Corrosion Monitoring
Training & Certification
ITS, 23 Agustus 2017
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METODA MONITORING KOROSI
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Ultrasonic
Ultrasonic digunakan sebagai salah satu metoda NDT untuk mengevaluasi hasil
lasan di sekeliling pipa.
Prinsipnya adalah dengan memberikan frekuensi antara 0.1 sampai 25 MHz
kepada benda yang akan di evaluasi dan hasil dapat dilihat setelah sinyal kembali.
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Ultrasonic
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Radiography
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Radiography
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METODA MONITORING KOROSI
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Eddy Current
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Dye Penetrant
Metoda ini baik digunakan untuk mendeteksi adanya retakan/crack ataupun porous
pada sambungan dari las-lasan. Prinsipnya benda kerja dilapisi dengan penetrant
yang mempunyai warna mencolok atau fluorescent. Setelah beberapa waktu akan
berpenetrasi kedalam retakan atau bagian-bagian yang rusak.
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Keberhasilan Monitoring
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Keuntungan Monitoring
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Lokasi Monitoring
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Lokasi Monitoring
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Lokasi Monitoring
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Lokasi Monitoring
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Corrosion Monitoring
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Process Monitoring Matrix
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Coupon
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Coupon
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Coupon
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PROSEDUR
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BENDA UJI
BAJA KARBON
C 1045
A 515-70
C 1035
A 192
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KOMPOSISI
Baja
Karbon C Si S P Mn Ni Cr Cu Fe
C 1045 0.5383 0.2088 0.0030 0.0085 0.6784 0.0148 0.0273 0.0292 98.411
A 515- 0.2371 0.2503 0.0124 0.0147 0.5191 0.1275 0.2079 0.1938 98.351
70
C 1035 0.3364 0.5525 0.0127 0.0189 0.6770 0.0704 0.1325 0.1118 97.951
A 192 0.1798 0.2361 0.0203 0.0092 0.5151 0.0723 0.2057 0.0717 98.545
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C 1045 C 1035
A 515-70 A 192
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Preparasi benda uji PREPARASI BENDA UJI
Ampelas # 800
Celupkan di aceton/alkohol
Keringkan
Timbang
Ekspose
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Preparasi benda uji
Celupkan di aceton/alkohol
Keringkan
Timbang
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PRAKTIKUM
Waktu ekspos = jam
3
Sp.Gravity = 7.86 gr/cm
Luas
Kelmpok Benda uji permukaan Berat awal Berat akhir Laju korosi
2
cm gr gr mpy
A C 1045 19.3301
B A515-70 19.5540
C C 1035 18.7557
D A 192 17.2501
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coupon
C 1045 A 192
22 36
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Pengukuran luas terekspos
PRAKTIKUM
A
C
Luas terekspos =
2xA+2xB+2xC–2xD
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1
3
4
6
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Standar tingkat kebersihan permukaan
C Sa 1
C Sa 2
C Sa 3
C Sa 2½
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Waktu ekspos
menurut ASTM G 31
2000
exposure time (hours) =
expected corr.rate
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Jenis coupon dan holder
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Posisi coupon
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Penempatan Coupon
SALAH BENAR
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Coupon holder
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Retractable
corrosion coupon holder
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Metoda kehilangan berat
534 x W
laju korosi (mpy) =
AxDxt
dimana :
W = kehilangan berat (mg)
A = luas permukaan total (in2)
D = densitas specimen (gr/cm3)
t = waktu ekspos (jam)
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1 in = 2.54 cm
W mg 1 cm = 0.3937 in
