Corrosion Probe and Coupon - Emt Pipe Cleaning Pig

Description

Corrosion Probe and Coupon Usage Scenarios

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Because the petrochemical industry has a complex and changeable corrosive environment. (Oil-water mixing, gas-liquid mixing, etc.). There are also various types of corrosion. (Uniform corrosion, localized corrosion, erosion corrosion, pitting corrosion, pitting corrosion, etc.). So when addressing these issues. How to quickly (real-time) discover corrosion problems and accurately grasp the corrosion status (location, degree). This has always been the technical focus of petrochemical enterprises. At the same time, it is also the direction that domestic and foreign technicians have been working hard to study.

Therefore, the company produced this series of resistance corrosion probe products. It enables technological innovation in corrosion monitoring. At the same time, it realizes real-time online monitoring of pitting corrosion and localized corrosion, specifically including 3 types of products

PDS: Pitting Corrosion Monitoring System (patented technology) i-ER: ER resistance corrosion monitoring system based on AI technology MFS: Multifunctional Corrosion Monitoring System (PDS + i-ER)

Metal Material: 316&#;L DUPLEX SS
Sealing Material: Teflon/ Fluororubber
Working Temperature: -20~200&#;
Working Pressure: 0~26MPa
Access Fitting Body and Protective Cover :
Size of Flange : ANSI 2&#; RF (or RJ)
Material : CS &#;316L&#; DUPLEX SS
Working Pressure: 0~26MPa
Working Temperature: -20~200&#;

Product advantages

1. We can use it under any environmental conditions

2. Adapt to various standards on the market (ER probes, weightless coupons. ) The change of site conditions at the installation interface does not affect the continuity of monitoring

3. Real-time pitting corrosion/general corrosion/pitting corrosion penetration

4. Rate monitoring;

5. Pitting corrosion alarm display

6. ER probe life signal display

Name

Corrosion Probe and Coupon

MaterialStainless Steel 316&#;L DUPLEX SSOperating Temperature -20~200&#;FeatureFirstly, easy to operateSecondly, high Accuracy Long LifeAt last, high-Efficiency Low costPaymentTT/LCAdvantageFirstly, they are lightweight and flexible.And then nice Injection efficiency.At last, accurate location tracking.

Introduction:

In aggressive media, the wire as the measuring element will corrode. Then, the length of the wire remains the same, the diameter decreases, and the resistance increases. At this time, we can convert the corrosion and thinning amount of the metal wire by testing the change of resistance. When the material of the metal wire used is the same as that of the equipment to be measured, the corrosion rate of the metal wire can be used to approximately represent the corrosion rate of the equipment. The resistance probe measurement technique is based on the above principles for testing. Establishing the resistance probe measurement method can display the corrosion condition of the equipment pipeline in time. At the same time, it can detect abnormal corrosion conditions in time to avoid safety production conditions caused by equipment corrosion. This is an effective means of corrosion detection.

Working principle:

The corrosion rate measured by the resistance probe is based on the linear relationship between the cross-sectional area and the resistance at any time, under the premise that the length of the resistance probe wire is constant, to obtain the metal corrosion rate. At the same time, in order to eliminate the measurement error caused by temperature. Then we added a temperature compensation element to the measurement structure.
For example, the cross-sectional area of a metal material with a certain length decreases after corrosion and thinning, and the resistance value increases. Therefore, as long as the change value of the resistance is known. We can calculate the thinning amount.

Measurement system:

The Corrosion Probe and Coupon monitoring system consists of several parts. Examples include corrosion resistance probes, fasteners, corrosion data collectors, connecting cables. There are also data converters, computers, and online monitoring software systems.

• Resistance probe:

High-temperature Corrosion Probe and Coupon, including protective cap, measuring element, probe rod, and signal interface.

Since the resistivity of metal materials changes with temperature, in order to avoid measurement errors caused by medium temperature changes. Then, a temperature compensation element is built into the probe rod and connected in series with the measuring element in the circuit, so that the influence of temperature can be completely eliminated. The protective cap is on the outside of the probe to slow down the impact of high-speed medium flow on the probe measuring element. The card slot is to connect and fix the dismounting device when installing and dismounting the probe.

ER Corrosion Probe and Coupon

 

Because the key to the development of high-temperature resistance probes is the sealing of the probe and the insulation of the inner leads. So they are sintering at a high temperature above °C. The inner lead wire of the probe rod is insulated with a porcelain sleeve. All joints are laser connection wel. Install the sealed probe in a self-made simulated working condition device. The conditions are 450°C, 2.0MPa, and sulfur-containing diesel oil. After 72 hours, leakage no found. The sealing and high-temperature resistance of the probe can meet the design requirements.

In addition, in order to improve the pressure resistance performance, the sealing packing part of the probe is designed as a spiral inner sleeve base. The measuring element is made in the form of a filament.

