COSASCO TWO-INCH SYSTEM

INSTALLATION, OPERATION & MAINTENANCE

MANUAL

CORROSION COUPONS (Alloy Specimens) &

COUPON HOLDER ASSEMBLIES

Rohrback Cosasco Systems

11841 East Smith Ave.
Santa Fe Springs, CA 90670
Tel: (1) 562-949-0123
Fax: (1) 562-949-3065
E-mail: rcs@rohrbackcosasco.com
Web Site: http://www.rohrbackcosasco.com P/N 740075 Rev. -
Table of Contents

Chapter 1 Introduction….............................................................1

Chapter 2 General……………………………………………………2

Chapter 3 Types of Corrosion Coupons…................................3

Chapter 4 Field Handling and Cleaning of

Corrosion Coupons…..………………..………………5

Chapter 5 Coupon Holder Assemblies…………………………..7

Chapter 6 Corrosion Coupons and Holders;

Positioning & Orienting...…......................................9

Chapter 7 Corrosion Coupon Weight Loss Measurement….10

Chapter 8 Charts and/or Tables – Useful Conversion

Factors and Metal Densities……...…………………13
 1

Chapter 1
Introduction

Corrosion coupons are one of the longest used methods for the study of corrosion and its effects.
They are relatively small, easily inserted and retrieved, and are an economical means of
determining cause and effect of corrosion.

As with any type of corrosion detection device, coupons may not give absolute definitive
answers, but will indicate general corrosion behavior patterns. They may be used in conjunction
with other means of corrosion monitoring devices developed for specific and peculiar types of
corrosion (for example; galvanic, pH, thermal, etc.).

For best results, the interpretation of the results should take into consideration the location and
orientation of exposure, the composition of product media and other variables.
2

Chapter 2
General

It is important to remember that coupons indicate the attack of the environment only at the point
of exposure. Therefore, coupons should be installed as closely as possible to the point where
surveys are desired. That is, near pipe wall surfaces, vessel surfaces, tube sheets, trays, up-stream
of major tie-ins; and in areas of turbulence, changes in velocity and temperature. The single or
combined effect of the product environment temperature, solution concentration, agitation,
aeration, pH, velocity and bacteriological attack will also affect the coupons. To the degree that
each of these can be considered in relation to each other and entered into the interpretation of the
results, the more beneficial the coupon corrosion rate data will be.
 3

Chapter 3
Types of Corrosion Coupons
(Refer to Figure 1):

Coupon material may be as varied as line or containing vessel material. The most widely used
material is mild or low carbon steel, such as AISI-1018.

Additionally, coupon configuration may be quite varied depending upon their application.
Ideally, the ratio of area to material density and total area to edge area should be large. Several
types of coupons and a brief description of each follow:

Strip Coupons (Single or Ladder):

Generally used in nominal lengths of 2”, 3”, 4” or 6” (50.8 mm, 76.2 mm, 101.6 mm or 152.4
mm, respectively); .875” (22.23 mm) wide; and .125” (3.18 mm) thick. For particular
applications almost any size may be utilized, provided it is installable and retrievable within the
parameters of the Cosasco Access Fitting Assembly and its compatible Retriever and Service
Valve hook-up. Strip coupons are probably the most popular type of coupon. Of the varying
types of coupons available, they are generally the most economical, provide satisfactory
corrosion rate data; unless particular problems are encountered in the application (e.g., pigging or
orientation) are very adequate.

Disc Coupons (Adjustable, Single or Multiple):

Generally of 1.25” diameter and .125” thick (31.75 mm and 3.18 mm). Other sizes may be
utilized provided coupons are installable and retrievable within the parameters of the Cosasco
Access Fitting Assembly and its compatible Retriever and Service Valve Hook-up.

