Tackling corrosion in industrial infrastructure

CIEAM team display their many sensor products

A CIEAM project team, lead by CRC researchers Dr. Tony Trueman from the Defence Science and Technology Organisation and Dr. Scott Wade from the Department of Mechanical and Aerospace Engineering at Monash University, are investigating the use of both traditional and innovative sensing methods to provide information on the current and potential future health of industrial infrastructure.

The operation of modern infrastructure requires an understanding of material degradation and structural damage, as well as the early detection and repair of corrosion, especially in industry sectors such as civil infrastructure, mining, military aircraft, shipping, and marine structures.

An estimated $276 billion is spent annually in the United States to tackle corrosion issues, with an estimated 15% of US bridges structurally deficient (primarily due to corrosion of steel and steel reinforcement). Similar levels of corrosion problems are predicted to exist in Australia. What may seem like a bit of rust to the untrained eye may actually represent a wider, underlying problem which has significant safety and financial implications.

Last year in Western Australia there was an explosion at Varunus Island where the National Offshore Petroleum Safety Authority found ineffective anti-corrosion coating on a 30cm sales gas pipeline was one of the major causes of the June 3 explosion. Four pipelines were damages and NOPSA found that excessive stress in the pipeline wall, due to extensive external corrosion, caused the explosion. The explosion cut about 30 per cent of WA's gas supplies, and has been variously estimated to cost the state's economy between $1.8 billion and $6.7 billion.

The aim of the research is to incorporate the information provided from in-situ sensors with improved maintenance procedures, allowing corrosion issues to be identified and remedial actions taken at the most appropriate time.

Sensor development and deployment include electrical resistance-based corrosion sensors, optical fibre corrosion sensors, paint degradation sensors and sensors to detect microbiologically influenced corrosion. There are also sensors for the rapid assessment of thickness degradation and moisture detection, and self-powered sensors.

Traditionally, corrosion issues have been identified using routine periodic maintenance inspections.

This approach, however, unless properly managed, can result in too much time being spent on inspection (with costly associated downtime and personnel costs) or too little time (with the potential for a catastrophic failure).

The advanced sensor trials are being carried out in close collaboration with a number of industry partners including Rio Tinto, ASC Pty Ltd. and Izzat Consulting.

More information at www.cieam.com