Corrosion Coupons

Installation
Engineering Judgment

Hadi Veyse - Oil Processing & Transportation Superintendent

Preface

There are some recommendations regarding the location of corrosion coupons in some documents,
such as NACE SP0775; however, there is not any commendation concerning the position of access
fittings. Some experiences regarding the corrosion monitoring and management were introduced 6
o’clock as the most suitable position for the installation of access fitting assemblies.

Some disadvantages of the 6 o’clock position:

In some cases, this position is not accessible. Installing the access fitting at the 6 o’clock position in
systems with a fluid stream prone to sedimentation may cause some difficulties. In these systems,
accumulation of dense and compact sediments may result in lack of pressurizing of the retriever
column during the first stages of opening. This can be resolved by applying a back pressure.
However, the sedimentation of very dense and compact deposits is a little unexpected. It is
noteworthy that this issue is not relevant and will not be problematic in the case of systems that are
serviced by a hydraulic retriever.

Reference: Access-Fitting Position in Corrosion Management Programs By Hadi Nikpoo and

Mohammad Hossein Allahyarzadeh
 Guidelines:
Standard & Practice Designs
Saudi Aramco SABP-A-019
Pipeline Corrosion Control
Types of Metal Loss Coupons

The coupons can be designed to intrude some distance into the fluid as in the strip coupons (intrusive
styles) or be flush mounted with the surface of the pipeline as shown in Figure:

Generally, strip coupons are the most economical, provide satisfactory corrosion rate data, and are
adequate for most applications unless particular problems, such as scraping or orientation, are
encountered:

The most common fitting, known as a 2 inch access fitting, has a 2 inch opening through it and can
be purchased to contain pressures as high as 6,000 psig.
Corrosion Monitoring Location, Insertion & Orientation

In general, the selection of monitoring method and location of monitoring points shall take into
consideration system criticality, exposure environment corrosivity, water content and salinity, scarping
facilities and maintenance.
The monitoring point upstream of the corrosion inhibitor injection can monitor the uninhibited fluids
(worst case exposure). Where the downstream monitoring location provides information on the
treated system corrosion rates:

Coupons/probes for corrosion monitoring shall be located where there is a high probability of
corrosion taking place, e.g., bottom of line in stratified flow pipeline, top of line in condensing pipeline
and elsewhere in the corrosive phase. In oil pipelines, periodically stratified flow conditions can
develop at low flow rates where the brine separates from the oil leading to an increase in corrosion
activity at the 6 o’clock position in the pipeline.
Corrosion Monitoring Location, Insertion & Orientation

Consequently, the orientation of a coupon/probe access point is generally most favorable at the 6
o’clock position as shown in Figure:

This assures that the coupon would be continuously wetted by any free water, which is being swept
along the bottom of the pipeline where the most likely location of corrosion since produced water
denser than crude oil. However, positioning conventional coupons/probes at the 6 o’clock position
reduces, or in some cases, eliminates accessibility to service operations, primarily insertion and
retrieval. The 6 o’clock position has the additional drawback of possible shielding due to the presence
of sediment or sludge in the pipe. Devices that extend into a pipeline flow stream may impact the
ability to perform periodic scraping. So, the coupons/probes shall be mounted flush with the wall for
scrapable pipeline.
Corrosion Monitoring Location, Insertion & Orientation

For safety reasons, a provision to install corrosion monitoring manifolds at the bottom of line position
(BOL) is recommended instead of connecting the access fitting direct to the pipe from bottom:
Saudi Aramco SABP-A-036
Corrosion Monitoring Best
Practice
Types of Corrosion Coupons

Coupons flush with the pipe wall are subject to less turbulence than coupons that protrude into the
flowing stream. Therefore, the flush-mounted coupons should provide information that is more
representative of corrosion on the pipe wall.
Common Coupon Holders with Different Access Fittings:
Location in the System

Corrosion and design engineers should collaborate to ensure that sufficient access fittings for
corrosion monitoring are included in the design of new facilities. In existing operating plants,
inspection records can identify corrosive areas. Replacement coupons should have the same
orientation as previous coupons.
The following locations for coupons should be considered:
 Stagnant fluid areas
 High-velocity fluid streams and impingement points
 Locations where water is likely to collect
Areas of Possible Water Accumulation in Hydrocarbon Lines:
 TOTAL GS EP COR 161
Internal corrosion and
erosion-corrosion monitoring:
Design and installation
Safety and Installation

For 2” size, hydraulic access fittings are mandatory for all new constructed facilities.
Intrusive probes and coupons installed on lines subject to pigging shall be systematically flush-
mounted.

