A measurement system permits environmental, corrosion damage, and mechanical property measurements to assess protection properties of coatings. The system includes one or more multi-sensor panels, each multi-sensor panel having sensors for assessing coating barrier properties, free corrosion, and galvanic corrosion. Each multi-sensor panel is installed on a test rack that contains electronics for sensor excitation and sensor data acquisition throughout a corrosion test. Sensor data is collected, stored, and communicated to a base station. A network of multiple test racks can be supported by a base station to compare the performance of different coatings and material combinations simultaneously. The test racks can be used in accelerated atmospheric corrosion tests, outdoor test sites, or application service environments. Measurements of the capacity of a coating to maintain barrier properties, prevent free corrosion, galvanic corrosion, and environment-assisted cracking can be used to develop, select, and predict service performance of coatings.

A measurement system permits environmental, corrosion damage, and mechanical property measurements to assess protection properties of coatings. The system includes one or more multi-sensor panels, each multi-sensor panel having sensors for assessing coating barrier properties, free corrosion, and galvanic corrosion. Each multi-sensor panel is installed on a test rack that contains electronics for sensor excitation and sensor data acquisition throughout a corrosion test. Sensor data is collected, stored, and communicated to a base station. A network of multiple test racks can be supported by a base station to compare the performance of different coatings and material combinations simultaneously. The test racks can be used in accelerated atmospheric corrosion tests, outdoor test sites, or application service environments. Measurements of the capacity of a coating to maintain barrier properties, prevent free corrosion, galvanic corrosion, and environment-assisted cracking can be used to develop, select, and predict service performance of coatings.

A method for determining a corrosion rate includes receiving an input signal including corrosion data from a sensor. A signal-to-noise ratio (SNR) and a type of noise is determined from the input signal. A corrosion rate computation method is selected based on the SNR and the type of noise. The corrosion rate is determined, using a processor, based on a selected corrosion rate computation method.

Systems and sensor elements for indirect monitoring of cumulative damage to downhole components are described. The systems include a sensor body defining an internal cavity with at least one electrical wear element located within the sensor body. A portion of the at least one electrical wear element electrically extends from the internal cavity, through the sensor body, and to an exterior of the sensor body. An abrasive substance is located within the internal cavity, the abrasive substance being moveable within the internal cavity to contact and erode material of the at least one electrical wear element such that erosion of the at least one electrical wear element causes a resistance of the at least one electrical wear element to increase.

A method of analyzing a substrate contacting a fluid present in an industrial system is provided. The method comprises creating a series of digital images of the substrate while contacting the fluid present in the industrial system. A region of interest in the series of digital images of the substrate is defined. A corrosion feature in the region of interest in the series of digital images of the substrate is identified. The corrosion feature in the region of interest in the series of digital images of the substrate is analyzed to determine a corrosion trend of the industrial system. In certain embodiments of the method, the fluid is industrial water, and the industrial system is an industrial water system.

A method of analyzing a substrate contacting a fluid present in an industrial system is provided. The method comprises creating a series of digital images of the substrate while contacting the fluid present in the industrial system. A region of interest in the series of digital images of the substrate is defined. A corrosion feature in the region of interest in the series of digital images of the substrate is identified. The corrosion feature in the region of interest in the series of digital images of the substrate is analyzed to determine a corrosion trend of the industrial system. In certain embodiments of the method, the fluid is industrial water, and the industrial system is an industrial water system.

A system for measuring the voltage potential across test coupons, reference cells and metal structures is disclosed. The system may evaluate the amount of cathodic protection that may be applied to the metal structure. A series resistor may be configured between at least one of the test coupons and the metal structure so that the at least one test coupon may be at a lower voltage potential than the metal structure.

A system for measuring corrosion and corrosion-erosion rates in a high temperature, high pressure multiphase dynamic environment includes a plurality of ring-shaped test coupons disposed within a test vessel in a vertical arrangement relative to one another. A test fluid mixture is added to the vessel and the temperature and pressure are maintained such that the mixture exists in a multiphase condition that has a vertical stratification such that each test coupon is exposed to a different phase and/or combination of phases of the fluid. Impellers can be used to stir the fluid to provide a dynamic environment. The fluid can include particulate matter to simulate real world test conditions. Separator plates can be disposed at different vertical locations within the vessel to maintain separation between various phases of the fluids and further restrict particulate matter from migrating between sections of the test system.

A method of analyzing a substrate contacting a fluid present in an industrial system is provided. The method comprises creating a series of digital images of the substrate while contacting the fluid present in the industrial system. A region of interest in the series of digital images of the substrate is defined. A corrosion feature in the region of interest in the series of digital images of the substrate is identified. The corrosion feature in the region of interest in the series of digital images of the substrate is analyzed to determine a corrosion trend of the industrial system. In certain embodiments of the method, the fluid is industrial water, and the industrial system is an industrial water system.

A probe for measuring a cathodic protection condition of a buried steel structure includes: a steel electrode; a reference electrode; and a coupon fabricated of a conductive material. The steel electrode, the reference electrode and the conductive coupon are positioned in an ionically conductive medium in proximity with each other and are isolated from direct electrical contact with each other.