Corrosion coupons report

Corrosion Coupons

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Maintain constant flow throughout the study. Store the coupon envelopes in the controller or in a dry place near the coupon rack. Remove the coupons after 60, 90 or days as specified by the study. Carefully remove and dry each coupon on a paper towel. Take care not to remove material deposited on the coupon because deposits are an important part of the evaluation. Place the coupon into the original envelope without the plastic bag. Record the date of removal and send the coupon back to the Technical Support Laboratory as soon as possible.

The results of the corrosion coupon analysis will be presented on a Laboratory Report for and include a written analysis, a photograph of the coupon, and a corrosion rate in mills per year, or MPY. Use the table below to evaluate the results from your study. If you have questions about this or any other technical matter, ask your Chardon Master Service Technician or call one of our Technical Support Team Members at What Are Corrosion Coupons?

What Do Corrosion Coupons Do? Be careful not to touch the coupons. Oil from your hands will promote corrosion and bias the test results.

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Maintain constant flow at feet per second during the test period. This makes the technique ideal for process monitoring, process control, inhibitor evaluation, and cathodic protection studies. This design has the advantage of a more economical field installation cost. A single cable may be used to connect up to 32 transmitters with a single cable run. This single multi-drop cable contains the 24VDC supply to power the transmitters and the RS communication bus.

This design avoids the need to run a cable to each transmitter which is required with other designs. For dedicated on-line systems the RS bus is connected from isolating RS cards mounted directly in the monitoring computer. A separate 24 VDC supply is also required to power the Microcor transmitters.

See the figure below. The first option is ICMS3 software that provides complete corrosion management, where corrosion rate data can be plotted in real time in parallel with related process variables such as temperature, pressure, pH, dissolved oxygen, inhibitor concentrations etc. See below. For flexible non on-line systems the Microcor transmitter can be used with the Model B explosion-proof data logger. This unit provides battery power and data-logging in a second enclosure with the same form as the Microcor transmitter. Collected data is transferred from the data-logger to the PC with the Checkmate DL intrinsically safe hand-held instrument.

Typical Configuration of smaller scale Microcor System Microcor Data Logger and Checkmate DL System A complete transportable test system with a rugged case, in the form of the MK , provides a set up suitable for monitoring the performance of inhibitors in laboratory and field trials. Access Fittings: PN High Pressure For permanent connection at 10, psi max. Transmitter Connection cable: North America: Conformity assessment document is available for Australia.

Transportable System: Microcor is the result of patented technology which combines the rapid response of LPR and the universal applicability of ER. This design has the advantage of a more economical field. This single multi-drop cable contains the 24 VDC supply to power the transmitters and the RS communication bus. It combines the rapid response of linear polarization resistance LPR with the universal applicability of ER metal loss. The Data-Logger is ideal for remote locations. There are two types. For non-hazardous areas.

Microcor and Quicksand Probes. A wide range of fixed. A separate mounting bracket is then required to mount the Data-Logger. For special applications. Corrdata II software is a total corrosion management software and is preferable when multiple sites and corrosion monitoring methods are used.

The Data-Logging System comprises the following: However if high vibration or excessive temperature is present. Probe Connecting Adapter — The probe connecting adapter allows the Data-Logger to be close-coupled to the probe and provides a mounting for the Data-Logger. Class 1. System Specifications: Hazardous Area Certifications: All Microcor Probes 18 bit 1 part in M Series Probes. The battery powered Microcor MLB DataLogger adds autonomous power and data collection for applications where direct on-line operation is not possible.

Microcor Probe.

Probe Connecting Adapter — The probe connecting adapter allows the Microcor transmitter to be close-coupled to the probe and provides a mounting for the transmitter. Probe Adapter Battery 1. This system is ideal for remote locations. Microcor Probe 4. MTA Transmitter 5. A separate mounting bracket is then required to mount the transmitter. The Checkmate DL collects data from all of the data-loggers in the field. Data Transfer to the PC For non-hazardous areas. Transmitter to Data-Logger Cable — This cable enables the data-logger to be mounted up to ft from the Microcor transmitter at a convenient location for data collection and battery change-out.

The Microcor Datalogger rating is explosion proof plus intrinsic safety. Div 2. Zone 1 North America: CE compliant EMC. The Data Logger certification thereby becomes the system certification. Probe Connecting Adapter 2a. Microcor Transmitter 4. Transmitter to Data-Logger Cable 5.