Disc Coupons are particularly useful for multiple phase flow, as separation due to gravity will
expose certain disc coupons to varying degrees of environment corrosiveness, depending upon
the stratification encountered in the product flow. When they are used singly and mounted flush
with pipe ID surfaces they offer the advantage of not having to be retrieved from the line for
pigging operations. Also, orientation with product flow is not required.
4 Chapter 3

Rod Coupons (Single or Multiple):

Rod Coupons are normally of 3” length and of .25” diameter (76.5 mm and 6.4 mm). As with
other coupon types, rod coupons are available in other sizes provided they are installable and
retrievable within the parameters of the Cosasco Access Fitting Assembly and its compatible
Retriever and Service Valve hook-up.

Rod coupons may be attached to their holder singly; however, they are usually used in groups of
two (2) to five (5) to a holder. An advantage may be obtained if they are replaced sequentially;
(i.e., one (1) or two (2) changed each month or periodically, with comparisons made in the
intervening exposure times).

Prestressed (Single or Multiple) and Basket Coupons:

Prestressed Coupons are a variant of the strip coupon, but with an applied stress – usually at mid-
coupon, which bends the coupon(s). This type measures the effect of the stress on the
susceptibility to corrosion and can monitor the success of treatments to control stress corrosion.

Basket Coupons are a variant of the prestressed coupon, but non-insulated from its small
stainless steel mesh basket container, which prevents loss of the coupon to the product flow
stream.
 5

Chapter 4
Field Handling and Cleaning
of Corrosion Coupons
(Refer NACE Standard RP-07-75):

A. Field Handling:

1. All corrosion coupons must be handled with clean gloves. NEVER HANDLE WITH THE
BARE HAND! To do so, will assuredly affect the coupon and give false test data due to body
oils, salts and other rust promoting matter being deposited on them. Handle coupons carefully to
prevent scratching or otherwise marring the surface.

2. All Cosasco corrosion coupons are weighed to 0.1 milligrams (0.0001 grams), serialized and
packaged in moisture-proof envelopes. Coupon weight sheet data which are supplied with each
order furnish the specifics of each coupon as to material composition, weight in grams and its
identifiable serial number.

3. If on-site field handling conditions prohibit the cleaning procedure described below, the
coupons should be placed in the original moisture-proof envelope and shipped to a laboratory
immediately for analysis. The corrosion coupon should not be wiped off, coated with grease, or
otherwise altered.

B. Cleaning:

1. Photograph coupons, before and after cleaning, if possible.

2. Visually examine coupons and analyze any scale or foreign materials build-up on them.

3. Clean the coupon(s) by immersing in a suitable hydrocarbon solvent, such as clean benzene.
Do this long enough to remove any oil or paraffin deposits.

4. Immerse the coupon in fifteen percent (15%) inhibited hydrochloric acid (HCl) for one (1) to
two (2) minutes to remove scale or iron oxide. Repeated immersion or a slightly more acidic
solution may be required to clean severely coated coupons.

5. Immerse the coupon in saturated sodium bicarbonate (NaHCO3) solution for one (1) minute to
neutralize the acid.

6. Rinse the coupon immediately in isopropyl alcohol or acetone to dry. BE CAREFUL WITH
ISOPROPYL ALCOHOL and/or ACETONE!…..they are volatile flammable solvents.
6 Chapter 4

7. Weigh the coupon to 0.1 milligrams (0.0001 grams). Pit depths may be measured with a depth
gauge or micrometer caliper with sharp pointed probes. A microscope calibrated for depth
measurement may also be used. (Depth of deepest pit – in mils, inches, or micrometers – times
(x) 365 and divided by exposure time in days will give an effective calculation of pitting rate).

8. Be sure serial numbers are matched; compare weight loss with coupon weight sheet data for
differential.
 7

Chapter 5
Coupon Holder Assemblies
(Refer to Figure 2):

IMPORTANT NOTE: If fitting of corrosion coupons to coupon holder assemblies or coupon

holder assemblies to solid plug assemblies is being conducted on lines where installation and
retrieval are to be done under pressure; first, see Manual P/N: 600000-MANUAL – Retriever
and Service Valve Manual, and in particular Section 5 thereof!

