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Continuous corrosion surveillance of process equipment by new - electrochemical - sensing techniques and devices

Objective


During this project a 'Continuous Corrosion Surveillance System' was developed. The following results have been achieved:
a) Positive evaluation of the EFM -method and EES-method on laboratory scale;
b) the elaboration of a UT inspection procedure and the development of powerful data processing software;
c) The first prototype of the data management system is ready.

The corrosion management tool is based on the software shell of the ALIAS system into which new modules for corrosion monitoring and NDT analysis were integrated;
d) Study on general hardware and software requirements for an industrial monitoring system has been carried out, taking into account the specifications and the requirements of the end-users. Software development has been carried out. An integrated system has been built;
e) The integrated system has been tested on industrial scale. Special electrodes have been developed for each application separately. Plant validation has been carried out at Cires, EDP and Akzo. Test results are available from the industrial partners. The industrial benefits, relevance and future potential has been studied.
A 'Continuous Corrosion Surveillance system' has been developed. A prototype is ready and tested in various industrial environments. A corrosion management tool has been developed and integrated in the monitoring system.
The overall objective of this project (and its commercial 'follow up' phase) is to develop and operate by the year 2001 an innovative CONTlNUOUS CORROSION SURVEILLANCE system, which permanently monitors the condition of process installations (reactors, storage vessels, heat exchangers & water circuits, piping & pipelines, ...) in service and reduces the number of forced outages due to degradation by corrosion.

This corrosion surveillance system will be based on:

new (electrochemical) sensing techniques which allow on line monitoring of both uniform and localized types of corrosion:
incorporation of these techniques into innovative industrially sound devices;
combination with some selected (adapted) NDE technologies and devices;
creation of improved software tools for "integral" corrosion monitoring and inspection management, allowing expert
evaluation/interpretation of the monitoring data for on line real time diagnostics and operator/plant engineer support.
The techniques and devices will be thoroughly tested and validated in laboratorv & field trials. The latter will include 3 radically different applications:
surveillance of protection system against external corrosion (i.e. monitoring of cathodic protection on buried pipeline),
surveillance of general (internal) corrosion in a chemical process vessel (by means of electrochemical monitoring),
surveillance of both general and localized corrosion in the water circuit of a power plant, by means of combined electrochemical monitoring and NDE, including the recommendation of corrective actions.

Finally, a manufacturing specification will be prepared for the device(s) that successfully complete the field trials. A number of prototype systems will be manufactured and distributed to the Partners (and to project 'sponsors' outside the Consortium) for longer term trials, outside the project, intended to support the long term exploitation of the technologies.

It is expected that after the end of the project (1999), about two years of additional on site tests at the premises of end users and further development will be needed to make the surveillance tools sufficiently reliable and user friendly to function in an industrial environment. Introduction into the market will therefore start about two years after the end of the project (2001).

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

METALOGIC N.V. A.I. TECHNOLOGIES & ENGINEERING
Address
60,Kapeldreef 60
3001 Heverlee
Belgium

Participants (6)

Akzo Nobel Chemicals BV
Netherlands
Address
76,Velperweg
6800 SB Arnhem
Companhia Industrial de Resinas Sinteticas SA
Portugal
Address
Quinta Da Industria
3861 Estarreja
EDP - ELECTRICIDADE DE PORTUGAL SA
Portugal
Address
55/2,Av. Estados Unidos Da America 55/2
1749-061 Lisboa
INSTITUTO DE SOLDADURA E QUALIDADE ASSOCIACAO*
Portugal
Address
Km 3,Avenida Do Professor Doutorcavaco Silva 33Parque D
2740-120 Porto Salvo
Katholieke Universiteit Leuven
Belgium
Address
2,Celestijnenlaan 300A
3001 Leuven
Staatliche Materialprüfungsanstalt
Germany
Address
Pfaffenwaldring 32
70569 Stuttgart