Model Series Probes For permanent connection at Microcor Probe 2. Alternate Probe to Transmitter Cable 3. Collected data can be transferred directly to a laptop if located in a safe area or with a Checkmate DL in a hazardous area. Chemical over-treatment can be expensive especially with corrosion prevention chemicals. One of the main purposes of a corrosion monitoring data logger is to check that the correct chemical injection rate is being applied and working properly.

In addition. The RDC-CI can be permanently piped in for continuous monitoring or piped in on a temporary basis with our accessory kit of flexible 6 ft hoses and sealing quick-connect couplings. The battery life is typically 6 months. The RDC-CI data logger directly monitors the flow to the chemical injection quills or nozzles with its accurate positive displacement flow meter designed to continuously check the actual injection rate. It is all too easy. Data is stored in a CSV file format and can be viewed graphically as flow rate and integrated flow on the supplied software.

Flowmeter Seals: Rate Sampling Interval: Reading Storage: Hazardous Area Rating: Uses currently rated area certified components Ordering Information: TEF Example: Chemical Injection Data Logger. Flow Rate: Viscosity Range: Temperature Range: Upstream Filter: Pressure Rating: The instrument is well suited for use in harsh field environments and certified for use in Class I. Zone 1 or Class 1. Zone 2 Hazardous Locations. The intrinsically safe communication between the instrument and Data Loggers enables the user to collect data without moving the Data Logger to a safe area.

Field carrying case. Zone 2 North America: For Corrater E the available outputs are instantaneous corrosion rate. Remote Desktop. On-site commissioning and training is given by our experienced field engineers on a day rate basis to meet your requirements. The IIU allows flexible input configurations for up to transmitters in any combination of Microcor and Corrater E For Microcor transmitters the available outputs are metal loss. These include direct-wired configurations. The IIU provides data storage and archiving. The primary purpose of the IIU is to provide the computation of corrosion rate from the metal loss made by the Microcor transmitters.

See some typical system layouts on the following page. Up to Transmitters Transmitter Type: Corrater E LAN Ports: Wall Mount: Output Ports: One RS Galvanic E Transmitter Power Supply: Two direct hard-wired RS multi-drop cables with serial or parallel connection up to ft m max longest cable run. One for dial-up remote access Power Supply: Two — One rear panel.

Field 5 or 6. For higher alloys use option 1. The simple flexibility of the ICMS3 systems allows different configurations to be easily designed and implemented to meet your specific requirements. The combination of RCS field-proven hardware. Corrater corrosion rate. With the varying range of applications. Amulet software engine. Any other Related Analog Inputs 2. Gas Plant. According to the application. Corrosion and erosion monitoring is managed as a process parameter with constant streaming data directly into your preferred system interface.

By comparison. The overall ICMS3 system architecture comprises the following: An upstream oil and gas field is spread over large distances with operation through an existing communication network where the ICMS3 system must be integrated into this existing network. On-line Monitoring Hardware a. For example.

What Are Corrosion Coupons?

Corrater Analog f. The unmatched range of monitoring technologies offered by RCS allows the proper matching of the system to the application. RCS will typically incorporate one of several different types of corrosion and erosion monitoring system components. Corrosion rate is computed from the change of metal loss over time.

Example Corrosion Coupon Report.pdf

Useable in any process environment. Microcor digital or Corrosometer analog technology is essential in process fluids. The Quicksand Model STA transmitters operate on the same power and communication bus as the Microcor and Corrater digital transmitters. In addition it also has a pitting tendency measurement based on electrochemical current noise.

Often times sand production can cause rapid erosion and wear on the outer diameter of bends and areas downstream of changes in pipeline diameter. An example of a simple wired configuration is shown opposite. The ICMS3 system. This connection flexibility greatly reduces the cost of field wiring and installation. These systems have been deployed both onshore and offshore.

The Microcor Wireless transmitter has on-board computation of corrosion rate from metal loss. With the Cord-Com multi-channel input. This can be useful in extending existing systems with the newer technology. This enables all of the corrosion related data to be kept in one central database for ease of management. Both new and legacy systems can operate on the same ICMS3 system. CP impressed current rectifiers. Data can then be transferred directly in from the Ultracorr instrument into the ICMS3 server for analysis and computation of corrosion rates.

