Corrosive environment monitor and methods regarding same

• US 6,623,616 B1
• Filed: 04/26/2000
• Issued: 09/23/2003
• Est. Priority Date: 04/26/2000
• Status: Expired due to Fees

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Busch, Darryl G., Gibson, Paul L., Malver, Frederick S., Jiracek, Ronald H.
• Primary Examiner(s): Nguyen, Nam
• Assistant Examiner(s): Olsen, Kaj K.
• Application Number:
  US09/560,257
• Time in Patent Office: 1,245 Days
• Field of Search: 204/404, 204/433, 204/416, 205/775.5, 205/776, 205/776.5, 205/777, 205/787.5, 205/778.5, 73/86
• US Class Current: 205/775.5
• CPC Class Codes: G01N 17/00 Investigating resistance of materials to the weather, to corrosion, or to light
• CPC Class Codes: G01N 17/02 Electrochemical measuring systems for weathering, corrosion or corrosion-protection measurement

Abstract

A monitoring method and system to monitor an environment in which an object is located includes monitoring one or more environmental factors associated with corrosion of materials in the environment. Thereafter, an exposure index representative of cumulative exposure of the object to the one or more environmental factors is determined. For example, such environmental factors may include chloride ion concentration, pH level, humidity, and temperature.

Claims

1. A monitoring method for monitoring an environment in which an object is located, the method comprising:

monitoring one or more environmental factors associated with corrosion of materials in the environment; and

calculating, in real-time, an exposure index representative of an actual cumulative exposure of the object to the one or more environmental factors as a function of a real-time measure of each individually monitored environmental factor.

2. The method of claim 1, wherein the method further comprises providing indication of the exposure index.

3. The method of claim 2, wherein providing indication of the exposure index comprises displaying the exposure index.

4. The method of claim 2, wherein the method further comprises recording data representative of the monitored environmental factors.

5. The method of claim 2, wherein the method further comprises continuously updating the exposure index.

6. The method of claim 1, wherein the method further comprises inspecting the object as a function of the exposure index.

7. The method of claim 1, wherein monitoring one or more environmental factors associated with corrosion of materials comprises sensing at least one of chloride ion concentration and pH in the environment.

8. The method of claim 7, wherein monitoring one or more environmental factors further comprises at least one of sensing humidity.

9. The method of claim 7, wherein monitoring one or more environmental factors comprises sensing temperature in the environment.

10. The method of claim 9, wherein the method further comprises correcting temperature dependence of one or more sensors used to monitor the environment based on the sensed temperature.

11. The method of claim 7, wherein monitoring one or more environmental factors comprises measuring free potential of a material positioned in the environment, wherein the object is formed at least in part of such a material.

12. The method of claim 11, wherein the method further comprises verifying the exposure index using the measured free potential of the material.

13. The method of claim 1, wherein calculating an exposure index comprises calculating the exposure index as a function of a real-time measure of at least one of chloride ion concentration and pH.

14. The method of claim 13, wherein calculating an exposure index further comprises calculating the exposure index as a function of a real-time measure of at least one of temperature and humidity.

15. The method of claim 13, wherein calculating the exposure index comprises calculating the exposure index as a function of a real-time measure of chloride ion concentration, pH, temperature and humidity.

16. A monitoring apparatus for monitoring an environment in which an object is located, comprising:

one or more sensors, wherein each sensor is operable to detect the presence of at least one environmental factor associated with corrosion of materials and provide real-time sensor signals representative of the detected environmental factor, and

a processing unit operable to receive the sensor signals generated by the one or more sensors, wherein the processing unit is operable to provide a real-time calculation of an exposure index representative of an actual cumulative exposure of the object to the at least one environmental factor as a function of the a real-time measure of each individually received sensor signals.

17. The apparatus of claim 16, wherein the apparatus further comprises an indication device indicating the exposure index.

18. The apparatus of claim 17, wherein indication device comprises a display.

19. The apparatus of claim 17, wherein the indication device continuously updates an indicated exposure index.

20. The apparatus of claim 16, wherein the apparatus further comprises memory to store data representative of at least one of the exposure index and data representative of the sensor signals.

21. The apparatus of claim 16, wherein the one or more sensors comprise at least one of a chloride ion concentration sensor and a pH sensor.

22. The apparatus of claim 21, wherein the one or more sensors further comprise at least one humidity sensor.

23. The apparatus of claim 21, wherein the one or more sensors further comprise a temperature sensor.

24. The apparatus of claim 16, wherein the one or more sensors further comprise a sensor to measure free potential of a sample material positioned in the environment, wherein the object is formed at least in part of such a material.

25. The apparatus of claim 16, wherein the one or more sensors comprise at least a chloride ion concentration sensor, a pH sensor, a temperature sensor, and a humidity sensor, and further wherein the processing unit provides the real-time calculation of the exposure index as a function of real-time sensor signals from the at least chloride ion concentration, pH, temperature and humidity.

26. The apparatus of claim 16, wherein the one or more sensors are removable from a sensor module housing such that one or more additional sensors can be substituted therefor.

27. The apparatus of claim 16, wherein the one or more sensors are associated with a module that is separate from a module containing the processing unit.

28. A monitoring method for monitoring an environment in which an object is located, the method comprising:

monitoring at least chloride ion concentration and pH in the environment; and

calculating, in real-time, an exposure index representative of an actual cumulative exposure of the object to a real-time measure of at least chloride ion concentration and pH.

29. The method of claim 28, wherein the method further comprises displaying the exposure index.

30. The method of claim 29, wherein the method further comprises continuously updating and displaying the exposure index.

31. The method of claim 28, wherein monitoring at least chloride ion concentration and pH further comprises sensing a real-time measure of humidity in the environment.

32. The method of claim 28, wherein monitoring at least chloride ion concentration and pH further comprises sensing a real-time measure of temperature in the environment.