All Cosasco Coupon Holder Assemblies attach to the bottom of the solid plug assembly in the
same manner. Procedures for their attachment are as follows:

1. Unscrew and remove the solid plug assembly from the access fitting body.

2. Loosen the anti-vibration Allen head set screw on the bottom of the solid plug assembly. The
set screw is the locking device on the solid plug nut. The solid plug nut acts as a primary packing
retainer until a corrosion monitoring or preventing device is attached.

3. Remove the solid plug nut from the bottom of the solid plug assembly. (Note that this is a left-
hand threaded nut).

4. Attach the coupon holder assembly on the exposed threads at the bottom of the solid plug
assembly, while leaving the primary packing in place. Again, remember that it is left-hand
threaded.

5. Compress the coupon holder assembly against the primary packing by tightening up to not
more than 1/4 turn after making initial contact with the packing.

6. Lock the coupon holder assembly securely to the solid plug assembly by tightening the anti-
vibration Allen head set screw.

7. Assemble the coupons on the coupon holder assembly. (Some special coupons and their
holders, such as prestressed and basket, are already assembled to their respective holders when
they are received from the factory).

Ensure that the coupons are completely insulated from mounting screws, nuts, and coupon
holders. AGAIN, DO NOT HANDLE COUPONS WITH THE BARE HAND! Be sure and use
the proper insulation and mounting hardware when assembling the coupons to the coupon holder.

Cosasco mounting hardware (for all single disc coupons this is actually a Nylon screw) is
furnished with the coupon holder assembly. Insulation strips and bolt hole shoulders for all strip
coupons are furnished with the coupons. Insulation discs, o-rings and coupon-to-coupon spacers
for all multiple disc coupons are furnished with the multiple disc coupon holder assembly.
8 Chapter 5

8. Index the hex head of the solid plug assembly by making a reference mark to indicate the
position or orientation of the coupon placement. This can be done either by center-punching an
indentation or by filling a notch across the hex head of the solid plug assembly assuring
alignment with the narrow edge of the strip coupon. (Not a required procedure for disc coupon
holder assemblies, since their positioning is in the horizontal plane in relation to product flow).

9. The coupon holder assembly, with its attendant coupons, is now ready for installation into the
access fitting body. Remember!….IF INSTALLATION IS TO BE ON LINES OR VESSELS
WHILE THEY ARE OPERATING UNDER PRESSURE, see Manual 600000-MANUAL –
Retriever and Service Valve Manual, Section 5.

FIG. 2 TYPICAL COUPON HOLDERS

 9

Chapter 6
Corrosion Coupon
Positioning & Orienting
Strip coupons require orientation. They should be exposed narrow edge in line with product flow
or so that the broad face of the strip coupon does not confront the product flow. Rod coupons
may, or may not, require orientation depending upon the number of rod coupons used in a single
application. Disc coupons do not require orienting for reasons indicated in paragraph 8 of the
preceding section.
10

Chapter 7
Corrosion Coupon
Weight Loss Measurement
(Refer NACE Standard TM-01-69 and RP-07-75):

The use of any criteria in determining corrosion rates or weight loss requires judgment on the
part of the user and should be tempered by economic and safety requirements. Some rate
expressions assume a uniform loss of metal. Experience has shown that coupons rarely exhibit a
uniform loss of metal. Variables on the coupon surface in the form of pitting, and/or localized
concentrated corrosion along grain boundaries, or in transgranular paths usually appear.

In determining weight loss there are a number of ways of expressing measurements. The ultimate
goal of any way of expressing weight loss or corrosion rate is to have a readily definable and
communicable way of determining and expressing the amount of metal or alloy that has corroded
or been “eaten away” by the corrosion process.

The following are some of the commonly used methods to report or express corrosion rate data:

1. General Corrosion Rate (Figure 3).

2. Average Corrosion Rate (Figure 4).
3. Percent Change (Figure 5).
4. Engineering System (mils-per-year – Figure 6).
5. Metric System (mdd or milligrams per square decimeter per day – Figure 7).
6. Pitting Rates (Figure 8).

