Handbook Corrosion & Sand Monitoring - ironhaven.nl · Handbook Corrosion Monitoring Version: June...

Ironhaven B.V. [email protected] Tel: +31 (0)85 2733501

Planetenweg 5

2132 HN HOOFDDORP The Netherlands

www.ironhaven.nl Fax: +31 (0)85 2733502

Handbook

Corrosion & Sand Monitoring

For oil and gas, process systems, water and internal pipelines

Electrical Resistance (ER) and Electrochemical (LPR and Corrtran)

Sand and Erosion Monitoring

2-inch Access System for Retrievable High Pressure Systems 2-inch Injection and Sampling Systems

Handbook Corrosion Monitoring

Version: June 2016


Planetenweg 5



of 49

1 CORROSION MONITORING ............................................................................... 4

1.1 Introduction .......................................................................................................... 4

1.2 Objectives of corrosion monitoring ....................................................................... 4

1.3 Innovation based on a long tradition ..................................................................... 5

2 ELECTRICAL RESISTANCE MEASURING ......................................................... 5

2.1 Metal loss measuring ........................................................................................... 5

2.2 SensCorr ER instrument ....................................................................................... 7

2.3 Megacorr ER ........................................................................................................ 8

2.4 ER probes 2-inch (2”) ........................................................................................... 8

2.5 Flush Spiral Element ER probe 2-inch .................................................................. 8

2.6 Flush Strip element .............................................................................................. 9

2.7 Tubular ............................................................................................................... 10

2.8 Sand and Erosion Monitoring ............................................................................. 10

3 ELECTROCHEMICAL (EC) CORROSION MONITORING ................................. 11

3.1 Basic theory ....................................................................................................... 11

3.2 Classic LPR measurement with ‘B-constant’ ...................................................... 11

3.3 Localized corrosion measurement ...................................................................... 13

3.4 Corrtran electrochemical instruments ................................................................. 15

3.5 Corrtran MV Aluminium Enclosure ..................................................................... 16

3.5.1 Corrtran MV Direct Mount for 1-inch probe ..................................................... 17

3.5.2 Corrtran MV remote for 2-inch probes............................................................. 19

3.6 SensCorr LPR/Corrtran ...................................................................................... 20

3.7 CorrTran® Aqua ................................................................................................. 20

3.8 LPR/Corrtran Electrochemical Probes 2-inch ..................................................... 21

3.9 LPR Flush probes 2-inch .................................................................................... 21

3.10 LPR Tubular/projecting probes 2-inch ................................................................ 22

4 COMBINED ER/EC/COUPON IN 2-INCH ACCESS FITTING ............................ 23

4.1 SensCorr combi (ER/LPR) ................................................................................. 23

4.2 Combined probe/coupon in one 2-inch access fitting .......................................... 25

4.3 Probe Cables ..................................................................................................... 26

5 COUPONS ......................................................................................................... 27

5.1 Disc Coupons ..................................................................................................... 27

5.2 Strip Coupons .................................................................................................... 27

5.3 Specialty coupons .............................................................................................. 28

5.4 Coupon Holders ................................................................................................. 28

6 INJECTION QUILLS ........................................................................................... 29

7 MECHANICAL 2-INCH ACCESS FITTING ......................................................... 29

7.1 Welded Mechanical ............................................................................................ 30

7.2 Flanges Mechanical ........................................................................................... 30

7.2.1 Flanges 2-inch 150# RF ................................................................................. 30

7.2.2 Flanges 2-inch 300# RF ................................................................................. 30

7.2.3 Flanges 2-inch 600# RF ................................................................................. 30

7.2.4 Flanges 2-inch 900# RTJ ................................................................................ 31

7.2.5 Flanges 2-inch 1.500# RTJ ............................................................................. 31

7.2.6 Flanges 2-inch 2.500# RTJ ............................................................................. 31

7.2.7 Flanges 2-inch API 10.000# ............................................................................ 31

7.3 Flanges Mechanical with Tee for injection and sampling .................................... 32

7.3.1 Flanges 2-inch 1-inch Tee 300# RF ................................................................ 32


7.3.3 Flanges 2-inch 1-inch Tee 900# RTJ .............................................................. 32


Version: June 2016


Planetenweg 5



of 49

7.3.4 Flanges 2-inch 1-inch Tee 1.500# RTJ ........................................................... 33


7.3.6 Flanges 2-inch 1-inch Tee API 10.000# .......................................................... 33

7.4 Plugs Mechanical ............................................................................................... 33

7.4.1 Hollow plug for probe ...................................................................................... 33

7.4.2 Solid plug for coupon ...................................................................................... 34

7.4.3 Solid plug for injection quill ............................................................................. 34

7.5 Mechanical covers .............................................................................................. 35

7.6 Sealings and Spare parts Mechanical ................................................................ 36

8 HYDRAULIC 2-INCH ACCESS-FITTINGS ......................................................... 37

8.1 Welded Hydraulic ............................................................................................... 37

8.2 Flanges Hydraulic............................................................................................... 38

8.2.1 Flanges 2-inch 300# RF ................................................................................. 38

8.2.2 Flanges 2-inch 600# RF ................................................................................. 38

8.2.3 Flanges 2-inch 900# RTJ ................................................................................ 38

8.2.4 Flanges 2-inch 1.500# RTJ ............................................................................. 38

8.2.5 Flanges 2-inch 2.500# RTJ ............................................................................. 38

8.2.6 Flanges 2-inch API 10.000# ............................................................................ 39

8.3 Flanges Hydraulic with Tee for injection and sampling ....................................... 39



8.3.3 Flanges 2-inch 1-inch Tee 900# RTJ .............................................................. 39



8.3.6 Flanges 2-inch 1-inch Tee API 10.000# .......................................................... 40

8.4 Plugs Hydraulic .................................................................................................. 40

8.4.1 Hollow plug for probe ...................................................................................... 40

8.4.2 Solid plug for coupon ...................................................................................... 41

8.4.3 Solid plug for injection quill ............................................................................. 41

8.5 Hydraulic Covers ................................................................................................ 41

8.6 Sealing and Spare parts Hydraulic ..................................................................... 42

9 RETRIEVAL TOOLS .......................................................................................... 43

10 CORROSIE MONITORING ASSEMBLY DRAWINGS ........................................ 44

10.1 Mechanical Access Fitting Flareweld with Probe ................................................ 44

10.2 Mechanical Access Fitting Flareweld with coupon .............................................. 45

10.3 Mechanical Access Fitting Flanged with Probe ................................................... 46

10.4 Mechanical Access Fitting Flanged with injection tube ....................................... 47

10.5 Mechanical Access Fitting for Sand probe .......................................................... 48

10.6 Hydraulic Access Fitting with Probe ................................................................... 49


Version: June 2016


Planetenweg 5



of 49

1 CORROSION MONITORING

1.1 Introduction Maintenance, inspection management and corrosion control are optimized by corrosion monitoring. Ironhaven B.V.. works with electrical resistance technology and the sophisticated electrochemical technology developed by Pepperl + Fuchs (Corrtran). Most common is the 2-inch access system, widely used for oil and gas production for more than 50 years. With the 2-inch access system the following retrievable can be achieved under high pressure (up to 420 bar or ASME 2.500#): - Insert and retrieval of ER probes and LPR (Corrtran) probes. - Insert and retrieval of coupons. - Insert and retrieval of injection quills and sample points. With its long term proven record, corrosion monitoring with probes and coupons is very reliable and certified for pressure equipment (PED) and electrical integrity (ATEX). We supply and commission such equipment, but more important, also guarantee the best data quality and results by our long term experience in the optimal use of such probes. The results of the probes, which nowadays mostly operate online to the DCS system (process computer), are translated to direct actions, such as an inhibitor injection, a process change or a change in the inspection interval.