AxDxt in2 x g/cm3 x jam 1 cm2 = 0.1549 in2
1 cm3 = 0.0610 in3
534 mpy
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Nomograph
Density = 7.90
7.90
mpy = 30
mdd = 165
6.50
Density = 6.50
mpy = 60
mdd = 270
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CORROSION RATE CONVERSION
mdd = 270
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Densitas beberapa logam
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Posisi coupon
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jawaban soal 1
534 x W
Laju korosi (mpy) =
AxDxt
W = 2.3 g = 2300 mg
A = 2 in x 4 in = 8 in2
D = 7.93 g/cm3
t = 30 x 24 = 720 jam 534 x 2300
=
8 x 7.93 x 720
= 26.88 mpy
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Contoh perhitungan laju korosi
1 in = 2.54 cm
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jawaban soal 2
W = 5600 mg
A = {(2.5 x 0.39 in) x (4.5x0.39 in)} x 2 = 3.42 in2
D = 6.54 gr/cm3
T = 100 x 24 = 2400 jam
534 x 5600
laju korosi =
3.42 x 6.54 x 2400
= 55.70 mpy
dari tabel hubungan antara laju korosi dan ketahanan korosi logam bahwa nilai 55.70
mpy menunjukkan bahwa logam M tersebut mempunyai ketahanan korosi yang buruk
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Installation of corrosion chamber Ø 2½ “
(inlet water)
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sumber : pribadi
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Pemasangan coupon pada chamber
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Hasil ekspose coupon pada
unit heat exchanger
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Hasil ekspose coupon pada unit heat
exchanger
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Planned interval test
At + 1 A2
At
A1 B
0 1 t t+1
time
(t+1) : waktu total pengujian
A2 : dihitung dengan mengurangi At dari At + 1
A1, At, At + 1, B : perioda waktu pengujian untuk masing-masing spesimen
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Planned interval test
unchanged A1 = B unchanged A2 = B
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Planned interval test
combinations of situations
liquid metal criteria
corrosiveness corrodibility
unchanged decreased A2 < A1 = B
unchanged increased A1 = B < A 2
decreased unchanged A2 = B < A 1
decreased decreased A2 < B < A 1
decreased increased A1 > B < A2
increased unchanged A1 < A2 = B
increased decreased A1 < B > A 2
increased increased A1 < B < A 2
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Planned interval corrosion test
A1 0–1 1080
At 0-3 1430
B 3–4 70
A2 Calc, 4-3 30
A2 B A1
< <
conditions : duplicate strips of low carbon steel, ¾ x 3 in (sp.grav = 8.61 gr/cm 3), immersed in
200 ml 0f 10% AlCl – 90% SbCl misture through which dried HCl gas was slowly bubbled at atm
pressure, 90oC.
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Planned interval corrosion test
B 3–4 70 0.11 40
A2 Calc, 4-3 30 0.05 18
A2 < B < A1
0.05 < 0.11 < 1.69
Liquid : decreased, Metal : decreased
conditions : duplicate strips of low carbon steel, ¾ x 3 in (sp.grav = 8.61 gr/cm3), immersed in
200 ml 0f 10% AlCl – 90% SbCl misture through which dried HCl gas was slowly bubbled at atm
pressure, 90oC.
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Planned interval test
combinations of situations
liquid metal criteria
corrosiveness corrodibility
unchanged decreased A2 < A1 = B
unchanged increased A1 = B < A 2
decreased unchanged A2 = B < A 1
decreased decreased A2 < B < A 1
decreased increased A1 > B < A2
increased unchanged A1 < A2 = B
increased decreased A1 < B > A 2
increased increased A1 < B < A 2
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Planned interval corrosion test
A1 0 – 10 1000
At 0 – 30 1500
At+1 0 – 40 2000
B 30 – 40 400
A2 Calc,30-40 500
A2 B A1
conditions : duplicate strips of low carbon steel, ¾ x 3 in (sp.grav = 8.61 gr/cm3), immersed in 200 ml 0f
10% AlCl – 90% SbCl moisture through which dried HCl gas was slowly bubbled at atm pressure, 90oC.
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Planned interval corrosion test
A2 B A1
0.78 > 0.64 < 1.57
liquid corrosiveness : decreased
metal corrodibility : increased
conditions : duplicate strips of low carbon steel, ¾ x 3 in (sp.grav = 8.61 gr/cm3), immersed in 200 ml 0f
10% AlCl – 90% SbCl misture through which dried HCl gas was slowly bubbled at atm pressure, 90oC.