Compared with flakes, its advantages are:

One is long life. Secondly, the surface of the filamentary measuring element is relatively uniform. So this is not prone to edge effects like chip measuring cells. From the perspective of use and installation, the probe has two forms: detachable under pressure and flange. Generally speaking, the former is suitable for environments where the pipeline pressure is less than 2.0MPa. The latter is suitable for environments where the pipeline pressure is greater than 2.0MPa.

• Monitor:

(1) Remote acquisition, amplification, and digital conversion of weak signals:

Petrochemical equipment operating above 300°C is potentially dangerous due to corrosion. Field testing should be done away from the danger zone. Previously known resistance probe testers. (Including the early imported ER and domestically developed). The lead wire between it and the probe is very short, only 1~2m. To avoid operating in high temperature areas. Therefore, the design of RPM- instrument adopts independent differential amplification and filter noise reduction technology of measuring element and temperature compensation element. This enables measurement leads up to 50m or more. It also makes multi-probe measurements possible with one instrument. After the original signal is collected and amplified, the analog-to-digital conversion is performed, and the operation, display, and storage are completed by the single-chip microcomputer.

(2) Long-distance transmission of digital signals, computer software system design:

To perform real-time online measurements, the monitor must have the functions of automatic signal collection and transmission to the monitoring room. Computers are equipped with RS-232 standard communication interface. But its transmission distance is only 15m, which cannot meet the requirements for industrial sites.

In order to extend the transmission distance, an RS-485 interface module is connected between the on-site monitor and the RS-232 of the computer in the monitoring room. The corresponding circuit MAX487 is also designed in the monitor. It makes the original signal transmitted in the form of potential into the form of current loop transmission. The transmission distance reaches m, which meets the needs of the scene. Computer software system design is also required for online measurement. The monitoring program of the corrosion online monitoring system is written using the Visual Basic software platform. This fulfills the requirements of a clear interface, easy operation, standardized data management, etc.

Application prospects:

Corrosion Probe and Coupon measurement can track the corrosion behavior of the metal surface in the real environment, and grasp the corrosion rate and corrosion status. Therefore, the corresponding process anti-corrosion measures are taken in a timely manner. Timely measures can also be taken to control the corrosion rate within the required range. Establishing the resistance probe measurement method can display the corrosion condition of the equipment pipeline in time. Or quickly spot corrosion anomalies. In this way, safety production situations caused by equipment corrosion can be avoided. So it is an effective means of corrosion detection. Then the design of the resistance probe measurement data processing software is simple and practical, and it can effectively manage the probe data. This improves the efficiency of data processing. It is convenient to query the corrosion data.

The development and application of the resistance probe measurement system have enriched the corrosion monitoring methods. At the same time, it fills the gap in the country. This provides favorable technical support for the safe operation of the equipment.

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At last, 24 hours,7 days online.

We use PLYWOOD CASE as packaging, it has the following advantages:

Firstly, lightweight, clear lines, insulation, high strength, not easy to deform;

Secondly, no fumigation is required.

Made of similar metals and materials to the system components; scaling and or corrosion coupons are installed within a hydraulic system [chilled water/condenser water] to allow the examination of the overall &#;corrosion rate&#;, allowing the system&#;s current condition to be understood and the ability to also predict its future life expectancy allowing for preventative maintenance measures.

What is a corrosion coupon

A coupon is a &#;strip&#; of metal that is manufactured to precise tolerances focusing upon its weight and dimensions to allow accurate testing after a period of being installed within a system.

Coupons should be manufactured from a metal similar to the system materials, or from a one that is more reactive, similar to zinc or aluminum, to accelerate the corrosive conditions, providing earlier warnings.

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They are usually stenciled with numbers which will allow proper identification when being used on-site and recording the testing.

How do they work and how do you test them?

They are installed into a closed or open loop system where they should be electrically isolated to ensure any corrosive effect is only from the fluid within the system.

If using the &#;weight-loss method&#;, prior to installation, each coupon should be weighed, with an accurate calibrated scale and the information recorded for future reference.

During the time they are installed and the system water is flowing over and around them, they will start to corrode &#; the recommended installation time for the coupons would be 90 days. This is to allow acclimatization to the system. It has been noticed if only install for a short period of time, under 30 days, the corrosion rate is usually higher.

Once the testing has been completed, they are removed and sent to a laboratory, where they will be cleaned and weighed to understand the rate of corrosion.