1.2 Objectives of corrosion monitoring In oil and gas production, corrosion monitoring is a widespread tool for asset integrity management since the 1960’s. Also in refineries and process industry, corrosion monitoring is upcoming, particularly for (cooling)water systems. Since industrial sensors have been automated to a high degree, also corrosion monitoring has become a very easy way to collect data on assets integrity easily and reliable. Nowadays monitoring systems normally are online signals to the DCS (process) computer. Alarms can be set upon which specialists can take proper actions such as inspections, repair or change in corrosion inhibitor or process regime. As most process plants work with the Risc Based Inspection (RBI) philosophy, corrosion monitoring helps to increase inspection terms and safety. Besides, costs on inspection and maintenance as well as unnecessary production stops, are being avoided.

The objectives of corrosion monitoring are:

• Controlling the corrosion inhibitor regime.

• Performing inhibitor trials, testing new corrosion inhibitors.

• Collecting data for the RBI program, thus improving reliability of inspection and maintenance planning.

• Saving costs on inspections, maintenance and unnecessary production stops.

• Improving the asset integrity management system. Improving lifetime and sustainability of the process plant and pipeline assets.


Version: June 2016


Planetenweg 5



of 49

1.3 Innovation based on a long tradition Our people work with corrosion monitoring in oil and gas since the 1990’s. We use the traditional technology as a basis but have done several innovations on online electrochemistry measurements. These innovations are described in this brochure and have resulted in several patents. Besides we are the first company that combines the traditional ER and LPR technology with new electrochemical methods and coupons in one 2-inch probe. This method has been patented as well. Ironhaven B.V. service personnel has been certified for all offshore work and for safe working (HSE trainings).

2 ELECTRICAL RESISTANCE MEASURING

2.1 Metal loss measuring The basic principle of electrical resistance measuring is very straightforward: The electrical resistance of the corroding element is compared to a similar element that is not corroding but at similar temperature. In this way, resistance changes caused by temperature changes are being eliminated. The figure at the right shows the basic circuit for ER measurements. Basic scheme of Electrical Resistance (ER) Corrosion Monitoring. The Voltage drop over metal elements is amplified at very high resolution using Opamps (operational amplifiers). ER probes are made in large variety of configurations. However the 2-inch probes for the retrievable 2-inch access fittings are most widely used. The sensing element can be of flush, tubular or wire type. For probes, the element thickness is 0.25-5 mm. The thicker the element, the lower the sensitivity of measurement, but the longer the

lifetime. For high sensitivity, probe elements of 0,25 mm (sensitivity 0,05 µm) are used. For probes that require a lifetime long performance, normally probes up to 5 mm are used

(sensitivity 1 µm). The thickness of the probe element among others depends on the corrosion rate that is being expected. Buried ER probes are used for monitoring the outside of coated buried pipelines under cathodic protection. The function of the probes is to monitor the cathodic protection system and influences of AC currents and other stray currents from railroads, electricity transport and other cathodic protection systems.


Version: June 2016


Planetenweg 5



of 49

ER probe: basic principle of flush strip element.

The figure above shows an example of data output for a 2-inch high pressure probe, installed in a pipe for injection water on an oil platform. On November 9th 2011, the probe element had been corroded 336 µm and no significant metal loss occurred until November 20th . Between November 20th and December 4th the metal loss was 10 µm, which results in a corrosion rate of 0.26 mm/year. By injection of corrosion inhibitor the corrosion was stopped. A new high sensitivity online 4-20 mA ER meter was developed. The resolution of this meter for a 0,5 mm thick element is better than 0,05 micrometer.

Metal loss of an ER probe (2-inch, flush element, 1 mm thick).


Version: June 2016


Planetenweg 5



of 49

SensCorr ER sensitivity meter with 4-20 mA interface. Test during one day of carbon steel in artificial seawater at room temperature. From 8:30h till 16:00h the water was aerated, resulting into a steeper metal loss slope. Note the excellent measurement resolution of better than 0,05 micrometer.

2.2 SensCorr ER instrument The SensCorr ER is a very sensitive and robust ER meter with a 4-20 mA output for online measuring to the DCS. The instrument is powered by the 4-20 mA loop. For stand alone data logging, the instrument has an integrated battery holder and SD memory card holder. The data can easily be copied on a computer and spreadsheets graphs can be made. The instrument is ATEX certified.

9,00

9,20

9,40

9,60

9,80

10,00

10,20

10,40

19:12 0:00 4:48 9:36 14:24 19:12

Me

tal

Loss

(m

icro

me

ter)

time

Metal Loss

100 per. Zw. Gem. (Metal Loss)

Aeration

start stop


Version: June 2016


Planetenweg 5



of 49

Art. Nr. Description Material Specifications/remarks

70100316 SensCorr ER Enclosure in stainless steel 316

4-20 mA online to DCS and stand alone data logging with SD card.

70120001 Electronic Test Probe ER

Plastic enclosure With Amphenol 6 pin connection.

2.3 Megacorr ER Instrument for Electrical Resistance (ER) readings. Interface: 4-20 mA

2.4 ER probes 2-inch (2”) Like all 2-inch probes, ER probes resist a pressure up to 400 bar. The measuring principle can be obtained from paragraph 2.1. Probes are available in several implementations such as flush, tubular or high sensitivity. Normally, elements are made of carbon steel. However, on customer demand, elements can be made of any metal or alloy. ER probes only measure uniform corrosion and cannot measure localized corrosion properly. For measuring localized corrosion the 2-inch LPR probes are suitable. However you will need an electrolyte (water with salt) for electrochemical measurements whereas ER can even be used in dry air for measuring erosion.

2.5 Flush Spiral Element ER probe 2-inch The spiral allows thick sensing elements with an acceptable sensitivity. This gives this probe considerably longer service life than traditional ER probes. The probe is recommended for use where high corrosion rates are expected, or where inspection is more sporadic.


70605316 ER probe flush spiral 2-inch

Housing in stainless steel 316, element in carbon steel

p max = 420 bar (ASME 2500# flanged fitting)

T max = 180 °C


Housing in duplex stainless steel 2205, element in carbon steel


T max = 180 °C


Customized


T max = 180 °C


Version: June 2016


Planetenweg 5



of 49

2.6 Flush Strip element The strip design gives a high sensitivity. The probe is recommended for use where corrosion rates are expected to be low to moderate. As a standard we supply element thickness of 0,5 or 1 mm.


70615316 ER probe flush strip 2-inch

Housing in stainless steel 316, element in carbon steel, 0,5mm thickness


T max = 180 °C


Housing in duplex stainless steel 2205, element in carbon steel, 0,5mm thickness


T max = 180 °C


Housing in stainless steel 316, element in carbon steel, 1 mm thickness


T max = 180 °C


Housing in duplex stainless steel 2205, element in carbon steel, 1mm thickness


T max = 180 °C


Customized


T max = 180 °C


Version: June 2016


Planetenweg 5



of 49

2.7 Tubular The tubular probe design provides very good sensitivity combined with good temperature stability. Protective shields for the tubular element are available and are supplied in the same material as the probe element in order to avoid galvanic effects.

