Condition monitoring and predictive modelling of coating delamination applied to remote stationary and mobile assets

Abstract

The ambiguous nature of meteorological parameters in uncontrolled environmental conditions makes it difficult to determine the structural integrity of stationary and mobile assets. The weather conditions for large vehicles, at The Tank Museum at Bovington, UK, which are operating in controlled and uncontrolled environmental conditions are investigated through weather history and corrosion monitoring techniques applied to large military vehicles by using linear polarisation resistance method. Corrosion initiation and propagation was found on several occasions during the operation of large vehicles within uncontrolled environment due to critical level of metrological parameters including salinity, relative humidity and rainfall. Comprehensive solutions have been proposed to detect damage initiation at the earliest possible stage to prompt maintenance professionals to take necessary actions to avoid damage. Early detection techniques will help to prolong the service life of large vehicles or metal structures which are operating or installed remotely. The analysis of diffusion of salt particles into coating during summer and winter season is also presented by estimating the salt concentration by taking linear relationship between wind speed and salt deposition rate based on ISO classification of airborne salinity. The proposed solutions can be applied to valuable assets operating in coastal, non-coastal and near the sea regions to predict and estimate the damage. The research will directly impact the maintenance and reliability of the automotive, oil and gas pipelines, aerospace and defence applications through remote condition monitoring technique.

An optimal condition based maintenance scheduling for metal structures based on a multidisciplinary research approach

“…The proposed historical database requires recording several parameters at each stage. The several methodologies including optical microscopy, X-ray fluorescence and Scanning electron microscopy to acquire parameters such as interfacial roughness of metal-substrate or thickness of coating have been reported in previous experimental research work of NCEM (Khan et al, 2018;Khan, Latif, Nazir, Stokes, & Plummer, 2017;Latif, Khan, Nazir, Stokes, & Plummer, 2018a;Nazir, Khan, & Stokes, 2015a;Nazir, Khan, Saeed, et al, 2015;Nazir, Khan, et al, 2016a;Nazir, Khan, Saeed, & Stokes, 2016b;Nazir, Khan, & Stokes, 2015b;Nazir, Khan, et al, 2015c, 2015dNazir, Khan, & Stokes, 2016;Saeed, Khan, Nazir, Hadfield, & Smith, 2017;Saeed, Khan, & Nazir, 2016). The independent steel sample with same coating and substrate specifications can be used for measurements.…”

“…Furthermore, the sensor technology along with wireless communication system can be installed on metal structure to acquire the critical parameters during its operational activities such as corrosion, temperature, humidity and stresses. The corrosion can be monitored using linear polarisation resistor sensors reported comprehensively in (Latif et al, 2018a). The strain gauge sensors can be used to monitor the development of stresses within coating during operational activities reported in .…”

“…The salinity reacts with water to form an electrochemical cell which results in corrosion damage and coating failure (Latif et al, 2018a). The prediction can be made more efficient based on the accumulation of salinity on structure.…”

Structural monitoring system for proactive detection of corrosion and coating failure

“…The organic coatings are susceptible to numerous types of failure modes including micro-cracking within the coating surface which allows the corrosive species to diffuse into the coating-substrate interface to initiate corrosion damage [2]. According to recent experimental investigations, parameters including interfacial roughness, interfacial toughness, diffusion-induced stresses and residual stresses are considered to be responsible for micro-cracks and adhesion loss in protective coatings applied to metal structures [2][3][4][5][6][7][8][9][10][11][12]. Various maintenance activities are implemented to protect and repair the metal structures e.g.…”

“…Using these sensors, the NanoCorr Energy Modelling and Research (NCEM) group have investigated corrosion damage within large vehicles at The Tank Museum, Bovington, Dorset UK. The µLPR sensors were embedded on vehicles operating in both controlled and uncontrolled environment at remote locations [4,15]. The Tank Museum is located near the English Channel, hence a high amount of salinity is present in the atmosphere.…”