Development of a Novel Process of Corrosion Rate Estimation of Steel under Stray Current Interference: Q235A Pipe Steel as an Example

 Chengtao Wang Chengtao Wang , Wei Li Wei Li , Yuqiao Wang Yuqiao Wang , Xuefeng Yang Xuefeng Yang , Shaoyi Xu Shaoyi Xu
Russian Journal of Electrochemistry
Abstract / Full Text

With the progress of urbanization, stray current corrosion has attracted numerous attention due to its safety threaten to buried metallic pipelines around the urban rail transit system, especially to gas pipelines. A method to monitor the corrosion rate of the gas pipeline is urgently needed in view of the existing indirect method of the long-life reference electrode. In this work, a novel process model of corrosion rate estimation steel under stray current interference was proposed. The electrochemical noise (EN) signal was studied in the frequency domain through combined analysis in terms of fast Fourier transform (FFT) and discrete wavelet transform (DWT). According to the energy value of each crystal, the active energy was proposed as a parameter for the estimation of the corrosion rate under the excitation of stray current. The results showed that there is a negative correlation relationship between corrosion rate rcorr and active energy Ea. Thus, the active crystal energy of EN signal may be applied as the possible monitoring method of corrosion hazard during the stray current corrosion process.

Author information
  • School of Mechatronic Engineering, China University of Mining and Technology, 221116, Xuzhou, People’s Republic of China

    Chengtao Wang, Wei Li, Yuqiao Wang, Xuefeng Yang & Shaoyi Xu

  • Department of Civil Engineering, University of Calgary, T2N 1N4, Calgary, Canada