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Planned interval test
combinations of situations
liquid metal criteria
corrosiveness corrodibility
unchanged decreased A2 < A1 = B
unchanged increased A 1 = B < A2
decreased unchanged A 2 = B < A1
decreased decreased A 2 < B < A1
decreased increased A1 > B < A2
increased unchanged A1 < A2 = B
increased decreased A 1 < B > A2
increased increased A 1 < B < A2
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Table 1. Experimental data of corrosion coupon
No. of hole and Alloy code Surface Initial Final Weight Duration Corrosion Penetrati
specimens area weight weight loss of test rate on rate
(cm2) (gr) (gr) (mg) (days) (mpy) (mils)
1 A1 A 192 28.75 16.5616 16.0891 28
No. of hole and Alloy code Surface Initial Final Weight Duration Corrosion Penetrati
specimens area weight weight loss of test rate on rate
(cm2) (gr) (gr) (mg) (days) (mpy) (mils)
1 A1 A 192 28.75 16.5616 16.0891 28
No.of hole and Alloy code Weigth loss Duration Corr. Rate Penetration
specimens mg days mpy mils
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Waktu ekpose Baja Karbon A192
A3
A2
A4
A1
0 28 56 84 112 140
hari
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Table 2. Exprimental data of corrosion coupon at plant interval test
B1 A1 0-28 A1 B A2
B2 At 0-112
B3 At+1 0-140
B4 B 112-140
C1015 A2 112-140
C1 A1 0-28 A1 B A2
C2 At 0-112
C3 At+1 0-140
C4 B 112-140
A515- A2 112-140
70
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Table 2. Exprimental data of corrosion coupon at plant interval test
B1 A1 0-28 610.7 A1 B A2
B2 At 0-112 1890.9
B3 At+1 0-140 1908
B4 B 112-140 307.6
C1015 A2 112-140
C1 A1 0-28 456.7 A1 B A2
C2 At 0-112 882.4
C3 At+1 0-140 1057.8
C4 B 112-140 565.5
A515- A2 112-140
70
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Table 2. Exprimental data of corrosion coupon at plant interval test
mdd = mgr/dm2/day
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Scale coupon
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Scale coupon
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Experimental data of scale coupon
mdd = mgr/dm2/day
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Y gram
X gram
Temp 105oC
T = 1 jam
Y +X + Z gram
Oven
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Relationship between time of exposure and scale rate
40
35
30
25
Scale rate (mdd)
20
15
10
0
28 56 84 112 140
Time of exposure
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Cara cepat mengindikasikan sifat air akan menyebabkan korosi atau
terbentuknya kerak
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Cara cepat mengindikasikan sifat air akan menyebabkan korosi atau
terbentuknya kerak
Water A Water B
pH 9.0 9.0
Temperature 50 oF 50 oF
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BA Ca = 40
BA C = 12
BA O = 16
Water A Water B
Total Hardness, CaCO3 160 mg/l 80 mg/l
40
Ca = x 160 = 64
100
40
Ca = x 80 = 32
100
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BA Ca = 40
BA C =12
BA O = 16
Water A
Dari tabel di dapat pH1 = 8.25
Selisih dengan pH ideal
= 9 – 8.25
= 0.75 little or light scaling
Water B
Dari tabel di dapat pH1 = 10.1
Selisih dengan pH ideal
= 9 – 10.1
= -1.1 light to significantly
corrosion
8.25 Temp 50 o F
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Water A
Dari tabel di dapat pH1 = 8.25
o
Δt = 120-50 = 70 F
Temp.correction dikalikan -0.0167
ΔpH1 = 70 x -0.0167 = - 1.17
= 8.25-1.17 = 7.08
Selisih dengan pH ideal
= 9 - 7.08
= 1.92 little to significant
scaling
Water B
Dari tabel di dapat pH1 = 10.1
ΔpH1 = 10.1 – 1.17 = 8.93
Selisih dengan pH ideal
= 9 -8.93
= 0.07 little or no scaling
8.25
10.1ronald nasoetion Temp 120 o F86
PRAKTIKUM
Waktu ekspos = 5 jam
3
Sp.Gravity = 7.86 gr/cm
Luas
Nama Benda uji permukaan Berat awal Berat akhir Laju korosi
2
cm gr gr mpy
87
Pengujian laju korosi di lingkungan atmosfir
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Classification of corrosivity
based on corrosion rate measurements of standard specimens
C1 g/(m2.a) rcorr < 10 rcorr < 0.7 rcorr < 0.9 negligible
C2 g/(m2.a) 10< rcorr <200 0.7< rcorr <5 0.9< rcorr <5 rcorr < 0.6
C3 g/(m2.a) 200< rcorr <400 5< rcorr <15 5< rcorr <12 0.6< rcorr <2
C4 g/(m2.a) 400< rcorr <650 15< rcorr <30 12< rcorr <25 2< rcorr <5
C5 g/(m2.a) 650< rcorr <1500 30< rcorr <60 25< rcorr <50 5< rcorr <10
ISO 9223
corrosion of metals and alloys – corrosivity of atmospheres - classification
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Categories of corrosivity
