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Pipeline Corrosion Tracking Coupons & Analyzers
CORROSION COUPONS
CORROSION COUPONS Image

Accurate monitoring of corrosion rates in any environment is critical when viewed in terms of the maintenance and repair costs associated with corrosion and material failure. Test coupons provide an inexpensive means of on-line monitoring that will allow you to effectively measure the corrosivity within your system. By observing the mils-per-year corrosion rate of an exposed coupon, valuable information can be provided regarding the material’s life expectancy. Biolab can make coupons in any size, shape, or material you need. Coupons can be stenciled with alloy and sequence numbers for proper identification. Mill test reports, identifying element compositions of materials used, are provided on all orders. The following coupons are four of the most commonly used in corrosion testing.


 


Finishes

  • Mill - finished as produced from mill.
  • Glass Bead - blasted with fine glass beads to remove mill scale.
  • 120 Grit - fine finish using a 120 grit belt. Commonly used in corrosion tests, such as pitting studies, where smooth surface finish is desired. Finishes up to 600 grit (extremely fine) can be provided.
  • Double Disc Ground - extra fine finish using an abrasive disc that leaves minimal residue. Excellent for studies where surface finish is critical. Can produce 16-32 RMS finishes on common steels and 8 RMS on carbide steels.

Coupon Ordering and Services Available

When placing your order for coupons, be ready to provide the sales person with information regarding the type of material you are testing, the size coupons required, surface finish desired, and if applicable, mounting hole size and location. The following options are available:

  • Manufacturing on time and material basis
  • Samples mounted on test racks and ready for installation
  • Preweighing - coupons are cleaned, preweighed on an electronic scale, and individually packaged
  • Weight log charts provided on computer disk
  • Non-standard coupons
  • Coupon measuring
  • Heat-treating, sensitizing, hot dip galvanizing
  • Manufacturing from your material if requested
  • Coupons made to specific requirements for mounting hole locations, coupon welding, stressing, and packaging
  • Plating - nickel, nickel cadmium, cadmium, chrome, silve, gold, and others upon request
  • Electro-polishing, hard facing
  • Non-metallic coatings
  • Anodizing and alonizing

Standard Coupons

Flat Coupons

P/N Size Hole Hole Location Area Sq. In.
CO100 1/2” x 3” x 1/16” 3/16” 1/4” fr. end 3.38
C0101 1”    x 2” x 1/16” 3/16” 1/4” fr. end 4.32
CO102 1/2” x 3” x 1/16” 9/64” 1/8” fr. end 3.41
CO103 1/2” x 3” x 1/16” 1/4” 1/4” fr. end 3.34
CO104 1/2” x 3” x 1/16” (2) 1/4” 1/2” fr. ea. end 3.24
CO105 1/2” x 3” x 1/16” 3/16” 1/2” fr. end 3.38
CO106 1/2” x 3” x 1/16” 1/4” 1/2” fr. end 3.34
CO115 1/2” x 3” x 1/16” 1/4” 1/4” fr. end
CO117 3/8” x 3  x 1/16” 9/64” 1/8” fr. end 2.64
CO118 1/2” x 3” x 1/16” (2) 1/4” 1/4 & 3/4” end 3.24
CO120 3/8” x 3” x 1/16” (2) 1/4” 1/4 & 3/4” end 2.48
                   

Cylindrical Coupons

P/N Size Thread Slot Area Sq. In.
ES200 1/4” x Ø x 2  1/2” 1/4”-20 x 3/8” 1/16” 1.96
ES201 1/4” x Ø x 2” 1/4”-20 x 3/8” 1/16” 1.57
ES202 1/4” x Ø x 3” 1/4”-20 x 3/8” 1/16” 2.45
ES204 1/4” x Ø x 1  1/2” 1/4”-20 x 3/8” 1/16” 1.18
ES209 1/4” x Ø x 3” 1/4”-20 x 3/8” 1/16”
COUPON HOLDERS
COUPON HOLDERS Image

Fixed (Pipe Plug) Coupon Holders

Biolab carries a variety of standard pipe plug coupon holders for flat and cylindrical specimens. We can design and make these assemblies to meet your specifications for size and material requirements.

