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Metal corrosion
Definition of Corrosion
Corrosion is a natural process that occurs when a material, usually a metal, reacts
with its environment, leading to a deterioration of the material and its properties.
Corrosion can occur in various settings, but it is particularly dangerous in major industrial
plants like power plants or chemical processing plants. Corrosion can cause plant
shutdowns, which can have direct and indirect consequences. The effects of corrosion on
equipment or structures can be serious and varied, and they can go beyond the simple loss
of metal. Even small amounts of metal loss can lead to failures of various kinds and the
need for expensive replacements (Razvi & Khedekar, 2016). Therefore, it is important to
address corrosion to ensure the safe, reliable, and efficient operation of equipment or
structures.
Various forms of corrosion can affect metals, including uniform corrosion, pitting
corrosion, crevice corrosion, intergranular corrosion, hot corrosion, and stress corrosion
cracking. One of the most common types of metal corrosion is uniform corrosion which
occurs evenly across the surface of a metal. It typically happens when a metal is exposed
to a corrosive environment, such as an acidic or salty solution, and the metal reacts with
the surrounding environment causing a gradual, uniform loss of metal thickness. This
type of corrosion can result in a general deterioration of the metal's surface and can
weaken the metal over time. To prevent uniform corrosion of metal, commonly used
plating, cladding, and cathodic protection (Balan, 2018). These measures are aimed at
modifying the electrochemical properties of the metal's surface to reduce its reactivity
small localized areas (pits), is the most destructive form of corrosion due to its insidious
nature, making it difficult to detect, and its devastating effects on structural integrity (Yu
et al., 2016). Pitting corrosion is widely recognized as one of the primary degradation
corrosion (Akpanyung & Loto, 2019). These pits can penetrate deep into the metal,
resulting in reduced metal thickness and potentially leading to structural integrity issues.
Pitting corrosion is often challenging to detect and can be highly localized, making it a
significant concern in industries such as marine, aerospace, and oil and gas. The key
strategy to prevent pitting corrosion is to carefully choose a material that is more resistant
to this type of corrosion. For instance, using stainless steel like type 316 with a higher
compared to type 304 stainless steel (Balan, 2018). Material selection plays a critical role
in mitigating the risk of pitting corrosion and can be an effective preventive measure in
initially defined as localized corrosion that occurs within narrow gaps created by metal-
materials known for their high corrosion resistance, such as stainless steel 316 (or 316L)
and nickel alloys, particularly in industrial applications (Wu et al., 2019). Crevice
crevice, preventing proper access to oxygen or other protective agents, while exposing
the metal to a corrosive environment. This disparity in the chemical environment can
result in accelerated corrosion at the crevice, leading to localized damage and potential
structural failure. According to a book by Khoshnaw & Gubner (2022), crevice corrosion
is typically seen in areas where there is stagnant electrolyte solution, such as in gaps
between flanges, bolts, nuts, and similar components. Khoshnaw & Gubner (2022) also
noted that the presence of chloride ions is particularly conducive to crevice corrosion.
The crevice must be of a size that allows for moisture to enter and create a stagnant
environment but is also narrow enough to retain the electrolyte solution. Preventing
crevice corrosion does not have a universal solution, as the most effective approach may
vary depending on the specific circumstances and environmental conditions of each case
(Balan, 2018). Nevertheless, preventive measures for crevice corrosion include careful
design and fabrication to minimize crevice formation, as well as the use of corrosion-
resistant materials, coatings, or sealants to protect vulnerable crevice areas from corrosive
attack.
Finally, intergranular (IGC) or intercrystalline corrosion is a prevalent type of
corrosion that is influenced by the grain structure of the material. IGC is characterized by
selective corrosion occurring at the grain boundaries or closely adjacent regions, without
significant attack on the grains or crystals themselves (di Caprio et al., 2016). This can
Intergranular corrosion (IGC) can significantly reduce the bonding strength between
strength. In certain cases, the combination of stress and IGC can result in intergranular
serious concern as it can lead to catastrophic failure of materials under stress, further
highlighting the damaging effects of IGC on the integrity of metals and alloys (Zhou and
Zuo, 2015). As mentioned by Streicher (2016) in a paper, there are several methods to
heat treatments; (2) refining the material to reduce the concentration of residual
impurities; (3) adding stabilizing alloying elements, such as titanium or niobium, to react
with residual carbon in stainless alloys; and (4) adjusting the alloying elements to
nickel, 15% chromium, and 15% molybdenum. The paper also stated that these
approaches can help mitigate the risk of intergranular corrosion by improving the
microstructure and composition of the material to make it more resistant to this type of
corrosion.