FIG. 3 GENERAL CORROSION RATE CLASSIFICATIONS

Classification Expression
Poor (sample shape and exposure Percent weight change
time influence results)

Good (Expressions do not give Milligrams per square decimeter per day (mdd)
penetration rates) Grams per square decimeter per day
Grams per square centimeter per day
Grams per square meter per hour
Grams per square inch per hour
Better (Expressions give Inches-per-year (ipy)
penetration rates) Inches-per-month
Millimeters-per-year (mmpy)
Best (Expresses penetration rates Mils-per-year (mpy) – Is equivalent to one
without decimals or large numbers) thousandth of an inch per year
Chapter 7 11

FIG. 4 AVERAGE CORROSION RATE CLASSIFICATIONS

Average Corrosion Rate Average Pitting Rate
Classification
mpy µm/a mils/yr µm/a
Low 1.0 25 12 305
Moderate 1.0 - 4.9 25 - 125 12 - 24 305 - 610
Severe 5.0 - 10.0 126 - 254 25 - 96 635 - 2438
Very Severe 10.0 - 254 - 96 - 2438 -

mpy = mils-per-year (one thousandth of an inch per year or 0.001”)

µm/a = micrometers per annum (one thousandth of a millimeter per year or
0.000001; is equivalent to 0.04 mpy)

FIG. 5 PERCENT CHANGE

Original Value minus Final Value
Divided by
Original Value…………X 100 = Percent weight change

FIG. 6 ENGINEERING SYSTEM

Commonly used unit of corrosion rate expression measuring Dimensional Change or Loss of
Metal Thickness per Unit Time and referred to as mils-per-year (mpy). A mil is one
thousandth of an inch or 0.001”; if multiplied by 1000 is the same as inches-per-year or (ipy).

Formula 1: mpy = 534 x W W = Weight loss in milligrams

DAT D = Density of coupon in grams divided by
cubic centimeters (g/cm3)
A = Area of coupon in square inches (in2)
T = Time exposed in hours
Formula 2: mpy =
Weight loss of coupon (g) x 1000 (mils/in) x 365 (days/yr)
Density of metal (g/cm3) x 16.4 (cm3/in3) x area (in2) x days exposure

or
The weight loss of the corrosion coupon divided by the quantity of the product of the
metal density, the total exposed surface area (including sides) and the exposure time.
12 Corrosion Coupon Weight Loss Measurement

FIG. 7 METRIC SYSTEM

Commonly used unit of corrosion rate expression measuring Weight Change or Weight Loss or Gain per Unit
Area per Unit Time and referred to as milligrams per square decimeter per day or “mdd”. A milligram is one
thousandth of a gram; a decimeter is 10 centimeters or almost four inches. If mdd is multiplied by 0.03652/D (D
= density in grams per cubic centimeter or g/cm3) it is the same as millimeters per year or “mmpy”.

Formula 1: mmpy = 87.6 x W W = Weight loss in milligrams; D = Density of coupon in grams divided by
DAT cubic centimeters (g/cm3); A = Area in square centimeters (cm2); T = Time
exposed in hours

Formula 2: mdd = Weight loss coupon (g) x 1000 (=mg) x 100 cm2 (=dm2)
Area (cm2) x exposure time in days

FIG. 8 PITTING RATES

Pit depths may be measured with a depth gauge or micrometer caliper with sharp pointed probes. A microscope
calibrated for depth measurement may also be used. Depth of deepest pit in mils, inches or micrometers times (x)
365 and divided by exposure time in days will give an effective calculation of pitting rate.
 13

