]  H. Klapper,et al.  Evaluation of the corrosion of UNS G10200 steel in aerated brines under hydrodynamic conditions , 2008 .

[24]  K. Chiang,et al.  Development of diamond-like carbon-coated electrodes for corrosion sensor applications at high temperatures , 2008 .

[25]  Study Synergy Effect on Erosion-Corrosion in Oil Pipes , 2008 .

[26]  Faisal Khan,et al.  Simplified electrochemical potential noise method to predict corrosion and corrosion rate , 2017 .

[27]  S. Nešić,et al.  Technical Note: Electrochemistry of CO2 Corrosion of Mild Steel: Effect of CO2 on Cathodic Currents , 2018 .

[28]  A. Cranny,et al.  Electrochemical detection of cupric ions with boron-doped diamond electrode for marine corrosion monitoring , 2016 .

[29]  Fabiana Arduini,et al.  Screen-printed electrode as a cost-effective and miniaturized analytical tool for corrosion monitoring of reinforced concrete , 2019, Electrochemistry Communications.

[30]  S. R. Taylor,et al.  Electrical Resistance Changes as an Alternate Method for Monitoring the Corrosion of Steel in Concrete and Mortar , 2000 .

[31]  P. Cristiani,et al.  The study of marine corrosion of copper alloys in chlorinated condenser cooling circuits: the role of microbiological components. , 2014, Bioelectrochemistry.

[32]  M. Itagaki,et al.  Screen-printed atmospheric corrosion monitoring sensor based on electrochemical impedance spectroscopy , 2009 .

[33]  G. D. Davis,et al.  In-Situ Corrosion Sensor for Coating Testing and Screening , 2000 .

[34]  Yoon-Cheol Ha,et al.  A promising potential embeddable sensor for corrosion monitoring application in concrete structures , 2007 .

[35]  S. Bachu,et al.  Experimental assessment of brine and/or CO2 leakage through well cements at reservoir conditions , 2009 .

[36]  J. E. Strutt,et al.  THE PREDICTION OF CORROSION BY STATISTICAL ANALYSIS OF CORROSION PROFILES , 1985 .

[37]  V. Barranco,et al.  A Critical Review of the Application of Electrochemical Techniques for Studying Corrosion of Mg and Mg Alloys: Opportunities and Challenges , 2018, Magnesium Alloys - Selected Issue.

[38]  M. Itagaki,et al.  Development of Printed-Type Corrosion Monitoring Sensor and Analysis of Electrochemical Impedance Response , 2018 .

[39]  B. V. Randall,et al.  Use of Reactive Iron Oxide To Remove H2S From Drilling Fluid , 1979 .

[40]  Robert Lee,et al.  A downhole CO 2 sensor to monitor CO 2 movement in situ for geologic carbon storage , 2016 .

[41]  M. Stern,et al.  Electrochemical Polarization I . A Theoretical Analysis of the Shape of Polarization Curves , 1957 .

[42]  Georgios Nakos,et al.  Monitoring , 1976, Encyclopedia of the UN Sustainable Development Goals.

[43]  X. Tan,et al.  Investigation of novel membrane reactors for removal of dissolved oxygen from water , 2000 .

[44]  Dalei Zhang,et al.  An electrode array study of electrochemical inhomogeneity of zinc in zinc/steel couple during galvanic corrosion , 2010 .

[45]  Velu Saraswathy,et al.  Nickel ferrite (NiFe2O4): A possible candidate material as reference electrode for corrosion monitoring of steel in concrete environments , 2010 .

[46]  K. Chiang,et al.  High-Temperature Electrochemical Sensor for Online Corrosion Monitoring , 2010 .

[47]  M. M. Jordan,et al.  On-Site, Near-Real-Time Monitoring of Scale Deposition , 1999 .

[48]  K. Chiang,et al.  Internal Current Effects on Localized Corrosion Rate Measurements Using Coupled Multielectrode Array Sensors , 2010 .

[49]  S. Nešić,et al.  Electrochemistry of CO2 corrosion of mild steel: Effect of CO2 on iron dissolution reaction , 2017 .

[50]  Elsa Vaz Pereira,et al.  A Galvanic Sensor for Monitoring the Corrosion Condition of the Concrete Reinforcing Steel: Relationship Between the Galvanic and the Corrosion Currents , 2009, Sensors.

[51]  R. B. Figueira Electrochemical Sensors for Monitoring the Corrosion Conditions of Reinforced Concrete Structures: A Review , 2017 .

[52]  V. Gelling,et al.  Electrochemically characterizing the ac–dc–ac accelerated test method using embedded electrodes , 2009 .

[53]  Lisbeth Rischel Hilbert,et al.  Monitoring corrosion rates and localised corrosion in low conductivity water , 2006 .

[54]  Oskar Klinghoffer,et al.  Long Term Performance Of Mno2-Reference Electrodes In Concrete , 1997 .

[55]  Ruishu F. Wright,et al.  Corrosion Sensors for Structural Health Monitoring of Oil and Natural Gas Infrastructure: A Review , 2019, Sensors.

[56]  Xingbo Liu,et al.  High temperature electrochemical sensor for in situ monitoring of hot corrosion , 2012 .