Battery operated Remote Data Collectors are well suited for these locations. Ultracorr uses high resolution technology to detect both erosion and corrosion. Multiple transducers are connected to a junction box where the Ultracorr instrument can easily be connected to download periodic time and date stamped measurements of wall thickness.

PI system drivers or OPC. With the present practice of separating the process network from the business network with a firewall to protect the process control system. Cost information can be added to the system so that financial parameters can be tracked. Typically process data is made available across the business network through a Process Data Historian. Coupons are then retrieved. Coupon data is used in on-line systems as a calibration standard for other means of corrosion monitoring ER and LPR. Data exchange between the two servers is usually accomplished through Modbus.

Coupon monitoring points are strategically located throughout the system. In addition coupons can be examined for evidence of pitting and other localized forms of attack that are not recognized by other on-line monitoring techniques. Calculation Designer Rohrback Cosasco Systems. The ICMS3 system is essential to be able to do this effectively and reap the financial rewards. Metal Loss Coupons Coupon data is one of the simplest forms of corrosion monitoring. Factors affecting corrosion can be quite complex in many applications and require careful analysis to first understand the controlling factors.

A recent customer had installed ICMS3 systems at three of their main gas processing plants. A concerted study and analysis of the system was undertaken with the ICMS3 system over a 6 month period. Through a VPN connection to our secure maintenance server. They had initially made significant savings in the plant operation that had paid for the system in the first 12 months. Security is a major concern for IT departments of all corporations these days. Later at one of the plants. As staffing levels get lower and less experienced staff are available. Designed by corrosion engineers for corrosion engineers.

Some of its many features are as follows: Properties Screen Contact us for further assistance and remote access to a demonstration system at our California Headquarters over an internet link. RCS can work with you to choose the most convenient and economical choice. The following options are available: It is a matter of selecting the best for the existing system. The above system elements are representative of typical on-line Corrosion Monitoring Systems. A single cable may be used to connect up to 32 transmitters Microcor.

Throughout our long history as the originators of these field monitoring systems we have earned a reputation for reliable performance and the commitment to follow the equipment into its successful field implementation.

Each system is unique and can be designed to meet individual project specifications. With networks and communications becoming more complex. RCS is happy to work with you and directly assist with your communications and IT departments to help analyze your best solutions and make easier the system design process. RCS can provide this support from the initial design and specification stages through implementation and subsequent operation.

Communication Options There are many communication options available. The Checkmate with Corrdata Plus Software option enables stored readings to be easily downloaded to a PC where graphing and analysis can be performed with Corrdata Plus Software. Zone 1 Hazardous Locations. The measurement cycle time for direct probe readings has been reduced to 30 seconds while still maintaining high accuracy. Splash-proof enclosure with sealed membrane keyboard Weight: Test Probe. Conformity Assessment document is available for Australia. PC Comm. Extension Cables up to ft. Stored readings are easily downloaded to a PC where graphing and analysis can be performed with Corrdata Plus Software.

Splash-proof enclosure with sealed membrane keyboard Weight without carrying case: Corrdata Plus Software. Cable Assembly: Checkmate to Computer. Cable Adapter: Checkmate to RDC. CK-4 users will appreciate the additional corrosion management data and convenience which this low capital cost instrument provide.

What Do Corrosion Coupons Do?

Now operators and corrosion engineers can obtain a direct correlation between temperature and corrosion rate from one instrument.. High temperatures that push or exceed the design conditions may improve output.

CORROSION COUPON ANALYSIS | DTK Water Test Kits - Simplified Test Water Analysis

It even calculates a corrosion rate from the last probe reading to the present. The combination of corrosion and temperature measurement is particularly useful in process plants. The portable CK-4 has a built-in memory which stores readings for subsequent retrieval. Operation and Maintenance Manual. Extension cables up to 50 ft. The LT system is particularly useful where a process monitoring computer is not available or accessible. Zone 2. The transmitter has an integral 5-foot probe connection lead.