degrade protective coatings, increase maintenance and replacement costs, and pose safety
hazards. Corrosion can create an insulating layer, leading to increased resistance and
voltage drop, causing decreased efficiency and performance. It can also result in
hazards such as electrical shocks, short circuits, and fires can also arise. The severe
Dikici & Gavgali (2014), in the United States alone, it is estimated that the total annual
costs of corrosion will exceed $1 trillion in 2013. However, the ramifications of corrosion
go beyond just financial costs. The authors also stated that corrosion leads to plant
efficiency, costly maintenance, and the need for expensive overdesign. Proper corrosion
prevention measures, such as protective coatings and regular maintenance, are essential
Electrical equipment
specific functions. This can include a wide range of items, such as power distribution
panels, lighting fixtures, electronic devices, and other electrical components used in
and safe operation. Maintenance activities may include inspecting, cleaning, testing,
repairing, and replacing components as needed. Proper maintenance can help prevent
equipment failure, reduce downtime, extend the lifespan of the equipment, and ensure
industry standards, and safety guidelines when performing maintenance tasks. Improperly
electrical systems, which may not align with previously calculated short circuit capacity,
arc flash hazards, and device coordination (Malhotra, 2019). Additionally, keeping
crucial process aimed at identifying and resolving issues or faults in various types of
generators, control panels, and more. There are several types of fault detection methods
utilized in electrical equipment fault diagnosis, including voltage and current monitoring,
insulation resistance testing, thermal imaging, vibration analysis, functional testing, and
visual inspection. Voltage and current monitoring involve analyzing voltage and current
levels for deviations from expected values, while insulation resistance testing measures
abnormal patterns, functional testing conducts tests to verify proper functioning, and
Fault diagnosis technology is evolving to be more closely aligned with actual production,
enhancing diagnostic accuracy and speed through the integration of various technologies
such as new sensing methods, fast signal processing, and diverse sensor information,
while neural networks and fuzzy diagnosis are less commonly used (Li, 2015). These
methods necessitate expertise and experience to accurately interpret results and diagnose
Corrosion detection
Corrosion, the gradual deterioration of metal due to chemical reactions with the
environment, is a common issue that can lead to structural damage and safety concerns.
Detecting corrosion in its early stages is crucial for preventing further damage. There are
Electrochemical methods
detection tools for corrosion, as most corrosion processes are of electrochemical in nature
(Xia et al., 2022). These methods involve measuring the electrochemical properties of a
analysis, and electrochemical impedance spectroscopy are commonly used for detecting
and monitoring corrosion in metals. Xia et al., (2022) also pointed out that although
kinetics and mechanisms, their applicability for field assessment may be limited due to
Visual inspection involves visually examining the metal surface for signs of
identifying the level of corrosion requires an experienced expert who can accurately
determine the corrosion based on their experience and knowledge of different types of
corrosion, such as red rust which is a commonly encountered type (Idris et al., 2015).
This technique is relatively simple and cost-effective but may not be suitable for
detecting early stages of corrosion that may not be visible to the naked eye.
metal. Electrical equipment uses coating to create a barrier between the environment and
metal surface to prevent corrosion, but as Ruikun et al, (2021) stated, it's not reliable as
the metal can still corrode underneath the coating. They also pointed out that this type of
hidden corrosion can be difficult to detect as it occurs beneath the coating layer and can
radiographic testing, and magnetic particle testing can be used to detect corrosion in
microscopic levels in its early stages, making it difficult to detect with conventional
methods. Developing highly sensitive detection techniques that can accurately identify
types of corrosion may have unique characteristics and require specific detection
methods. Developing techniques that are specific to a particular type of corrosion can be
external corrosion that is difficult to detect directly due to its hidden nature, making it a
challenging form of corrosion that is not easily visually noticeable or accessible (Amer et
al., 2018). Accessing and detecting corrosion in such areas can be challenging and may
of corrosion detection techniques is crucial for obtaining consistent results. Factors such
as variability in environmental conditions, sample preparation, and measurement
achieve consistent and reliable results. In the past, human inspection was the traditional
and widely used method to assess the condition of infrastructures, but it was time-
consuming, expensive, and often unreliable due to limitations in accessing all locations
and collecting only qualitative data (He, 2016). Lastly, cost-effectiveness is an important
there is a strong drive to develop unique corrosion sensors with essential properties such
Image processing
Image processing is a field of study that focuses on the manipulation and analysis
employed to manipulate images, 3D models, and printouts, in order to extract the desired
data from these visual sources (Prabaharan et al., 2020). The advancement of computer
network technology has resulted in the progress of digital image processing, fueled by the
growing sophistication of mathematical techniques and the rising demand for digital
image processing across various industries. This has created new opportunities and
manipulate and analyze digital images. As Huang (2022) mentioned, digital image
processing is mainly composed of the following four aspects (1) image digitization, is to
convert the original image into a storage format that is compatible with the computer's
input and processing capabilities (2) correlation of digital images, which is one of the two
enhance the contrast ratio and clarity of the image, as a result, the processed image is
better suited for human visual perception or machine recognition systems, thanks to the
improvements made using this approach (4) image segmentation, which is to segment the
image into distinct regions with distinct properties, where each region comprises a
“Research on Digital Image Processing Technology and Its Application,” by Luo et al.,
2018. 10.2991/meici-18.2018.116.
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Tosic, N., Segura, I., Lozano-Galant, J. A., & Turmo, J.; Komary, M.;
the electrochemical and physical approaches for corrosion monitoring in metallic and
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Feng, X., Jiang, Y., Yang, X., Du, M., & Li, X. (2019) provide a comprehensive
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Esmaily et al. (2017) provide an overview of the fundamentals and most recent
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The study by Padilla, Netto, and Da Silva (2020) on performance measures for
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Angst (2018) shows the difficulties and potential associated with the corrosion of
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(2018) for the purpose of detecting corrosion on metallic surfaces. The authors compare
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The updated edition of Power System Protection by Anderson, Henville, Rifaat,
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systems, and the analytical foundation for the design, application, and setting of power
system protection equipment for today's engineer. For power system engineers and
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The most recent electrochemical techniques and equipment utilized for the field
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existing methodologies, the authors stressed the necessity for further advancement of
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