Art. Nr. Description Material Basic specifications

70625316 ER probe tubular 2-inch

Housing in stainless steel 316, element in carbon steel, 0,5mm thickness


T max = 180 °C


Housing in duplex stainless steel 2205, element in carbon steel, 0,5mm thickness


T max = 180 °C


Housing in stainless steel 316, element in carbon steel, 1 mm thickness


T max = 180 °C


Housing in duplex stainless steel 2205, element in carbon steel, 1mm thickness


T max = 180 °C


Customized


T max = 180 °C

2.8 Sand and Erosion Monitoring ER technology is a very good method for sand and erosion monitoring. For sand an erosion monitoring, a non-corroding element material is selected. For example Stainless Steel 316 or Monel K400. Sand and erosion monitoring can be done in an effective way.

Normally ER probes with a stainless steel 316 tubular element are used for sand- and erosion monitoring.

Also flush probes are used where the element is placed under an angle of 45° facing the flow direction. Normally the element of such sand probes is made of Monel K400.


70693316 ER Sand Probe tubular 2-inch

Housing in stainless steel 316, element in stainless steel 316


T max = 180 °C

70694316 ER Sand Probe

flush 45°

Housing in stainless steel 316, element in Monel K400


T max = 180 °C

70699900 ER Sand Probe Customized


Version: June 2016


Planetenweg 5



of 49

3 ELECTROCHEMICAL (EC) CORROSION MONITORING

3.1 Basic theory The Corrtran MV is a corrosion-monitoring device, which uses electrochemical techniques to measure the corrosion rate of the metallic material of process plants, pipelines and other. The aim of this section is to outline the basic principles of electrochemical corrosion theory as applied to electrochemical corrosion rate measurement and to discuss details of the implementation of these measurement techniques in the Corrtran MV. In contrary with ER technology, EC measuring always requires an electrolyte. An electrolyte is a fluid with dissolved salts or ions, normally water, acids, or bases or related electrolytic chemicals. Corrtran is a very sophisticated electrochemical instrument that uses several scientific approaches in order to get the best realistic information with regard to uniform and localized corrosion (pitting, crevice corrosion and stress corrosion cracking).

3.2 Classic LPR measurement with ‘B-constant’ Corrosion of metals usually occurs as electrochemical dissolution. The corroding metal surface supports at least two distinct electrochemical processes : the anodic and the cathodic reactions. At the anode, metal atoms oxidize to metal ions. The metal ions then either react further with the surrounding electrolyte to form soluble or insoluble corrosion products or simply diffuse away from the metal surface. The anodic process produces electrons. At the cathode, a corresponding reduction reaction takes place, consuming the generated electrons. In acid aqueous environments, the cathodic reaction is usually that of hydrogen evolution. In neutral and alkaline aqueous environments, the cathodic reaction normally is the reduction of Oxygen and water to OH- or the reduction of acid (H+) to Hydrogen gas. The rates of the anodic and cathodic process, the anodic and cathodic currents (not current densities) must match, as there can be no net build-up of electrons in the metal other than a minor quantity of electrons used for polarization of the metal. The anodic and cathodic reactions do not occur at the same point on the electrode surface. On a uniformly corroding electrode they will normally be at adjacent points on the metal surface and the anodic and cathodic areas will move in time on the electrode surface. In the case of pitting corrosion, a pit will act as the anode whereas the surrounding surface will be predominantly cathodic. The relative sizes of the anodic and cathodic areas are important, as the rate of penetration is determined by the anodic current density (current per unit area). In the case of pitting corrosion a large cathodic area of a relatively small cathodic current density may support a high anodic current density (and hence high penetration rate) in the small anodic area of the active pit. The linear polarization resistance is the electric resistance of the system against a small Voltage change of the system. The higher the resistance, the lower the corrosion current, the lower the corrosion rate. In accordance with Ohms law:

�� ∆�

∆�

Rρ= Linear Polarization Resistance (LPR), Ohm.

∆E= Change in electrochemical potential (Voltage), mV.

∆L= Current density (mA/cm2). This is the Stern-Geary equation, which forms the basis for the linear polarization resistance method of corrosion rate measurement. It simply states that the corrosion current may be calculated from the slope of the potential-current curve at the free corrosion potential (polarization resistance, Rp); the proportionality constant (Stern- Geary constant, B) being related to the Tafel slopes.


Version: June 2016


Planetenweg 5



of 49

Once the corrosion current (Icorr) is known, it is simple to calculate the thickness of metal dissolved from a given electrode area in a given time period : the penetration rate.

penetrationrate � Icorrxatomicweightxtime

Faradayconstantxvalencyxdensityxarea

Penetration (or corrosion rate) is usually presented in the units of mm/year or mils/year (mpy). In real conditions the pure activation control assumed in these calculations may not apply – the rates of the anodic, cathodic or both processes may be limited by factors such as the rate of movement of reacting species to and from the electrode surface. The above equations may then be modified to take diffusion (also termed concentration polarization) control of one of the reactions into account - the Tafel constant of the diffusion limited process will tend to infinity. For example, if the cathodic process is diffusion limited then:

�� !"

2.3x

1

�'

It is important to note that all of these forms of the Stern-Geary equation assume that the areas of the anodic and cathodic processes are equal – this will rarely be the case in practice. The Stern-Geary constant usually lies somewhere in a relatively narrow range of between about 10 and 50 mV, with 20 mV being a typical value. There are a number of methods available for the determination of the Stern-Geary’s constant exact value. A commonly used approach is to estimate its value by comparison to weight loss measurements. This method however cannot track any changes in the chemistry of the corrosion process. An alternative approach is to measure the electrode response over a relatively wide range of applied potentials and then to use mathematical curve fitting to estimate the Tafel slope values. Harmonic Distortion Analysis for measuring ‘B-constant’. Harmonic distortion analysis (HDA) relies on a particular property of the mathematical description of the electrode potential-current response (the difference of two exponential curves), namely that the curvature of the response is such that if a sinusoidal potential perturbation is applied to the electrode then the current response will contain harmonics of the applied sine in proportions related to Icorr and to the Tafel slopes. A dynamic measurement, such as when using a sine potential perturbation, requires a consideration of the frequency domain response of the corroding interface. In reality the metal-electrolyte interface is not purely resistive, but has a frequency dependent reactive component caused by the interfacial double layer capacitance and by mass transport (diffusion) effects. To a first approximation the metal-electrolyte interface has a response of an equivalent circuit of this form :

Rs is the ohmic resistance of the electrolyte, Rp is the polarization (charge transfer) resistance, CDL is the interfacial double layer capacitance and X is an element representing the response of other processes, such as diffusion etc. At high frequencies the impedance of CDL will be low, effectively shorting the parallel components Rp and X, and the measurement will detect mainly Rs. Similarly, at low frequencies the series combination of Rs, Rp and X will predominate.


Version: June 2016


Planetenweg 5



of 49

Harmonic distortion analysis determination by applying a sine-wave on potential (Voltage) and measuring the cell current (Ampere).

3.3 Localized corrosion measurement In practical situations the corrosion attack is often not uniform. Localized corrosion (such as pitting attack, crevice corrosion, stress corrosion cracking etc.) can occur and can lead to considerably higher local penetration rates than those of general (uniform) corrosion. Perturbative electrochemical measurements average over the area of the test electrode. For example a small pit of a high corrosion current density (high corrosion rate) may exhibit a Rp similar to that of a large area of low corrosion current density (low corrosion rate), making it impossible to distinguish the two by an external measurement. Electrochemical noise techniques measure the time fluctuations of either the corrosion potential (Ecorr) or of the current between two ‘identical’ electrodes to give a qualitative estimate of the degree of localization of the corrosion attack process. Electrochemical potential noise measurement relies on the detection and analysis of time fluctuations of the corrosion potential (Ecorr).