Chapter 8
Charts and/or Tables –
Useful Conversion Factors and Metal Densities

FIG. 9 COMMON METAL ALLOYS AND THEIR DENSITIES

3
Aluminum Alloy g/cm Copper Alloys (cont’d) g/cm3 Ferrous Metals g/cm3 Nickel Alloys g/cm3
1100, 3004 2.72 Cartridge brass 260 8.52 Gray cast iron 7.20 Nickel 200 8.89
1199, 5005, 5357, 6061, Muntz metal 280 8.39 Carbon Steel 7.86 Monel Alloy 400 8.84
6062, 6070, & 6101 2.70 Admiralty 442, 443, Silicon iron 7.00 Inconel Alloy 600 8.51
2024 2.77 444 & 445 8.52 Low alloy steels 7.85 Incoloy Alloy 825 8.14
2219, 7178 2.81 Aluminum brass 687 8.33 Stainless steels: Hastelloy B 9.24
3003, 7079 2.74 Bronzes: 201, 202, 302, 304, “ C 8.93
5050 2.69 Aluminum bronze 5% 608 8.16 304L & 321 7.94 “ G 8.27
5052 & 5454 2.68 Aluminum bronze 8% 612 7.78 309, 310, 311, 316,
5083, 5086, 5154, & Composition M 8.45 316L, 317, 329, & 330 7.98 Other Metals
5456 2.66 Composition G 8.77 347 8.03 Silver 10.49
7075 2.80 Phosphor bronze 5% 510 8.86 410 7.70 Tantalum 16.60
“ “ 10% 524 8.77 430 7.72 Tin 7.30
Copper Alloys 85-5-5-5 8.80 446 7.65 Titanium 4.54
Copper 8.94 Silicon bronze 655 8.52 502 7.82 Zinc 6.52
Brasses: Copper Nickels 706, Durimet 20 8.02
Commercial brass 220 8.80 710 & 715 8.94 Carpenter 20 Cb 3 8.05
Red Brass 230 8.75 Nickel Silver 752 8.75
14 Chapter 8

FIG. 10 SHORT FORM CONVERSION FORMULAS

To get mpy and/or mdd:

Multiply By = mpy By = mdd

Grams per square inch per hour 536,300.0/D* 372,000.0
“ “ “ “ day 22,270.0/D* 15,500.0
“ “ “ “ “ year 61.0/D* 42.5

“ “ centimeter per hour 3,460,000.0/D* 2,400,000.0

“ “ “ “ “ day 143,700.0/D* 100,000.0
“ “ “ “ “ year 394.0/D* 274.0

“ “ meter per hour 346.0/D* 240.0

“ “ “ “ day 14.37/D* 10.0
“ “ “ “ year 0.0394/D* 0.0274

Ounces “ “ inch per day 632,160.0/D* 439,200.0

“ “ “ foot “ 4,390.0/D* 3,052.0

Centimeters per year 394.0 274 x D*

Millimeters “ “ 39.4 27.4 x D*

Inches per year 1,000.0 696.0 x D*

Mils-per-year ------------- 0.696 x D*
Milligrams per square decimeter per
day 1.437/D* ------------

Note: D* is density of metal in grams per cubic centimeter-g/cm3

 Conversion Factors 15

FIG. 11 CONVERSION FACTORS

To obtain Multiply By
Grams per square inch per hour Milligrams per square decimeter per day (mdd) 0.00000269

Grams per square meter per day “ 10.0

Grams per square meter per year “ 36.5

Inches per year “ 0.00144/D*

Milligrams per square decimeter per day Grams per square inch per hour 372000.0

“ Grams per square meter per year 0.0274

“ Pounds per square foot per year 133.8

Milligrams per square decimeter Ounces per square foot 3052.0

Millimeters per year Milligrams per square decimeter per day (mdd) 0.03652/D*

“ Grams per square meter per day 0.36525/D*

“ “ 365.25/D#

“ Inches per year 25.4

Ounces per square foot Milligrams per square decimeter 0.0003277

Pounds per square foot per year Milligrams per square decimeter per day 0.00748

Note: D* is density of metal in grams per cubic centimeter (g/cm3)

D# is density of metal in kilograms per cubic meter (kg/m3)