of the atmosphere
Category Corrosivity
C1 very low
C2 low
C3 medium
C4 high
C5 very high
ISO 9223
Corrosion of metals and alloys – corrosivity of atmospheres -
classification
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Peta tingkat
korosifitas DAS
citarum untuk
baja karbon
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Corrosometer
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Corrosometer
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Simplified electrical resistance
monitoring circuit
L
R= ρ
A
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Pemilihan
corrosometer probe
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Probe
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Jenis-jenis
probe
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Corrosometer probe
ordering
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E/R sensing element
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Lokasi Monitoring
∆ pengukuran
(mpy) = ------------------ x 365 x probe span
∆ waktu ( hari)
S4 0.001 (0.025)
S4, S8, T4 0.002 (0.050)
S8, T8 0.004 (0.100)
S10, T10 0.005 (0.125)
S20, T20, W40 0.010 (0.250)
S40, W80 0.020 (0.500)
T50 0.025 (0.625)
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SEBELUM DILAKUKAN PENGUKURAN, DILAKUKAN KALIBRASI TERLEBIH DAHULU ! 105
Corrosometer
Hasil pengukuran menggunakan probe W40
ronald KALIBRASI
SEBELUM DILAKUKAN PENGUKURAN, DILAKUKAN nasoetion TERLEBIH DAHULU ! 106
Contoh perhitungan
hasil pengukuran menggunakan corrosion probe W40 memberikan data-data seperti
terlihat pada gambar di bawah ini. Hitung laju korosi dari daerah yang sudah anda
tentukan dan jelaskan hasil pengukuran tersebut
180
140
120
Corrosion dial
100
80
60
40
20
0 10 20 30 40 50 60 70 80 90 100
Time, days
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Contoh perhitungan
hasil pengukuran menggunakan corrosion probe W40 memberikan data-data seperti terlihat
pada gambar di bawah ini. Hitung laju korosi dari daerah yang sudah anda tentukan dan
jelaskan hasil pengukuran tersebut
180
140
120
C
Corrosion dial
100
B
80
60
A
40
20
0 10 20 30 40 50 60 70 80 90 100
Time, days
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Garis singgung A
70 – 30
Laju korosi = --------------- x 365 x 0.010 = 10. 44 mpy
24 - 10
Probe span = 0.010
180
140
120
Corrosion dial
100
80
70
60
A
50
40
30
20
0 10 20 30 40 50 60 70 80 90 100
17 24
Time, days
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Garis singgung B
90 – 85
Laju korosi = --------------- x 365 x 0.010 = 1. 22 mpy
52 - 37
180
140
120
Corrosion dial
100
B
85
80
60
40
20
0 10 20 30 40 50 60 70 80 90 100
37 52
Time, days
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Garis singgung C
130 – 100
Laju korosi = --------------- x 365 x 0.010 = 5.48 mpy
90 - 70
180
140
130
C
120
Corrosion dial
100 100
80
60
40
20
0 10 20 30 40 50 60 70 80 90 100
70 90
Time,
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nasoetion 111
Garis singgung A = 10.44 mpy
Garis singgung B = 1.22 mpy
Garis singgung C = 5.48 mpy
180
140
120
C
Corrosion dial
100
B
80
60
A
40
20
0 10 20 30 40 50 60 70 80 90 100
Time, days
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Contoh perhitungan
hasil pengukuran menggunakan corrosion probe W40 memberikan data-data seperti
terlihat pada gambar di bawah ini. Hitung laju korosi dari daerah yang sudah anda
tentukan dan jelaskan hasil pengukuran tersebut
180
140
120
Corrosion dial
100
80
60
40
20
0 10 20 30 40 50 60 70 80 90 100
Time, days
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Contoh perhitungan
hasil pengukuran menggunakan corrosion probe S20 memberikan data-data seperti
terlihat pada gambar di bawah ini. Hitung laju korosinya
180
140
120
Corrosion dial
100
80
60
40
20
0 10 20 30 40 50 60 70 80 90 100
Time, days
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Contoh perhitungan
hasil pengukuran menggunakan corrosion probe S20 memberikan data-data seperti
terlihat pada gambar di bawah ini. Hitung laju korosinya
180
140
120
Corrosion dial
100
80
60
40
20
0 10 20 30 40 50 60 70 80 90 100
Time, days
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Contoh perhitungan
hasil pengukuran menggunakan corrosion probe S20 memberikan data-data seperti
terlihat pada gambar di bawah ini. Hitung laju korosinya
180
140
120
Corrosion dial
100
80
60
40
20
0 10 20 30 40 50 60 70 80 90 100
Time, days
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