Description

1. Introduction

EMT-CI Corrosion Test Coupon are essential tools used in the monitoring of corrosion within industrial piping systems and containers. By exposing a sample, known as a coupon, within the system, operators can measure the corrosion rate in mils-per-year, providing crucial data on the anticipated life expectancy of the material in use.

Example for a set of Corrosion Coupons Assembly：

EMT-CIPA-0F600#RF-0-1+ CC-P221-SR-6″-3″×1/2″×1/8″-MS1018-0-2

2. Composition and Design

The Corrosion Test Coupon are part of a high-pressure access system composed of three primary components:

1. Access Fitting Body: This can be either welded or flange-mounted to the system, providing a secure and stable interface.
2. Plug Assembly: Includes a solid plug body, an O-Ring, PTFE primary packing, and additional components necessary for maintaining a tight seal and secure placement within the fitting body.
3. Cover: Protects the internal components from external environmental conditions, ensuring the integrity of measurements.

The process connection size for these systems typically complies with ANSI 2” RF or RTJ standards, making them versatile for integration into various piping configurations.

3. Key Features

The EMT-CI Corrosion Test Coupon is designed to provide precise and reliable monitoring of corrosion rates within industrial piping systems and containers. Here are the key features summarized:

1. High-Pressure Compatibility: Designed to withstand pressures ranging from 150LB to 1500LB, making them suitable for a variety of industrial environments.
2. Material and Construction:
   • Body Materials: Specified as per material requirements to ensure compatibility with the operational environment.
   • Sealing Materials: Utilizes Fluororubber and Teflon for optimal sealing performance, capable of handling temperatures from -20℃ to 200℃.
3. Versatile Connection Sizes: Compatible with ANSI 2” RF or RTJ flange standards, allowing for flexible integration into existing systems.
4. Coupon Holder Variability:
   • Offers both fixed and adjustable coupon holders.
   • Accommodates both rectangular and circular coupons, enhancing the adaptability for different monitoring needs.
5. Diverse Coupon Sizes.: Available in multiple sizes (from 2″×1″ ×1/8″ to 3″×1″×1/8″ and circular Ф31.8×3.2), catering to specific requirements and enhancing measurement accuracy.
6. Installation Flexibility:
   • Can be installed via welding or flange-mounting, providing options based on the structural and operational needs of the system.
   • Designed for easy installation and maintenance, featuring a straightforward procedure for inserting and adjusting the corrosion coupon within the system.

4. Material Specifications

• Materials: As specified by MR (Material Requirement), ensuring compatibility and durability under specific operational conditions.
• Sealing Materials: Fluororubber and Teflon are used, offering excellent resistance to extreme temperatures and chemical exposures, suitable for temperatures ranging from -20℃ to 200℃.
• Pressure Ratings: The system is designed to handle pressures from 150LB up to 1500LB, accommodating a variety of industrial applications.

5. Coupon Holder and Coupon Design

• Coupon Holder: Available in fixed and adjustable configurations, with options for holding either rectangular or circular coupons, allowing for flexibility in monitoring and analysis.
• Coupon Sizes: Range from 3″×1″×1/8″ to Ф31.8×3.2 (1 1/4″×1/8″), providing options based on the specific requirements of the pipeline system.

6. Installation Procedure

1. Initial Setup: An insulating gasket is placed at both the front and back of the coupon holder’s mounting hole, with the larger end facing outward. The coupon is secured onto the holder using bolts and nuts.
2. Sealing and Assembly: The primary sealing ring is positioned on the plug’s screw rod, facing inward towards the center. The coupon holder is then threaded onto the plug and secured with a set screw, completing the plug assembly.
3. Base Integration: The welding base is affixed onto the pipeline, ensuring a stable platform for the coupon assembly.
4. Operational Placement: The fully assembled plug is attached to the welded base and tightened. The flow direction within the pipeline is marked on the hexagonal nut to ensure correct alignment.
5. Maintenance and Adjustment: For maintenance or reorientation, the coupon plug assembly is removed, and the orientation of the coupon adjusted perpendicularly to the flow direction for accurate corrosion monitoring.

7. Application

1. Oil and Gas Industry

Pipeline Monitoring

Corrosion coupons are installed in oil and gas pipelines to measure corrosion rates, which is crucial for preventing leaks and pipeline failures that could lead to environmental disasters and economic losses.
Refineries: Used in refineries to monitor the corrosion within processing units, which operate under high pressures and temperatures, and handle various corrosive substances.

2. Chemical Manufacturing

Process Vessels and Reactors

In chemical plants, corrosion coupons help monitor the degradation of materials used in reactors and other vessels that contain aggressive chemicals.
Cooling Systems: They are also placed in cooling water systems to assess the corrosive effects of the cooling mediums and the efficacy of corrosion inhibitors being used.

3. Water Treatment Plants

Water Pipes and Storage Tanks.

Monitoring corrosion in water transport and storage systems helps in maintaining the quality of water and the longevity of the infrastructure.
Desalination Plants: Particularly critical in monitoring the effects of highly corrosive saline environments on the plant’s metallic components.

4. Power Generation

Boilers and Steam Systems.

Corrosion coupons are used in boilers and steam lines where the combination of high temperatures and moisture can lead to accelerated corrosion.
Cooling Towers: To check the effectiveness of water treatment programs and the integrity of the metal structures within the cooling towers.

5. Marine Applications

Ballast Tanks and Ship Hulls.

The marine environment is highly corrosive due to seawater; corrosion coupons help in assessing the rate of corrosion on ships and offshore structures, aiding in predictive maintenance and repairs.