Potential (and current) between elecrodes constantly fluctuate in small magnitudes of 1-10 mV (electrochemical noise). The higher the amplitude of the noise, the more likely localized corrosion will occur, the higher the fluctuations, the more more noise you will see. Every fluctuation is an upcoming break-through of the passive layer on the alloy surface. The corrosion potential is measured as the potential difference between the test electrode and a second, stable, reference electrode (half-cell). As outlined above, the corrosion potential is an

Harmonic Distortion (ba = bc = 60mV)

-0.020

-0.015

-0.010

-0.005

0.000

0.005

0.010

0.015

0.020

0 1 2 3 4 5 6

Time [rad]

Vo

ltag

e [

V]

-1.69E-06

-1.19E-06

-6.90E-07

-1.90E-07

3.10E-07

8.10E-07

1.31E-06

Cu

rre

nt

[A]

Applied voltage [V]

Cell current [A]


Version: June 2016


Planetenweg 5



of 49

equilibrium value at which the anodic and cathodic currents are equal (though opposite in polarity). Any short term fluctuations of the rates of these two processes will cause a corresponding change in the corrosion potential. Consider for example a metal surface covered with a passive oxide film where a localized dissolution event (such a break in the passive film due to mechanical stress) occurs. The defect area will momentarily become anodic as the exposed base material reacts with the electrolyte and the passive film reforms. This increase in the anodic current will cause a corresponding momentary increase in the cathodic current drawn from the remaining passive surface and the overall potential of the electrode will change to a new value at which the anodic and cathodic current are again equal. The corrosion potential fluctuations are usually of a low magnitude (µV to mV) and of a low frequency (< 1Hz). Different morphologies and types of localized corrosion attack give rise to different time variations of the corrosion potential. For example passive film breakdown is characterized by sharp corrosion potential changes, each followed by a slower exponential recovery, whereas crevice corrosion tends to cause almost periodic fluctuations. Electrochemical current noise measurement uses the detection and analysis of fluctuations of a current between two nominally ‘identical’ electrodes connected through a low resistance current measuring device such a ‘zero resistance ammeter’ (ZRA). If the two electrodes are undergoing uniform corrosion then the measured current will be very low or zero, since the anodic and cathodic areas will be intermixed and evenly distributed over each of the electrodes. Electrons from a particular microscopic anode site will travel only a short distance to the nearest cathodic site, most likely located on the same electrode. The situation will be different if localized corrosion attack occurs. For example a break in a passive oxide film on one of the electrodes will cause current flow not just between the defect site on that electrode and the surrounding passive cathodic area, but also between the defect site and the still passive cathodic area of the other electrode. This current can then be measured and analyzed as electrochemical current noise. It is generally difficult to quantify electrochemical potential or current noise measurements as to relate them precisely to the morphology or rate of the localized attack. Empirical, qualitative, approaches are usually used. For example the standard deviation of electrochemical potential noise can be used to describe the intensity of (or propensity to) localized corrosion attack. In the case of electrochemical current noise a similar descriptor may be calculated from the mean (d.c.) current between the two electrodes and from the standard deviation of its fluctuations.

(��)(i*+,�� *-�.-.,+/ � *0).,) ,,+1-)0-�.�2�3 +.0

4*1)(3+�2�3 +.0


Version: June 2016


Planetenweg 5



of 49

3.4 Corrtran electrochemical instruments The Corrtran has been developed by Pepperl + Fuchs.

With regard to measurement principle and data interface (4-20 mA HART), Corrtran MV and Corrtran Aqua are identical instruments. The Corrtran MV is delivered in an aluminium housing (ATEX) or stainless steel housing (ATEX) for offshore applications. The Corrtran Aqua is for cooling water and other water and is delivered in a non-ATEX plastic (ABS) housing. A three electrode test cell configuration with a potentiostatic circuit cell control is used, as this offers the best possible control of the potential of the test electrode and of the applied electrochemical perturbation. In a potentiostatic arrangement the test cell is placed in the feedback loop of an amplifier. The feedback arrangement controls the applied potential difference between the test electrode (WE) and the reference electrode (RE) by supplying a polarization current through the third, auxiliary electrode (AE). The advantage of this arrangement over the sometimes-used simple two-electrode probe is that it eliminates any contribution of the reference and auxiliary electrode processes to the measurement result. This is especially important when a dynamic measurement technique such as HDA is used. The Corrosion Transmitter uses the combination of linear polarization and harmonic distortion analysis (HDA) for corrosion rate measurements. Unique for the corrosion transmitter is that it uses HDA for measuring the B-value, making this ‘constant’ floating. During corrosion measurements the B-value is optimized. Electrochemical current noise (ECN) is applied for localized corrosion detection. The more current and potential noise, the more localized corrosion activity. The corrosion transmitter uses a small amplitude sine wave (20 mV peak to peak) of a frequency of 0.1 Hz as the perturbation waveform. This is generated as a series of small voltage steps (96 per cycle). 20 cycles of this perturbation are applied to the probe test electrode, the resulting cell current is measured using an accurate analog to digital converter and analyzed by discrete Fourier transform algorithms to give the amplitude of the response both at the applied frequency and at the harmonic frequencies. The corrosion transmitter uses a high frequency (200 Hz) measurement to determine the electrolyte resistance Rs. The amplitude of this waveform is adjusted during the measurement to between 2 and 50 mV peak to peak, in order to make the best use of the dynamic range available in the circuitry. The measured conductance is available as one of the output variables. As Rs includes the resistance of any film present on the electrode surface, it may be used to monitor scale and film formation. The corrosion transmitter circuitry is capable of carrying out both potential and current electrochemical noise measurements. Electrochemical current noise is more suited to the detection of localized attack propagation and is used as the default technique to calculate a dimensionless and normalized ‘localized corrosion index’ variable, ranging from between zero and one. During the noise measurement the test (WE) and the auxiliary (AE) electrodes are effectively connected together through a small current sensing resistance. The coupling current between the two electrodes is sampled at regular intervals and its mean and standard deviation values are calculated using a running moment algorithm which avoids the need for intermediate storage of the measurement data. As default, during the noise measurement, corrosion transmitter uses a one second sampling rate and a time record length of 1000 samples.


Version: June 2016


Planetenweg 5



of 49

At the end of the noise measurement period the localized corrosion index is computed as the ratio of the standard deviation of the current fluctuations to the root-mean-square (rms) value of the same data. Tests carried out during the electrochemical corrosion transmitter development have shown that this ratio usually exceeds a value of about 0.3 for electrodes undergoing localized corrosion. The figure on the next page shows the corrosion behavior of stainless steel AISI 316 in water with 0,01M sodium chloride, during a temperature scan up to 60°C and back to 20°C. Clearly the pitting temperature is shown by the corrosion transmitter.

Output of corrosion transmitter during laboratory measurement of stainless steel AISI 316 in water with 0,01M sodium chloride. Red line: uniform corrosion. Green line: localized corrosion. At value >0,5 corrosion mainly will be localized distributed (mainly pitting corrosion in this case).