All testing and analysis should be completed in line with the following standards:

As can be seen within the AWT Standard for corrosion rates the classification of corrosion rates for open and closed recirculating cooling water systems are:

Open Pipework System [Condenser]

Description [Open System]Carbon Steel [mils-per-year]Copper Alloy [mils-per-year]Negligible or ExcellentLess than or equal to 1Less than or equal to 0.1Mild or Very Good1 to 30.1 to 0.25Good3 to 50.25 to 0.35Moderate to Fair5 to 80.35 to 0.5Poor8 to 100.5 to 1Very Poor to Severe>10>1

Closed Pipework System [Chilled Water/Heating]

Description [Closed System]Carbon Steel [mils-per-year]Copper Alloy [mils-per-year]ExcellentLess than or equal to 0.2Less than or equal to 0.1Good0.2 to 0.50.1 to 0.25Moderate0.5 to 0.80.25 to 0.35Poor0.8 to 10.35 to 0.5Very Poor to SevereGreater than or equal to 1Greater than or equal to 0.5

What are the benefits and disadvantages of using Coupons?

Advantages

• Inexpensive.
• Simple to use, no risk of &#;instrument&#; failure.
• Different metals can be tested at the same time.
• Corrosion and bacteria, if required, can be obtained from the surface for further anaysis.

Disadvantages:

• Time to complete the testing.
• Can only provide average readings and won&#;t be able to show annomolies across a time period.
• Corrosion is not normally constant, the coupons will not be able to show this.

What materials are coupons made from?

The coupon material used for monitoring will depend upon the materials in the system, below is a list of materials that are available:

• Mild Steel
• Copper
• Stainless Steel [303, 304, 316]
• Nickel
• Brass
• Bronze
• Aluminum
• Galvanized Steel

What are the common sizes?

Coupon strips are generally ½ inch (12.5 mm) wide, 3 inch (75 mm) in length, and 1/16 inch (1.6 mm) thick as per the ASTM standards.

How to install coupons?

Coupons would usually be installed in a &#;coupon rack&#;, see below for additional information. Within the rack will be &#;coupon holders&#;, usually one to six numbers, to allow installation and fixing of the metals being used.

They should be installed so that the flow of the water is from the back of the coupon and that its broad face is in the vertical position, this reduces the risk of accumulation of debris on its face.

The coupon strips should be easily installed and removed when needed.

Galvanic Series

If using multiple types of metals for the installation, the galvanic series should be considered.

The most active metal should be installed in the first position then leading through the metals in the next positions until the last being the most noble of the metals being tested.

For example:

• Aluminum [Least Noble]
• Galvanized Steel
• Mild Steel
• Brass
• Bronze
• Copper
• Nickel
• Stainless Steel [Most Noble]

What is a Corrosion Coupon Rack?

A rack will usually consist of a range of 1&#; / 25mm plastic PVC, CPVC, Carbon Steel or Stainless Steel pipework designed to the ASTM requirements, and wall-mountable for easy installation.

The rack should be installed at a distance of between 10 to 30 feet / 3m to 9m from the main system pipework.

A flow of water should pass through the rack from the bottom to the top, reducing any risks of airlocks, and at a flow rate that is between 0.4 m/s to 1.8 m/s. The flow can be controlled by a &#;rotameter&#;

They can be supplied with isolation valves, and solenoid valves for controlling the water [on/off], a paddlewheel water meter, coupon holders, and a Rotameter flow meter to ensure the required flow rates are met.

How do you monitor the Coupons

If the coupons are needing to be inspected then they can easily be removed from the &#;Rack&#;. This is usually achieved by unscrewing the co

upon holder and sliding out. Make sure the system is isolated and do not touch the &#;coupon&#; as grease from the hands may interfere with the results.

What are the differences between a Coupon and a Probe?

As noted in this article, a coupon is usually a metal strip that is installed into a &#;rack&#; and is manually cleaned, evaluated and weighed after a period of time has passed to understand the corrosion rate within a chilled water/condenser water system.

The installation is quite inexpensive but takes time to obtain any results which only show an average of corrosion, and sometimes the reaction to the problem can be quite a while.

Probes on the other hand are electronic monitoring devices that are installed into the system and are a lot more expensive.

They can provide instantaneous results, allowing trend monitoring to see all peaks and troughs of the corrosion being measured and immediate investigations and remedial actions can be taken.

Some people suggest having both types, the electronic probe for instantaneous detection and remedial actions, and the metal coupon strips for providing a visual picture of the corrosion in the system over a longer period of time.

How do you test and commissioning a Coupon Rack?

There is not much to be done to functionally test a coupon rack, general checks to complete would be:

• Ensure installed inline with manufacturers literature and requirements.
• Ensure coupon strips are of the correct material.
• Coupons are of the correct dimensions and weight.
• Coupons are stamped and numbered.
• Review the flow rate across the coupons to ensure it meets the requirements and that there is no risk of wear happening.

Maintenance of the Coupon Rack

Maintenance is quite simple, each month that the system is in operation, manually check all fasteners and visibly check for leaks and if there is any abnormal wear on the coupons.

If leaks are detected then there could be an issue with the &#;O&#; Rings at the joint the leakage is seen [cut, scored, debris, or missing].

If notice abnormal wear on the coupon, this could be due to high flow rates, so check those and reduce where necessary.

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