Pipe Plug Assemblies for Flat Coupons

P/N Plug Size 3” (Std.) Stem Used with Coupon P/N
RC12E*100036 3/4” NPT Nylon CO102, CO117
RC13E*100036 1” NPT Nylon CO102, CO117
RC12Q*100036 3/4” NPT Teflon CO102, CO117
RC13Q*100066 1” NPT Teflon CO102, CO117
RC12E*010036 3/4” NPT Nylon CO100, CO103, CO115
RC13E*010036 1” NPT Nylon CO100, CO103, CO115
RC12Q*010030 3/4” NPT Teflon CO100, CO103, CO115
RC13Q*010026 1” NPT Teflon CO100, CO103, CO115
RC12E*030036 3/4” NPT Nylon CO118, CO120
RC13E*030036 1” NPT Nylon CO118, CO120
RC12Q*030036 3/4” NPT Teflon CO118, CO120
RC13Q*030035 1” NPT Teflon CO118, CO120
RC12E*090036 3/4” NPT Nylon CO105, CO106
RC13E*090036 1” NPT Nylon CO105, CO106
RC12Q*090036 3/4” NPT Teflon CO105, CO106
RC13Q*090036 1” NPT Teflon CO105, CO106
RC11E*010036 3/4” NPT Nylon CO100, CO103, CO115

 


Pipe Plug Assemblies for Cylindrical Coupons

P/N Carbon Steel Plug Insert # of Stems
PA2080709413 2” NPT Nylon 8
PA2080783413 2” NPT Teflon 8
RC11E3040000 1/2” NPT Nylon 1
RC12E3040000 3/4” NPT Nylon 1
RC13E3040000 1” NPT Nylon 1

Bypass Piping Systems

We provide conventional or custom-designed bypass systems for on-line corrosion monitoring. Commonly used in the industrial water treatment industry to determine the corrosive properties of potable or cooling water, these systems are available in PVC, carbon and stainless steels, and other materials.

Bypass systems are easily installed to your existing piping. Normally, all you need is a 1” NPT male fitting on which to attach the bypass. Standard bypass systems come equipped with 4 pipe plug assemblies, 4 pre-weighed mild steel coupons, and a 5-gpm flow control valve.


Adjustable Coupon Holders

Low Pressure or Hand Insertable systems can be used for pressures up to 125 psi. This assembly is commonly used in the water treating industry for coupon insertion through a full port valve. An example of this is in a municipal water pumping station, where leakage during withdrawal of the test coupon would not be critical.

 

Retractable Coupon Holders

Packing Gland systems are used in more demanding environments, where ratings up to 1,500 psi are required and leakage is prohibited. These systems do not require line (process) shutdown to insert or withdraw coupons. The assembly is used for coupon insertion through at least a 1” full port valve. A safety chain is provided to prevent accidental ejection.


Retrievable Coupon Holders

These coupon holders are used with High Pressure Access Systems where pressure ratings up to 3,600 psi are required.

   
WELDED COUPONS
WELDED COUPONS Image

Corrosion rates can vary between welded and non-welded metals, therefore it is advisable to study the behavior of both conditions. Studies involve examination of the parent material, the heat affected zone, the weld metal, and the interfaces between all metals involved. The surface effects produced by welding, heat-tint formation or oxidation, fluxing action of slag, and the deliquescence of slag can be important factors in the corrosion behavior of metals.

Ideally, the coupon used should be the same thickness and welded with the same welding process as the material used in the production equipment. Usually this is not practical so a representative sample must be studied.

Typical welding techniques used are Shielded Metal Arc (SMAW), Gas Tungsten Arc (GTAW), and Gas Metal Arc (GMAW). Specimens are ground smooth after welding, unless otherwise specified, so as to provide a uniform surface for microscopic investigation.


Welded coupons can be prepared with or without the use of filler metal. The autogenous weld is prepared without the use of filler metal. This type of weld is the most economical method. Autogenous welds are commonly used to evaluate corrosion rates of welded materials and the usage of these materials in corrosive environments. An autogenous weld is produced by GTAW and can be used to test material weldability and gas shield usage, and to set welding parameters.
Autogenous Weld Coupon 1. 120 grit standard finish unless otherwise specified. 2. 1/8” nominal thickness. 3. Standard weld is autogenous weld across end (A.W.A.E.). Sanded after weld.
STRESSED COUPONS
STRESSED COUPONS Image
Stress corrosion cracking occurs when tensile stress combines with a corrosive environment to attack a material. Testing for this type of corrosion is critical in storage tanks, pressure piping, and vessels commonly used in chemical processing plants and petrochemical refineries. Biolab can make your stressed samples in accordance with all ASTM standards including G30, G38, G39, and G58 or to your custom specifications.
TEST RACKS
TEST RACKS Image

Biolab offers test racks used to mount coupons and secure them directly to operating equipment or within a process system. Test racks make it easy to evaluate how corrosion would effect differing alloys and material finishes under identical conditions. Rack usage helps eliminate coupon loss which might occur if samples were individually placed in a process flow.