Transmitter to receiver distances up to The transmitter is approved intrinsically safe when used with the appropriate safety barrier between the transmitter and receiver in the safe area. Only a single twisted pair cable is required to connect the transmitter back to the receiver unit. Complies with all applicable EU Product Directives: Div 1. Switch Selectable. The unit provides isolation between the probe and mA circuits. The DCS system should however have the ability to graph the data against time. Canadian and Europe and standard. The transmitter is well suited to plant locations with widely separated monitoring points for connection into a distributed control DCS system.

A 24VDC supply is typically required to power the loop via an approved intrinsic safety barrier. The system is intrinsically safe to USA. If a remote readout display is required for metal loss and rate. Supply Voltage Range: Probe Cable: Communication over cellular or telephone links allows data retrieval without ever leaving the office.

Programming of all the RDC's. For increased versatility. Communication Power Modules CPM's provide a wide range of power supply and remote communication options. RDC 4-Channel Specifications: Order required number to length max. All of the data is automatically overlaid on the time axis. Even different reading intervals on a single probe may now be handled in a single file for that probe tag. The program provides for multiple sites and groups within those sites all in one program.

Other users on the network can maintain their own local system. Powerful time-related graphical displays of corrosion data from multiple probes and for multiple parameters are easily produced for corrosion program management and report preparation. Provision for individual probe logging enables complete management in a single program. Engineering and management reports are made easy. Hence the PC requirements are the same as for these operating systems. Pentium is a registered trademark of Intel. Significant site events may be logged for automatic identification on the graphical displays.

The graphical displays may be saved and transferred to your favorite word processor applications. SVGA Monitor. Since this application is graphically intensive. Integral safety barriers permit conventional cabling connections to the probes without explosion proof conduit. An explosion proof enclosure allows the unit to be mounted in a electrically hazardous area of the plant as close to the probes as possible optimizing performance and minimizing cabling costs. For economy. Space is available for a full set of safety barriers.

The slope of the electrical resistance of the reference element. As the electrical resistance of the measurement element increases with temperature. For a give alloy at constant temperature. Non-removable under system pressure 2. Laboratory probes 3. Removable under system pressure b. External and structural monitoring probes 4. Plotting metal loss as a function of time permits corrosion rate to be determined. This method may be used in virtually any environment except liquid metals or some conductive molten salts. By energizing the probe elements with the same electrical current.

Internal process monitoring probes a. The major probe categories are as follows. Environmental monitoring probes Rohrback Cosasco Systems. They provide a large surface area for measurement. NPT connections are available with fixed or adjustable length. Internal Process Monitoring Probes Fixed Type Non-removable under system pressure Probes which are not removable under system pressure are sometimes used for reasons of economy or special process limitations.

Two systems are available depending on the pressure. Glass-to-metal seals provide the highest seal integrity and are generally suitable for process fluid in the range of pH and temperatures up to degrees F. Insertion force. A high temperature model is also available for temperatures above 50 degrees F. The construction enables these probes to be used in environments in pH range Flush Elements Flush element probes are available where it is particularly necessary to monitor localized wall effects.

The body of the cylindrical element probe is normally supplied in the same alloy as the element to prevent the effects of possible galvanic corrosion between the probe body and probe element. These may be mounted with a flange or NPT threaded connection. Selection of the most suitable element form and specially the correct probe sensitivity is important to obtaining good quality corrosion data. Two forms of element seals are available to protect the reference element within the probe body.

Cylindrical Elements These probes have the element directly welded to the probe body to provide the highest integrity seal for aggressive environments. Internal Process Monitoring Probes Removable Under System Pressure Probes that are removable under system pressure are particularly useful to enable inspection or change out of probes without shutting down or isolating the system. Details are given on the data sheet for each model probe. The probe bodies may be of the same alloy.

Elements are available in a wide variety of alloys. They are not suitable for fluids containing fluoride ions which attack glass. A specially-designed retracting device is available for insertion or removal of probes at pressures too high to permit safe operation by hand above psi requires over 50 lb. Cylindrical element probes generally have wetted parts of the same alloy as the probe element. Glass seals are rated to degrees F degrees C maximum in a pH range of less than 9. For standard cylindrical probes. In glass sealed loop probes and cylindrical element probes.

For this reason. For high temperature cylindrical element probes. Pressure ratings are specified on this basis. In nonglass sealed loop element probes. Probe Fill Material Standard probe fill materials are ceramic or epoxy. As an example. A T4 or more sensitive element must be used. A T8 element would respond in approximately 18 hours. A sensitive probe will respond more quickly to process upsets than one with a greater span. Sensitive elements T4.