3.5 Corrtran MV Aluminium Enclosure

Corrtran is available in two basic mechanical configurations; direct or remote mount. The direct mount is used for 1-inch probes with Swagelock system and the remote system is required for the 2-inch probes with 2-inch Access Fitting System.

0,0

0,2

0,4

0,6

0,8

1,0

20

30

40

50

60

70

80

90

100

25 225 425 625 825 1025 1225

pr.

: te

mp

era

ture

. se

c. c

orr

osi

on

ra

te

an

d l

oca

lise

d c

orr

osi

on

Time (minutes)

Corrtran Corrosion Measurement

Temperature [°C]

Uniform corrosion [μm/y]

Localised corrosion


Version: June 2016


Planetenweg 5



of 49

3.5.1 Corrtran MV Direct Mount for 1-inch probe

A direct mount version is always configured with a 1-inch probe either high pressure (max 90 bar) or low pressure (max 10 bar). The transmitter’s electronic housing has been secured directly to the probe while the remote version allows the housing to be mounted up to 3 meters from the probe. The direct mount version is considered the standard unit for most applications due to its rugged construction, while the

remote mounted Corrtran is most suited for space-critical applications. The electronic housing is built of rugged aluminum with two ¾ “ NPT electrical connections for easy wiring. Once inside the housing, the electronics are completely enclosed within a plastic housing for superior protection. The 1-inch probes on the direct mount Corrtran MV can either be fixed or adjustable in length. The underlying scientific data of the Corrtran MV can be downloaded using a HART modem. Besides, the Corrtran MV can be programmed with this HART modem.

Pepperl + Fuchs Hart Loop converter for converting the digital HART signal in 3x analogue 4-20 mA signals. NOTE: The

Corrtran 4-20 mA HART signal also can be directly plugged in a DCS HART interface card.

Right: Pepperl + Fuchs Corrtran transmitter

head.


Version: June 2016


Planetenweg 5



of 49

Art. Nr. Description Material Basic specifications

70200110 Corrtran MV instrument and transmitter head

Enclosure in aluminium

Measures uniform and localized corrosion. Sophisticated online electrochemical instrument. 4-20 mA HART interface.

70400111 HART loop converter Plastic

Electronic 4-20 mA-HART interface. Transfers digital HART signals to analogue 4-20 mA signals. ATEX barrier. Placement in the instrument cabinet.

70410111 HART modem Plastic

For communication, programming and download with a Windows PC. Modem.

70420316 1-inch probe. Electrodes excluded

Stainless steel housing p max = 90 bar

70420111 1-inch probe. Electrodes excluded

Epoxy houder p max = 90 bar

70430052

Probe electrodes, replaceable (set of 3)

Carbon steel St. 52N

Element surface: xxcm2. Work drawing upon request

70430304 Stainless steel 304

70430316 Stainless steel 316

70430205 Duplex stainless steel 2205

70430900 Customized


Version: June 2016


Planetenweg 5



of 49

3.5.2 Corrtran MV remote for 2-inch probes

The Corrtran remote is the standard Corrtran MV transmitter head mounted on a bracket. The probe is connected to the transmitter head with a probe cable. The Corrtran MV remote is used if 2-inch LPR/Corrtran probes are being installed.


70201110 Corrtran MV remote instrument and transmitter head

Enclosure in aluminium


70201316 Bracket for Corrtran MV remote

Stainless steel 316





70211110

Probe cable flexible. For 2-inch LPR/Corrtran MV probes with probe adapter and Amphenol (F)

Cable: HDPE 6x24 AWB OK 5,9mm Length 3 meter


Version: June 2016


Planetenweg 5



of 49

3.6 SensCorr LPR/Corrtran The SensCorr is a Corrtran instrument build in a Stainless Steel housing and ATEX certified.


70200316 SensCorr LPR/Corrtran Enclosure in Stainless Steel 316






3.7 CorrTran1® Aqua The CorrTran Aqua is a compact 4-20 mA corrosion transmitter used to detect general corrosion, localized corrosion, and conductance in cooling water and the water quality industry. The transmitter measures the corrosion rate and pitting factor. The readout is given in mil/year or a 0 - 1 pitting factor, respectively. It also provides a conductance measurement. The readings are taken in real-time and are updated in intervals of approximately 34 minutes. At the completion of each measurement cycle, the respective corrosion rate and pitting value in the form of a 4-20 mA/HART signal is produced and made available to the plant personnel. The CorrTran Aqua is sold as a complete kit. The CorrTran enclosure, cable, probe, and electrodes are all included. The CorrTran Aqua transmitter will monitor general corrosion, localized corrosion (pitting), and conductance through a 4 mA-20 mA signal and HART protocol in real-time. The corrosion rate or a pitting factor is configured as the primary variable using a standard 2-wire 4 mA-20 mA output. The remaining outputs are configured as secondary and tertiary HART variables. The probe is available in a three-electrode configuration with a wide selection of probe types and electrode materials.

® is a Trade Name by P+F1


Version: June 2016


Planetenweg 5



of 49

CorrTran Aqua multivariable output via HART allows monitoring of general corrosion, localized corrosion, and conductance using one transmitter. To utilize all three variables, a HART-compatible device must be used. If none is available, the interface unit will translate the HART signal into three separate, independent 4 mA-20 mA outputs. Using HART, the primary variable "PV", the secondary variable "SV", and the tertiary variable "TV" are available, and the user has the option of making either general or localized corro sion as the primary variable. Conductance cannot be changed and always is the tertiary variable. Because of the unique algorithm of the calculation method, the Stern-Geary B value is automatically updated during every measurement cycle. No calibrating in the field or updating this value is required. Through the HART signal, the updated B value can be acquired.


70300018

Corrtran Aqua Basic. Epoxy probe included. Probe elements excluded/

Enclosure in ABS


70301018

Corrtran Aqua with LCD Display. Epoxy probe included. Probe elements excluded/

Enclosure in ABS




70410111 HART modem Plastic For communication, programming and download with a Windows PC. Modem.

3.8 LPR/Corrtran Electrochemical Probes 2-inch Corrtran electrochemical probes always contain 3 electrodes: The working electrode, the reference electrode and the counter electrode. For electrochemistry settings it is important to know the surface area of the electrode. This will be mentioned in the probe certificate.

3.9 LPR Flush probes 2-inch Similar to ER probes, LPR/Corrtran probes can be delivered flush to the pipe wall. This is important for picking up corrosion of dropped out water at 6 o’clock, but besides that, flush is needed when pipes or pipelines are being pigged.


Version: June 2016


Planetenweg 5



of 49


70705316 LPR probe flush 2-inch, 3 elements


P-max = 420 bar (ASME 2500# flanged fitting)

T max = 180 °C



p max = for API 10.000# flanged fitting.

T max = 180 °C


Customized p max = for API 10.000# flanged fitting.

3.10 LPR Tubular/projecting probes 2-inch Projecting probes are used for applications with water. This can be either seawater, brackish water, produced water, surface water, tap water, cooling water, waste water, brewing water, water in the food industry and many other types of water. This type of probes also gives possibilities to measure other electrochemically-influenced processes than corrosion. In this way it is possible to measure biofilm formation, effect of chlorination and biocides, scaling formation and other applications.


70715316 LPR probe tubular/projecting 2-inch, 3 elements



T max = 180 °C



p max = for API 10.000# flanged fitting.

T max = 180 °C


Customized p max = for API 10.000# flanged fitting.