    Chengtao Wang

  1. Dann, M.R. and Maes, M.A.A., Stochastic corrosion growth modeling for pipelines using mass inspection data, Reliab. Eng. Syst. Safe, 2018, vol. 180, p. 245.
  2. Economic Impact, Assessment of the Global Cost of Corrosion. Accessed Nov. 21, 2019.
  3. Koch, G.H., Brongers, M.P.H., Thompson, N.G., Virmani, Y.P., and Payer, J.H., Corrosion costs and preventive strategies in the united states, Report no. FHWA-RD-01-156, US Federal Highway Administration, 2002.
  4. Chen, Z., Koleva, D., and Breugel, K.V., A review on stray current-induced steel corrosion in infrastructure, Corros. Rev., 2017, vol. 35, p. 397.
  5. Zhang, P., Su, L., Qin, G., Kong, X., and Peng, Y., Failure probability of corroded pipeline considering the correlation of random variables, Eng. Fail. Anal., 2019, vol. 99, p. 34.
  6. Shuai, Y., Shuai, J., and Xu, K., Probabilistic analysis of corroded pipelines based on a new failure pressure model, Eng. Fail. Anal., 2017, vol. 81, p. 216.
  7. Wang, C., Li, W., Wang, Y., Xu, S., and Li, K., Evaluation model for the scope of DC interference generated by stray currents in light rail systems, Energies, 2019, vol. 12, p. 746.
  8. Cotton, I., Charalambous, C.A., Aylott, P., and Ernst, P., Stray current control in DC mass transit systems, IEEE T. Veh. Technol., 2005, vol. 54, p. 722.
  9. Li, W., Stray Current Corrosion Monitoring and Protection Technology in DC Mass Transit Systems, Xuzhou: China Univ Mining & Technol Press, Xuzhou, 2004, p. 26.
  10. Xu, S., Li, W., and Wang, Y., Effects of vehicle running mode on rail potential and stray current in DC mass transit systems, IEEE Trans. Veh. Technol., 2013, vol. 62, p. 3569.
  11. Ogunsola, A., Sandrolini, L., and Mariscotti, A., Evaluation of stray current from a DC-electrified railway with integrated electric-electrochemical modeling and traffic simulation, IEEE T. Ind. Appl., 2015, vol. 51, p. 5431.
  12. Xu, S., Xing, F., Li, W., and Wang, Y., Stochastic noise identification in a stray current sensor, J. Cent. South Univ., 2017, vol. 24, p. 2596.
  13. Wang, X., Tang, X., Wang, L., Wang, C., and Zhou, W., Synergistic effect of stray current and stress on corrosion of API X65 steel, J. Nat. Gas Sci. Eng., 2014, vol. 21, p. 474.
  14. Bertolini, L., Carsana, M., and Pedeferri, P., Corrosion behavior of steel in concrete in the presence of stray current, Corros. Sci., 2007, vol. 49, p. 1056.
  15. Qian, S. and Cheng, Y.F., Accelerated corrosion of pipeline steel and reduced cathodic protection effectiveness under direct current interference, Constr. Build. Mater., 2017, vol. 148, p. 675.
  16. Susanto, A., Koleva, D.A., Copuroglu, O., Beek, K.V., and Breugel, K.V., Mechanical, electrical and microstructural properties of cement-based materials in conditions of stray current flow, J. Adv. Concr. Technol., 2013, vol. 11, p. 119.
  17. Yuan, W., Huang, F., Liu, J., Hu, Q., and Cheng, Y.F., Effects of temperature and applied strain on corrosion of X80 pipeline steel in chloride solutions, Corros. Eng. Sci. Techn., 2018, vol. 53, p. 393.
  18. Charalambous, C.A. and Cotton, I., Influence of soil structures on corrosion performance of floating-DC transit systems, IET Electr. Power Appl., 2007, vol. 1, p. 9.
  19. Wang, F., Li, Z., Cui, G., Liu, F., Kong, C., Wang, L., Gao, G., and Gao, F., Corrosion behaviors of X70 steel under direct current interference, Anti-Corros. Method M, 2019, vol. 66, p. 307.
  20. Wang, C., Li, W., Wang, Y.Q., Xu, S., and Yang, X., Chloride-induced stray current corrosion of Q235A steel and prediction model, Constr. Build. Mater., 2019, vol. 219, p. 164.
  21. Dong, Z., Guo, X., Zheng, J., and Xu, L., Calculation of noise resistance by use of the discrete wavelets transform, Electrochem. Commun., 2001, vol. 3, p. 561.
  22. Huang, J., Qiu, Y., and Guo, X., Comparison of polynomial fitting and wavelet transform to remove drift in electrochemical noise analysis, Corros. Eng. Sci. Techn., 2010, vol. 45, p. 288.
  23. Tan, Y., Bailey, S., and Kinsella, B., The monitoring of the formation and destruction of corrosion inhibitor films using electrochemical noise analysis (ENA), Corros. Sci., 2010, vol. 38, p. 1681.
  24. Mansfeld, F., Sun, Z., Hsu, C.H., and Nagiub, A., Concerning trend removal in electrochemical noise measurements, Corros. Sci., 2001, vol. 43, p. 341.
  25. Bertocci, U. and Huet, F., Drift removal procedures in the analysis of electrochemical noise, Corrosion, 2002, vol. 58, p. 337.