In general we recommend that elements be selected to be replaced every months to give the optimum combination of sensitivity and responsiveness. Less sensitive. A rule of thumb is that corrosion rates double for each 10 degrees C temperature rise. The ability to track temperature and corrosion rate simultaneously is a powerful tool in the corrosion management of such plants. The originality of the design permits both local and remote monitoring to be accomplished with accuracy. RCS Part No. Temperature Sensor Specification: Probe to soil measurements are taken with the reference cell placed inside the 3" diameter pipe to reduce IR drop errors.

The station may be installed during an excavation.

A permanent reference cell can be ordered as an option to minimize IR drop errors and eliminate the need for the tube. PVC or polycarbonate pipe. The ring coupon can be cathodically protected and used as a secondary source for measurements. Typical Installations: The cable must be ordered separately. Elements are normally 4 or 8 mils thick with a useful measuring range equal to half the original thickness. A thin strip. The probe may be grounded to an exposed metallic structure to monitor the effectiveness of cathodic protection being applied to the structure. One half the metal is exposed to the corrosive environment to obtain the measurement.

Model No. Element Availability: The Instrument Society of America ISA has classified reactive environments by the corrosion rate of copper as follows: G4 Severe…………………………. In most operations. The compact. Filter replacement is expensive and may be done prematurely without the use of a corrosion sensor. G3 Harsh……………………………….

CORROSION COUPON ANALYSIS

The Model gives early indication of filter replacement without jeopardizing the safety of costly.. Connection to monitoring instruments is through a separate adaptor cable see Accessories. Activated carbon filters have a finite life for absorbing contaminates. These environmental systems regulate temperature and humidity and remove corrosive contaminants by the use of activated carbon filters. Loss of control of these parameters can cause corrosive deterioration of equipment. Since an accurate corrosion rate measurement can be obtained after loss of less than one percent of the total sensor span.

Nominal vs. Adaptor Cables for use with electronic measurement instruments: Instrument Cable Model No. Either probe can be connected or not connected to a cathodically protected structure. Its slim profile is convenient for locations with restricted access such as concrete bridge structures and other infrastructure applications. When electrically connected. The probes may be ordered with or without a grounding lead for C. Both probes provide good sealing to the reference element. System to be made as required.

Depressions on the metal surface from corrosion. Pits vary in size, depth, and density. Pitting is typically caused by one of the following: Localized Corrosion: Caused from under-deposit corrosion. Could be caused by a low flow rate through the rack or necessity for better deposit control. Copper Plating: Soluble copper attaches to non-copper alloy samples. Can cause severe galvanic corrosion and metal failure due to pitting. Operating Experience — Information is generated by the actual operation of equipment.

The equipment itself is used as the corrosion coupon or corrosion test. Samples of pipe are taken for analysis of corrosion. Model Equipment — Model equipment can be installed in parallel with actual equipment or in a pilot plant. All variables must be identical to the actual plant. Instrumental Test Methods — Electrical resistance and polarization scans are valuable, and can generate a continuous record of corrosion rate. Corrosion Monitoring, Corrosion Coupons, and Corrosion Coupon Racks Corrosion monitoring is intended to provide an accurate representation of how well metallurgies of a system are protected against corrosion and to alert facility operators and service companies if a change is necessary before too much damage takes place to the system.

General Corrosion Facts. Corrosion can be expressed in mils per year MPY of metals degraded Corrosion produces by-products oxides that hurt systems through erosion, clogging, and fouling Corrosion oxides reduce system efficiency and increase energy costs by accumulating on heat transfer surfaces Corrosion can be reduced through proper system design, maintenance, and water treatment. Common Sources of System Corrosion. Dissolved oxygen Bacteria Electrolysis stray current Differential metal dielectric Differential cell Flow, temperature, and pressure can all influence corrosion.

Benefits of Corrosion Monitoring. Interpreting Corrosion Rates. What are corrosion coupons? Corrosion coupons vary by type of metal alloy and physical configurations: Strips Rods Flush Discs Discs. How are corrosion coupons analyzed? Corrosion Coupon Test Intervals. Benefits of Corrosion Coupons. No sophisticated instrumentation is required for results.

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