Version: June 2016


Planetenweg 5



of 49

4 COMBINED ER/EC/COUPON IN 2-INCH ACCESS FITTING

4.1 SensCorr combi (ER/LPR) Twenty or thirty years ago engineers had to manually download data, often on remote locations such as offshore platforms or in the desert. Nowadays most sensors are online to the DCS computer, and very easy to get access to, via intranet or internet. The combined probe ER (electrical resistance) / EC (electrochemical) uses modern but very robust industrial interfaces: 4-20 mA as reliable analog interface + HART for digitalizing the signals. Similar to other sensors, such as temperature or pressure sensors, data can be represented in any graph, and alarms can be set if an output exceeds a set-limit. The combined probe gives 4 linear outputs to the DCS via an intrinsic safe 4-20 mA-HART signal:

• Uniform corrosion by linear polarization resistance (LPR) with floating B-constant measured

and calculated by harmonic distortion analysis (HDA).

• Uniform corrosion (metal loss) by electrical resistance (ER).

• Localized corrosion (pitting, crevice corrosion and stress corrosion cracking) by

electrochemical noise (EN).

• Conductance.

LEFT: Combined 2-inch high pressure probe for ER (6 wires) and electrochemical measurements (3 wires). RIGHT: exploded view. Item 1: connector (9 pin). Item 2 and 3: probe body in stainless steel AISI 316. Item 6: electrochemical electrodes. Item 5: ER element. MIDDLE: further explanation of ER element. Each of the 4 signals can be set to an alarm after which a corrosion specialist analyzes the data as follows: - Compare the uniform corrosion data of the ER and electrochemical probe.

- Define the likelihood on and severity of localized corrosion by analyzing the 'localized

corrosion output' and both 'uniform corrosion' outputs.

- Check on any conductance variations by analyzing the 'conductance' output.


Version: June 2016


Planetenweg 5



of 49

Of course this online probe can be used for many other applications such as corrosion inhibitor control and water treatment efficacy. Besides, the probe can be used for process control functions other than corrosion measurements. These functions can include dissolved oxygen monitoring, biofilm activity and chlorination processes. The figure below depicts a flush 2-inch combined probe with schematic data interface to safe zone and DCS computer. Combined probes can be delivered from 2014. Later integration of the ER meter and Corrosion transmitter into one instrument box has been planned. Currently the two instruments are delivered in one stainless steel cabinet (ATEX).

2-inch flush probe (item 7) in high pressure mechanical 2-inch access fitting (item 1). Right: Schematic data interface and wiring scheme. The ER-meter (item 21) and corrosion transmitter (item 17) fit in a stainless steel cabinet (item 18). The entire setup is intrinsic safe for oil and gas zones.


Version: June 2016


Planetenweg 5



of 49


70805316 Combined probe 2-inch ER/LPR flush

Housing in stainless steel 316, elements and electrodes in carbon steel

p max = 420 bar

T max = 180 °C Measures simultaneously ER and EC (Corrtran)

70809900 SensCorr basic unit ER and MV for electro-chemistry

Enclosure in stainless steel 316

Measures electrochemical uniform corrosion (EC), metal loss (ER) pitting (EC) and conductance (EC). Combines Corrtran MV and Corrtran ER in one enclosure.

70200100 SensCorr combi (ER/LPR) Interface 4-20 mA – HART

Two interface cards for 4-20 mA HART

4-20 mA HART interface. The 4-20 mA loop powers the instrument.

70100101 Interface for SD Card Data Logging

Interface Card with Battery

For Stand Alone Datalogging. Powered by a Battery.

70400111 HART loop converter (Optional)

Plastic Electronic 4-20 mA-HART interface. Transfers digital HART signals to analogue 4-20 mA signals. ATEX barrier. Placement in the instrument cabinet. Pepperl + Fuchs Product

70410111 HART modem (Optional)

Plastic For communication, programming and download with a Windows PC. Modem.

4.2 Combined probe/coupon in one 2-inch access fitting ER- Electrochemical and Coupon technology can be combined in one 2-inch probe/coupon holder in one fitting. The advantages of this combination above separate probes and coupons are evident:

• Only one instead of two access fittings are required.

• The probe (the electrochemical corrosion transmitter) will tell

when to retrieve the coupon. If the corrosion transmitter shows

increasing localized corrosion output, the coupon can be

retrieved for further investigation on pitting corrosion, cracking,

weld root corrosion or crevice corrosion.

Installation of such combination has been planned for a high temperature wellhead for a gas platform. A duplex stainless steel fracture coupon with electrochemical probe has been foreseen. Similar to pitting corrosion, stress corrosion cracking shows strong increase in electrochemical noise. The localized corrosion output signal of the corrosion transmitter will tell when to retrieve the coupon for further investigation on stress corrosion cracking or other localized corrosion. An example of this probe/coupon is depicted in the figure below. Combinations of ER probes, EC probes and coupons can be extended. Both the coupon as the ER-element can function as EC element simultaneously. This can result in a three-element probe with three functions: ER, EC and coupon retrieval depending on ER/EC signal. This sophisticated corrosion probes only need 6 contact pins, which means similar connector as for standard ER or LPR probes can be applied2).

2 On combined probes and coupons technology: patents pending.


Version: June 2016


Planetenweg 5



of 49

Combined 3-element probe and fracture coupon with a notch for measuring stress corrosion cracking in a high pressure / high temperature duplex stainless steel flowline as planned to be installed on an offshore gas platform in the Northsea. Also the work electrode contains a notch.


70829900 LPR/Corrtran/Coupon probe, 2-inch

Customized


T max = 180 °C 3 element probe and standard strip coupon in one.

4.3 Probe Cables

Art. Nr. Description Material Specs/remarks

70111110 Probe cable with adapter. For CombiProbe ER probes with Amphenol connector (F)

Cable: HDPE 9 cores, length 10 mtr

70113316

Probe cable with adapter. For 2-inch CombiProbe ER probes with sealed adapter for high pressure

Stainless steel 316 9 cores, length 10 mtr

70112316 Probe adapter high pressure for 2-inch probes with Amphenol connector (M), with cable


70114316 Probe adapter low pressure for 2-inch probes with Amphenol connector (M), with cable



Version: June 2016


Planetenweg 5



of 49

5 COUPONS A common method for internal corrosion and condition monitoring is the use of coupons. Using the same material as the pipe, the weight loss or other change of the coupons will be representative for the condition of the pipe or vessel. All coupons are made to NACE specifications. Each coupon is certified to show the serial number, weight (given in grams to four decimal points), dimensions and material type. Each coupon is individually packed in inhibited envelopes with a corrosion free shelf life of one year (in normal room atmosphere). Coupons and coupon holders can be used both with the hydraulic access retrieval system and with any threaded 2-inch system.

5.1 Disc Coupons Disc Coupons are circular discs, often mounted to be flush with the pipe wall. Disc coupons are typically used as weight loss coupons, and must be used if pigging of the line takes place.

Disc coupons in coupon holder (left) and strip coupon in coupon holder


71600052 Coupon disc flush Carbon steel St. 52N

71600316 Coupon disc flush Stainless steel 316

71600205 Coupon disc flush Duplex stainless steel 2205

71600900 Coupon disc flush Customized

5.2 Strip Coupons Strip Coupons are rectangular plates which project into the monitored flow. Because of the larger surface, strip coupons are better suited for detecting and quantifying phenomena like pitting and grooving.