Racks can be fabricated to meet your requirements for material and size. Typical racks are flat bar racks, spool racks, and pipeline insertion racks. Other racks include angle bar racks and outdoor exposure racks. A variety of insulators, washers, and spacers used to isolate coupons can also be ordered separately.


Guidelines for Supporting Specimens

Corrosive behavior of materials subjected to immersion, partial immersion, or vapor phase can have great variance. For this reason, specimens to be tested should be properly positioned. There are several important points to be considered when supporting specimens for exposure:

  • Each specimen location should be identified by sketch and recorded.
  • The corrosive media should have access to the coupons.
  • The test rack should have adequate corrosion resistance to endure the test.
  • Specimens should be electrically isolated from other metals unless galvanic effects are being studied.
  • Specimens should be located in easily accessible areas.

INSULATORS, WASHERS & SPACERS
INSULATORS, WASHERS & SPACERS Image
Biolab makes a variety of insulators, washers, and spacers used to isolate test specimens. We also make insulator kits (R5102) that contain an assortment of washers, screws, nuts, and stems. These kits are designed for field use when a variety of insulators are needed. The chart shown here is a general guide to material applications. Call for recommendations on use in hazardous or severe environments.
Material vs. Environment
ELECTRODES
ELECTRODES Image
Biolab provides electrodes compatible with our various probes and instruments, as well as those of most other major manufacturers. Other electrodes not shown here are also available. Electrodes are made from a variety of materials (see Alloys list).
DATA LOGGER
DATA LOGGER Image
  • Digital, hand-held, menu-driven corrosion meters that take probe measurements and store the data to be later downloaded to a computer for analysis.
  • Data loggers used to continuously monitor probes in remote locations, automatically read the probes at selected intervals, and store the readings in memory.
  • Field transmitters which transmit measurements to a receiver (such as a DCS or SCADA system). Wireless radio options are available to eliminate cable and conduit setup.
Pipeline Corrosion Tracking Coupons & Analyzers
CORROSION COUPONS Image
CORROSION COUPONS
Accurate monitoring of corrosion rates in any environment is critical when viewed in terms of the maintenance and repair costs associated with corrosion and material failure. Test coupons provide an inexpensive ... Read More
COUPON HOLDERS Image
COUPON HOLDERS
Fixed (Pipe Plug) Coupon Holders Biolab carries a variety of standard pipe plug coupon holders for flat and cylind... Read More
WELDED COUPONS Image
WELDED COUPONS
Corrosion rates can vary between welded and non-welded metals... Read More
STRESSED COUPONS Image
STRESSED COUPONS
Stress corrosion cracking occurs when tensile stress combines with a corrosive environment to attack a material. Testing for this type of corrosion is critical in storage tanks, pressure piping, and vessels commonly used in chemical process... Read More
TEST RACKS Image
TEST RACKS
Biolab offers test racks used to mount coupons and secure them directly to operating equipment or within a process system. Test racks make it easy to evaluate how corrosion would effect differing alloys and mate... Read More
INSULATORS, WASHERS & SPACERS Image
INSULATORS, WASHERS & SPACERS
Biolab makes a variety of insulators, washers, and spacers used to isolate test specimens. We also make insulator kits (R5102) that contain an assortment of washers, screws, nuts, and stems. These kits are designed for field use when a vari... Read More
ELECTRODES Image
ELECTRODES
Biolab provides electrodes compatible with our various probes and instruments, as well as those of most other major manufacturers. Other electrodes not shown here are also available. Electrodes are made from a variety of materials (see Allo... Read More
DATA LOGGER Image
DATA LOGGER
Digital, hand-held, menu-driven corrosion meters that take probe measurements and store the data to be later downloaded to a computer for analysis. Data loggers used to continuously monitor probes in remote locations... Read More