As a minimum, access fittings shall be positioned with a 2 m long x 1 m diameter cylindrical clearance
from the access fitting, to allow easy access and safe operability of the retriever tool during the whole
installation/removal operation:

When several access fittings are installed at the same location, a minimum distance of 1 meter
between each fitting shall be provided.
Location

Corrosion monitoring systems shall be based on typical corrosion monitoring requirements (applicable
methods and effluents to be monitored) as summarized:

Monitoring devices shall be located, whenever possible, at a minimum distance of 2 m

upstream/downstream bends, reductions and any other item disturbing the flow.
Corrosion monitoring points aiming at assessing the efficiency of corrosion inhibition shall be installed
downstream corrosion inhibitor injection point with a minimum distance of 10 m for straight pipe
sections and 5 m for piping with complex geometry (2 tees or elbows, diameter change, etc.).
Position

When the 12 o'clock position is selected and the probe element or coupon is located close to the
pipe bottom, flow velocities shall be compatible with the selected monitoring system.
The design of probes/coupons inserted from top to bottom shall be verified by the probe/coupon
supplier, using wake frequency calculations based on the methods indicated in ASME PTC 19.3TW.
Such calculations are part of the supplier deliverables.
Sample Points shall always be installed at the bottom of horizontal lines.
 NACE SP0775
Preparation, Installation,
Analysis, and Interpretation
of Corrosion Coupons in
Hydrocarbon Operations
Recommendations and Important Considerations

Sampling points shall be installed at corrosion monitoring stations for sample collection for analysis.
This is beneficial for corrosion assessments and correlation between corrosivity of the process stream
environment and the corrosion/pitting rates from corrosion coupons or probes.

Accessibility considerations for corrosion monitoring stations:

Concrete Access Pits (1.8 m to 2 m height)
 BP GP 06-70
Corrosion Monitoring
Location

The corrosive phase is almost always an aqueous phase. Therefore, monitoring devices should be
located at positions most likely to have the presence of water. If corrosion is expected to occur at the
bottom of a horizontal line, the monitoring device should be located in that position. If water
condensation is expected, locating monitoring devices on top of the line should also be considered.

Access fittings should be located a minimum distance of seven pipe diameters downstream and a
minimum of three pipe diameters upstream of flow disturbances (e.g., bends, reducers, valves, orifice
plates, thermowells) for the measurement to be representative of most of the system.

Corrosion monitoring devices should be placed a minimum of five pipe diameters downstream of
treatment chemical injection points. Depending on the monitoring philosophy, additional monitoring
points upstream of production chemical injection (e.g., corrosion inhibitor, asphaltene inhibitor)
should be considered. Measuring corrosion rates before and after corrosion inhibitor injection is
important in assessing its efficiency. Some production chemicals can be corrosive to certain steels and
render corrosion inhibitors less effective if they are not fully compatible.
Monitoring Device Access

The total pressure of the system shall be considered for selecting access fittings:
 For systems of less than 10 barg, low pressure DN 25 (NPS 1) access fittings may be used.
 For high pressure systems from 10 barg to 137 barg, proprietary DN 50 (NPS 2) access fittings
shall be used.

The selected location shall have adequate clearance for the operation of the retrieval tool. Without
adequate clearance, the access fitting is unusable.

If possible, fittings should also be located in places of easy and safe access to personnel. Permanent
platforms should be provided for access to fittings more than 2 m above grade or deck level.
Corrosion Monitoring Principles

 Flush mounted coupons:

Flush mounted monitoring devices are designed such that the coupon or probe element is flush with
the inside of pipe or vessel wall.

a. These devices should be used for monitoring specific metal loss processes that occur
preferentially at the wall surface (e.g., low water cut situations, water dropout or condensation,
under deposit corrosion).
b. Flush mounted devices should be considered where pigging is required or where debris may
damage an intrusive device.
c. A back pressure procedure should be implemented for retrieving flush mounted devices located at
the bottom of the pipe, to prevent plugging or getting stuck.

 Intrusive coupons:
Intrusive devices protrude well into the process stream and are suited to measure the overall
corrosivity of the stream rather than the more specific phenomena that are targets of flush mounted
probes.

a. Intrusive devices should be considered to monitor process upsets in single phase, high wall shear
stresses, “worst case” situations, or in systems where fouling is likely.
b. In piggable pipelines, intrusive probes should be installed upstream of any pig launcher or
downstream of pig receivers. Otherwise, the probe shall be retrieved prior to each pigging
operation.
Corrosion Monitoring Selection

 Produced water injection systems

Produced water systems should use, as a minimum, corrosion coupons to monitor accumulated
uniform and localized corrosion. Intrusive coupons should not be used in lines that are pigged, or they
need to be withdrawn before pigging operations are undertaken. If corrosion under deposits is
possible, flush mounted coupons located at the bottom of the pipe and ideally at low spots should be
considered.

 Multiphase gas/oil/water pipeline

Multiphase systems should use, as a minimum:
1. Corrosion coupons located in the corrosive phase(s) to monitor accumulated uniform and localized
corrosion.
2. On-line corrosion monitoring technique(s) with response time(s) consistent with the defined
corrosion philosophy.
Intrusive coupons/probes should not be used in lines that are pigged, or they need to be withdrawn
before pigging operations are undertaken. Flush mounted coupons should be considered in low water
cut situation, under deposit corrosion, areas of water dropout or condensation, and where
maintenance pigging or well debris could mechanically damage the coupon/probe.

 Export quality crude oil pipeline

Systems transporting crude oil which may contain water and sediments should use, as a minimum,
flush mounted coupons located at the bottom of the pipe, in areas where water or solids may
accumulate (e.g., low spots, long horizontal sections at low flow velocities).

 Flowlines (oil, water and gas)

Flowlines in this context are pipelines carrying unprocessed fluids from the wellhead to the processing
facilities. At the wellhead, intrusive coupons can be used as the fluids will be well mixed. Further
down the line flush coupons may be preferred so as to reflect the corrosivity of any separated water.
Thanks for your attention