71700052 Coupon strip Carbon steel St. 52N

71700316 Coupon strip Stainless steel 316

71700205 Coupon strip Duplex stainless steel 2205

71700900 Coupon strip Customized


Version: June 2016


Planetenweg 5



of 49

5.3 Specialty coupons Specialty Coupons are coupons for specific purposes, such as: Weld Coupons - for assessment of corrosion in connection with welds Bio Coupons - for assessment of biofilm Fracture Coupons - for assessment of stress corrosion cracking Scale Coupons - for assessment of the formation and effect of scaling


71800052 Coupon weld Carbon steel St. 52N

71800316 Coupon weld Stainless steel 316

71800205 Coupon weld Duplex stainless steel 2205

71800900 Coupon weld Customized

71900052 Coupon bio Carbon steel St. 52N

71900316 Coupon bio Stainless steel 316

71900205 Coupon bio Duplex stainless steel 2205

71900900 Coupon bio Customized

72000052 Coupon fracture Carbon steel St. 52N

72000316 Coupon fracture Stainless steel 316

72000205 Coupon fracture Duplex stainless steel 2205

72000900 Coupon fracture Customized

72009999 Coupon scale Customized

5.4 Coupon Holders Coupon Holders for placing the appropriate coupon correctly in the flow (typically top, middle or bottom of line), and for making the coupons retrievable.


72100316 Coupon holder disc Stainless steel 316 L= variable

72100205 Coupon holder disc Duplex stainless steel 2205

L= variable

72100900 Coupon holder disc Customized L= variable

72200316 Coupon holder strip Stainless steel 316 L= variable

72200205 Coupon holder strip Duplex stainless steel 2205

L= variable

72200900 Coupon holder strip Customized L= variable


Version: June 2016


Planetenweg 5



of 49

6 INJECTION QUILLS Injection Quill with solid plug, access fitting and cover

Injection Quills are used for injection of water or chemicals in pipe-lines and vessels. The Quills are installed in 2-inch access fitting, either hydraulic or chemical. Injection quills can be provided with an injection nozzle. For injection chemical supply, a 1-inch Tee is welded to the 2-inch access fitting. (see chapter 7 for description of access fittings and plugs)


52500316 Injection quill Stainless steel 316

52500205 Injection quill Duplex stainless steel 2205

52500900 Injection quill Customized

7 MECHANICAL 2-INCH ACCESS FITTING Ironhaven B.V. offers a complete range of access fitting assemblies for installation of corrosion probes and weight loss coupons. The product range comprises both the traditional 2-inch mechanical system with threaded plug as well as the 2-inch hydraulic access system with locking pins. (chapter 8) The body of the mechanical access fitting has a threaded outlet, to mate with standard service valves for traditional retrieval tools. It can be supplied with configurations for flareweld, buttweld, socketweld, NPT and flanged installation. Mechanical access fittings are also available as Tee-type access fittings for use with injection and sampling equipment. The 2-inch mechanical access fitting system is being made since the 1960’s. The plugs are secured with a threading. The pressure is being hold by a primary packing between the plug and the fitting. For the probe hollow plug, 2 types of sealings assure pressure tightness: the probe packing and an O-ring. Standard we supply forged carbon steel ASTM A350 LF2 or forged Duplex SS 2205 (ASTM A182 F51), however we can manufacture all materials on customer specifications. Such as SS 316, alloy C276, Super Duplex SS and Titanium.


Version: June 2016


Planetenweg 5



of 49

7.1 Welded Mechanical


73000350 Mechanical access fitting 2-inch flareweld

Carbon steel ASTM A350 LF2


Duplex stainless steel ASTM A182 F51


Customized

73010350 Mechanical access fitting 2-inch buttweld





Customized

7.2 Flanges Mechanical

7.2.1 Flanges 2-inch 150# RF

Art. Nr. Description Material

73100350 Mechanical access fitting 2-inch flanged 150# RF





Customized








Customized








Customized


Version: June 2016


Planetenweg 5



of 49

7.2.4 Flanges 2-inch 900# RTJ


73300350 Mechanical access fitting 2-inch flanged 900# RTJ





Customized

7.2.5 Flanges 2-inch 1.500# RTJ


73400350 Mechanical access fitting 2-inch flanged 1.500# RTJ





Customized








Customized

7.2.7 Flanges 2-inch API 10.000#


73600350 Mechanical access fitting 2-inch flanged API 10.000#





Customized


Version: June 2016


Planetenweg 5



of 49

7.3 Flanges Mechanical with Tee for injection and sampling

Access fitting with Tee for Injection Quill

7.3.1 Flanges 2-inch 1-inch Tee 300# RF


53100316 Mechanical access fitting 2-inch 1-inch Tee flanged 300# RF

Stainless steel ASTM A182 F316




Customized








Customized

7.3.3 Flanges 2-inch 1-inch Tee 900# RTJ


53300316 Mechanical access fitting 2-inch 1-inch Tee flanged 900# RTJ





Customized


Version: June 2016


Planetenweg 5



of 49

7.3.4 Flanges 2-inch 1-inch Tee 1.500# RTJ


53400316 Mechanical access fitting 2-inch 1-inch Tee flanged 1.500# RTJ





Customized








Customized

7.3.6 Flanges 2-inch 1-inch Tee API 10.000#

7.4 Plugs Mechanical The hollow and solid plugs carry the pressure se al i n the access fitting, and are also the retrievable carrier for the monitoring device. The plug seal is made in PTFE (25% glass filled), but metal seals are available for high temperature service. The plug threads are film coated to reduce the risk of galling.

7.4.1 Hollow plug for probe

The hollow plug assembly is a retrievable carrier for monitoring devices such as linear polarization probes, electrical resistance probes, sand probes, hydrogen probes, galvanic probes and other probes or sensors requiring a cable connection.


74600316 Hollow Plug Mechanical for Probe

Stainless steel 316


Duplex stainless steel 2205


Customized


53600316 Mechanical access fitting 2-inch 1-inch Tee flanged API 10.000#





Customized


Version: June 2016


Planetenweg 5



of 49

7.4.2 Solid plug for coupon

The solid plug assembly is a retrievable carrier for monitoring devices such as coupon holders, injection systems and sampling equipment


74700316 Solid Plug Mechanical for coupon

Stainless steel 316




Customized

7.4.3 Solid plug for injection quill

The solid plug for injection quills contains holes in order to guide the fluid to the injection quill and injection nozzle.

Solid plug + nut + quill


54800316 Solid Plug Mechanical for injection quill

Stainless steel 316




Customized


Version: June 2016


Planetenweg 5



of 49

7.5 Mechanical covers The protective cover for the mechanical access fitting system is us ed to protect the external ACME threads of the access fitting from mechanical and environmental damage. For the mechanical system, the product range comprises covers with hole for use with probes and sensors, and covers without hole for use with coupons. Pressure retaining covers are also available.


