Corrosion has been a great concern in the oil and natural gas industry costing billions of dollars annually in the U.S. The ability to monitor corrosion online before structural integrity is compromised can have a significant impact on preventing catastrophic events resulting from corrosion. This article critically reviews conventional corrosion sensors and emerging sensor technologies in terms of sensing principles, sensor designs, advantages, and limitations. Conventional corrosion sensors encompass corrosion coupons, electrical resistance probes, electrochemical sensors, ultrasonic testing sensors, magnetic flux leakage sensors, electromagnetic sensors, and in-line inspection tools. Emerging sensor technologies highlight optical fiber sensors (point, quasi-distributed, distributed) and passive wireless sensors such as passive radio-frequency identification sensors and surface acoustic wave sensors. Emerging sensors show great potential in continuous real-time in-situ monitoring of oil and natural gas infrastructure. Distributed chemical sensing is emphasized based on recent studies as a promising method to detect early corrosion onset and monitor corrosive environments for corrosion mitigation management. Additionally, challenges are discussed including durability and stability in extreme and harsh conditions such as high temperature high pressure in subsurface wellbores.

A novel graphene-coated Ni electrode was developed in this investigation to improve corrosion resistance while unexpectedly enhancing the ammonia generation rate in the electrochemically induced urea to ammonia (eU2A) process, which is an electrochemical onsite ammonia generation method. The development of the electrode is crucial for the eU2A reactions since in the ammonia generation process, the concentration of ammonia is inevitably high on the surface of the electrode, leading to severe corrosion of the electrode and the loss of generated ammonia as well. In this paper, the graphene was derived from raw coal by using the chemical vapor deposition method and self-lifted onto a Ni electrode to form a protective layer for corrosion prevention. Transmission electron microscopy showed the synthesized graphene had few-layers and Raman spectroscopy indicated that the coating of graphene was stable during the eU2A reaction. As a result, the ammonia corrosion of the Ni electrode was dramatically reduced by ~20 times with the graphene coating method. More importantly, a higher ammonia generation rate (~2 times) was achieved using the graphene-coated Ni working electrode compared to a bare Ni electrode in the eU2A process.