  26. Aballe, A., Bethencourt M., Botana, F.J., and Marcos, M., Using wavelets transform in the analysis of electrochemical noise data, Electrochim. Acta, 1999, vol. 44, p. 4805.
  27. Mansfeld, F. and Xiao, H., Electrochemical noise analysis of iron exposed to NaCl solutions of different corrosivity, J. Electrochem. Soc., 1993, vol. 140, p. 2205.
  28. Yi, C., Du, X., Yang, Y., Zhu, B., and Zhang, Z., Correlation between the corrosion rate and electrochemical noise energy of copper in chloride electrolyte, RSC Adv., 2018, vol. 8, p. 19208.
  29. Cao, F., Zhang, Z., Su, J., Shi, Y., and Zhang, J., Electrochemical noise analysis of LY12-T3 in EXCO solution by discrete wavelet transform technique, Electrochem. Acta, 2006, vol. 51, p. 1359.
  30. Hoseinieh, S.M., Homborg, A.M., Shahrabi, T., Mol, J.M.C., and Ramezanzadeh, B., A novel approach for the evaluation of under deposit corrosion in marine environments using combined analysis by electrochemical impedance spectroscopy and electrochemical noise, Electrochim. Acta, 2016, vol. 217, p. 226.
  31. Tang, K., Corrosion of steel fibre reinforced concrete (SFRC) subjected to simulated stray direct (DC) interference, Mater. Today Commun., 2019, vol. 20, p. 100564.
  32. Dann, M.R. and Huyse, L., Pragmatic approach to estimate corrosion rates for pipelines subject to complex corrosion, Proc. 10th Int. Pipeline Conf., Calgary, 2014, vol. 3.
  33. Mahjani, M.G., Neshati, J., Masiha, H.P., and Jafarian, M., Electrochemical noise analysis for estimation of corrosion rate of carbon steel in crude oil, Anti-Corros. Method M, 2007, vol. 54/1, p. 27.
  34. Caines, S., Khan, F., Zhang, Y., and Shirokoff, J., Simplified electrochemical potential noise method to predict corrosion and corrosion rate, J. Loss Prevent. Proc., 2017, vol. 47, p. 72.
  35. Haruna, T., Morikawa, Y., Fujimoto, S., and Shibata, T., Electrochemical noise analysis for estimation of corrosion rate of carbon steel in bicarbonate solution, Corros. Sci., 2003, vol. 45, p. 1.
  36. Allahkaram, S.R., Isakhani-Zakaria, M., Derakhshani, M., Samadian, M., and Razmjoo, A., Investigation on corrosion rate and a novel corrosion criterion for gas pipelines affected by dynamic stray current, J. Nat. Gas Sci. Eng., 2015, vol. 26, p. 453.
  37. Wang, C., Li, W., Wang, Y., Yang, X., and Xu, S., Study of electrochemical corrosion on Q235A steel under stray current excitation using combined analysis by electrochemical impedance spectroscopy and artificial neural network, Constr. Build. Mater., 2020, vol. 247, p. 118562.
  38. Charalambous, C.A., Cotton, I., Aylott, P., and Kokkinos, N.D., A holistic stray current assessment of bored tunnel sections of DC transit systems, IEEE Trans. Power Delivery, 2013, vol. 28, p. 1048.
  39. Wharton, J.A., Wood, R.J.K., and Mellor, B.G., Wavelet analysis of electrochemical noise measurements during corrosion of austenitic and superduplex stainless steels in chloride media, Corros. Sci., 2003, vol. 45, p. 97.
  40. Malamud, B.D. and Turcotte, D.L., Self-affine time series: measures of weak and strong persistence, J. Stat. Plan. Infer., 1999, vol. 80, p. 173.
  41. Planinsic, P. and Petek, A., Characterization of corrosion process by current noise wavelet-based fractal and correlation analysis, Electrochim. Acta, 2008, vol. 53, p. 5206.
  42. Sekine, M., Tamura, T., Akay, M., Fujimoto, T., Togawa, T., and Fukui, Y., Discrimination of walking patterns using wavelet-based fractal analysis, IEEE Neural Syst. Rehabil. Eng., 2002, vol. 10, p. 188.
  43. Cheng, Y.F., Luo, J., and Wilmott, M., Spectral analysis of electrochemical noise with different transient shapes, Electrochim. Acta, 2000, vol. 45, p. 1763.
  44. Searson, P.C. and Dawson, J.L., Analysis of electrochemical noise generated by corroding electrodes under open-circuit conditions, J. Electrochem. Soc., 1998, vol. 135, p. 1908.
  45. Cottis, R.A. and Loto, C.A., Electrochemical noise generation during SCC of a high-strength carbon steel, Corrosion, 1990, vol. 46, p. 12.
  46. Kim, J.J., Wavelet analysis of potentiostatic electrochemical noise, Mater. Lett., 2007, vol. 61, p. 4000.
  47. Aballe, A., Bethencourt, M., Botana, F.J., and Marcos, M., Using wavelets transform in the analysis of electrochemical noise data, Electrochim. Acta, 1999, vol. 44, p. 4805.
  48. Chen, Y., Yang, Z., Liu, Y., Zhang, H., Yin, J., Xie, Y., and Zhang, Z., In-situ monitoring the inhibition effect of benzotriazole on copper corrosion by electrochemical noise technique, J. Taiwan Inst. Chem. E, 2017, vol. 80, p. 1.