[57]  Velu Saraswathy,et al.  Evaluation of embeddable potential sensor for corrosion monitoring in concrete structures , 2008 .

[58]  J. Al-Ashhab,et al.  Techniques Used To Monitor and Remove Strontium Sulfate Scale in UZ Producing Wells , 2006 .

[59]  C. D. Waard,et al.  Predictive Model for CO2 Corrosion Engineering in Wet Natural Gas Pipelines , 1991 .

[60]  Xingbo Liu,et al.  Effect of SO2 in flue gas on coal ash hot corrosion of Inconel 740 alloy – A high temperature electrochemical sensor study , 2013 .

[61]  Rolf Nyborg,et al.  Overview of CO2 Corrosion Models for Wells and Pipelines , 2002 .

[62]  K. DunlopA,et al.  Fundamental considerations in sweet gas well corrosion. , 1983 .

[63]  Justin Beck,et al.  Membrane-Coated Electrochemical Sensor for Corrosion Monitoring in Natural Gas Pipelines , 2017 .

[64]  Jinping Ou,et al.  Remote corrosion monitoring of the RC structures using the electrochemical wireless energy-harvesting sensors and networks , 2011 .

[65]  George V. Chilingarian,et al.  Surface operations in petroleum production , 1991 .

[66]  P. Chu,et al.  Corrosion behavior of ZnO nanosheets on brass substrate in NaCl solutions , 2009 .

[67]  W. Hu,et al.  Development of an electrochemical sensor and measuring the shelf life of tinplate cans , 2019, Measurement.

[68]  A. Rossi,et al.  A non-destructive in-situ approach to monitor corrosion inside historical brass wind instruments , 2015 .

[69]  Paul R. Ohodnicki,et al.  Effect of HCO3− on electrochemical kinetics of carbon steel corrosion in CO2-saturated brines , 2018, Electrochimica Acta.

[70]  E. Cano,et al.  Advances in the design of a gel-cell electrochemical sensor for corrosion measurements on metallic cultural heritage , 2018 .

[71]  S. A. Umoren,et al.  Electrochemical noise (EN) technique: review of recent practical applications to corrosion electrochemistry research , 2019, Journal of Adhesion Science and Technology.

[72]  Richard L. Martin Corrosion Consequences of Oxygen Entry into Oilfield Brines , 2002 .

[74]  Geraint P Williams Reference Module in Materials Science and Materials Engineering , 1970 .

[75]  Jinping Ou,et al.  Electrochemical characterization of the solid-state reference electrode based on NiFe2O4 film for the corrosion monitoring of RC structures , 2012 .

[76]  C. Joia,et al.  Flow Loop Study of NaCl Concentration Effect on Erosion, Corrosion, and Erosion-Corrosion of Carbon Steel in CO2-Saturated Systems , 2012 .

[77]  X.-L. Zhang,et al.  Development of an Electrochemical In Situ Detection Sensor for Grounding Grid Corrosion , 2010 .

[78]  Guenter Schmitt,et al.  Fundamental Aspects of CO2 Metal Loss Corrosion - Part II: Influence of Different Parameters on CO2 Corrosion Mechanisms , 2006 .

[79]  F.L. Degertekin,et al.  Lamb wave tomography and its application in pipe erosion/corrosion monitoring , 1995, 1995 IEEE Ultrasonics Symposium. Proceedings. An International Symposium.

[80]  William R. Kinsey,et al.  Underground pipeline corrosion , 1973 .

[81]  Shuang Lu,et al.  Corrosion Sensor for Monitoring the Service Condition of Chloride-Contaminated Cement Mortar , 2010, Sensors.

[82]  Z. Ahmad Principles of Corrosion Engineering and Corrosion Control , 2006 .

[83]  B. Nagaratnam,et al.  A review on cement degradation under CO2-rich environment of sequestration projects , 2015 .

[84]  A. Makhlouf,et al.  Failure of the metallic structures due to microbiologically induced corrosion and the techniques for protection , 2018 .

[85]  Da-Hai Xia,et al.  Identifying defect size in organic coatings by electrochemical noise, galvanostatic step and potentiostatic step techniques , 2020 .

[86]  Rudolph G. Buchheit,et al.  Active corrosion protection and corrosion sensing in chromate-free organic coatings , 2003 .

[87]  S. Nešić,et al.  34 – Mathematical modeling of uniform CO2 corrosion , 2017 .

[88]  W. Heineman,et al.  Electrochemical Sensing of Dissolved Hydrogen in Aqueous Solutions as a Tool to Monitor Magnesium Alloy Corrosion , 2013 .

[89]  Jacques Pironon,et al.  Armouring of well cement in H2S–CO2 saturated brine by calcite coating – Experiments and numerical modelling , 2012 .

[90]  F. Ropital Environmental degradation in hydrocarbon fuel processing plant: issues and mitigation , 2011 .

[91]  G. S. Duffó,et al.  Characterization of solid embeddable reference electrodes for corrosion monitoring in reinforced concrete structures , 2009 .

[92]  Y. Gu,et al.  A comparative study on the corrosion behaviors of X100 steel in simulated oilfield brines under the static and dynamic conditions , 2019, Journal of Petroleum Science and Engineering.

[93]  A. Mathiazhagan Corrosion Management for effective mitigation of corrosion in Ships - Overview , 2011 .