75000042 Mechanical cover with hole

Carbon steel 42CrMo4

Hole for probe adapter

75000316 Mechanical cover with hole

Stainless steel 316 Hole for probe adapter

75010105 Mechanical pressure retaining cover for probe

Carbon steel ASTM105

With manometer, bleed valve and hole for probe adapter





Stainless steel 316 With manometer, bleed valve and hole for probe adapter

75020042 Mechanical pressure retaining cover for coupons


With manometer and bleed valve





Stainless steel 316 With manometer and bleed valve

75030042 Mechanical cover without hole


For coupons

75030316 Mechanical cover without hole

Stainless steel 316 For coupons


Version: June 2016


Planetenweg 5



of 49

7.6 Sealings and Spare parts Mechanical


75100001 Primary Packing for Mechanical/Hydraulic plug

PTFE with glass fibre reinforcement

75100002 Probe Packing for Mechanical/Hydraulic

PTFE

75100003 O-ring for probe for Mechanical/Hydraulic

Viton Set of 2 for each probe

75100004 O-ring for pressure retaining cover Mechanical

Viton

75100007 Set screw M5x5

75100008 Sealing bolt for hollow plug for Mechanical/Hydraulic

75100009 Hollow plug nut Mechanical

AISI 316

75100010 Hollow plug body for Mechanical/Hydraulic

75100100 Grease for sealings and threadings for Mechanical/Hydraulic

75100005 Manometer for pressure retaining covers

Stainless steel 316

75100006 Bleed Valve for pressure retaining covers

Stainless steel 316


Version: June 2016


Planetenweg 5



of 49

8 HYDRAULIC 2-INCH ACCESS-FITTINGS The Ironhaven B.V. hydraulic access system has several advantages over traditional Mechanical systems. The small size, low weight retrieval tool requires far less operational

clearance and has no external moving parts for increased safety. The hydraulic access fitting assembly comprises: • Hydraulic Access Fitting (with Locking Pins) • Hydraulic Hollow/Solid Plug • Hydraulic Cover Existing 2-inch Hydraulic systems can easily be updated (even during operation) to the safer and more reliable hydraulic retrieval system by means of a hydraulic adapter. The access fitting body has an ACME threaded outlet to mate with the service valve. It is available for Flareweld, Buttweld, NPT or Flanged mounting. The access fitting has no internal threads, thereby eliminating the danger of a seized plug. Four locking pins hold the internal plug in position during retrieval operations. Designed and manufactured in compliance with the requirements of the Pressure Equipment Directive (PED) 97/23/EC

Standard we supply forged carbon steel ASTM A350 LF2 or forged Duplex SS 2205 (ASTM A182 F51), however we can manufacture all materials on customer specifications. Such as SS 316, alloy C276, Super Duplex SS and Titanium.

8.1 Welded Hydraulic


76000350 Hydraulic access fitting 2-inch flareweld





Customized

76010350 Hydraulic access fitting 2-inch buttweld





Customized


Version: June 2016


Planetenweg 5



of 49

8.2 Flanges Hydraulic



76100350 Hydraulic access fitting 2-inch flanged 300# RF





Customized








Customized

8.2.3 Flanges 2-inch 900# RTJ


76300350 Hydraulic access fitting 2-inch flanged 900# RTJ





Customized



76400350 Hydraulic access fitting 2-inch flanged 1.500# RTJ





Customized








Customized


Version: June 2016


Planetenweg 5



of 49

8.2.6 Flanges 2-inch API 10.000#


76600350 Hydraulic access fitting 2-inch flanged API 10.000#





Customized

8.3 Flanges Hydraulic with Tee for injection and sampling



56100316 Hydraulic access fitting 2-inch 1-inch Tee flanged 300# RF





Customized








Customized

8.3.3 Flanges 2-inch 1-inch Tee 900# RTJ


56300316 Hydraulic access fitting 2-inch 1-inch Tee flanged 900# RTJ





Customized



56400316 Hydraulic access fitting 2-inch 1-inch Tee flanged 1.500# RTJ





Customized


Version: June 2016


Planetenweg 5



of 49








Customized

8.3.6 Flanges 2-inch 1-inch Tee API 10.000#


56600316 Hydraulic access fitting 2-inch 1-inch Tee flanged API 10.000#





Customized

8.4 Plugs Hydraulic Ironhaven B.V. offers a complete range of hydraulic access fitting assemblies for installation of

corrosion probes and weight loss coupons. The access fittings are designed to be used with hydraulic retrieval tools under full operational pressure. The hollow and solid plugs carry the pressure seal in the access fitting, and are also the retrievable carrier for the monitoring device. The hydraulic hollow and solid plugs are of a unique design with no external threads. The design eliminates galling, which is a common problem with traditional threaded plugs. The hydraulic access fitting assembly comprises the following components: • Hydraulic Access Fitting body • Hydraulic Hollow/Solid Plug • Hydraulic Cover, standard or pressure retaining)

8.4.1 Hollow plug for probe

The hollow plug assembly is a retrievable carrier for monitoring devices such as linear polarisation (LPR) probes, electrical resistance (ER) probes, sand probes, hydrogen probes, galvanic probes and other probes or sensors that require a cable connection.


77600316 Hollow Plug Hydraulic for Probe Stainless steel 316

77600205 Hollow Plug Hydraulic for Probe Duplex stainless steel 2205

77600900 Hollow Plug Hydraulic for Probe Customized


Version: June 2016


Planetenweg 5



of 49

8.4.2 Solid plug for coupon

The solid plug assembly is a retrievable carrier for monitoring devices such as coupon holders, injection systems and sampling equipment.


77700316 Solid Plug Hydraulic for coupon Stainless steel 316

77700205 Solid Plug Hydraulic for coupon Duplex stainless steel 2205

77700900 Solid Plug Hydraulic for coupon Customized

8.4.3 Solid plug for injection quill

The solid plug for injection quills contains holes in order to guide the fluid to the injection quill and injection nozzle.


57800316 Solid Plug Hydraulic for injection quill

Stainless steel 316




Customized

8.5 Hydraulic Covers Hydraulic covers are used to protect the ACME threads of the access fitting from Hydraulic and environmental damage. The cover for the hydraulic access system is also designed to hold the probe in position inside the access fitting.


78000042 Hydraulic cover with hole Carbon steel 42CrMo4

For probe adapter

78000174 Hydraulic cover with hole ASTM A564 Gr. 630 17-4PH

For probe adapter

78000316 Hydraulic cover with hole Stainless steel 316 For probe adapter

78010042 Hydraulic Pressure retaining cover for probe







Stainless steel 316 With manometer, bleed valve and hole for probe adapter

78020042 Hydraulic Pressure retaining cover for coupons







Stainless steel 316 With manometer and bleed valve


Version: June 2016


Planetenweg 5



of 49

8.6 Sealing and Spare parts Hydraulic


75100001 Primary Packing for Mechanical/Hydraulic plug

PTFE with glass fibre reinforcement

75100002 Probe Packing for Mechanical/Hydraulic

PTFE

75100003 O-ring for probe for Mechanical/Hydraulic

Viton Set of 2 for each probe

78100004 O-ring for Hydraulic Pressure retaining cover

Viton

78100005 Locking pins Set of 4. With 2 pcs of O-ring per locking pin

78100006 O-rings for locking pins Viton Set of 8 for 4 locking pins

78100007 Wear ring for Hydraulic

75100007 Set screw M5x5

75100008 Sealing bolt for hollow plug for Mechanical/Hydraulic

78100008 Hollow plug nut Hydraulic

AISI 316

75100010 Hollow plug body for Mechanical/Hydraulic

75100100 Grease for sealings and threading for Mechanical/Hydraulic

75100005 Manometer for pressure retaining covers

Stainless steel 316

75100006 Bleed Valve for pressure retaining covers

Stainless steel 316


Version: June 2016


Planetenweg 5



of 49

9 RETRIEVAL TOOLS

The high pressure balanced Mechanical Retrieval Tool and Service Valve are designed to operate with any existing 2” traditional Mechanical system with ACME OD threads and can be used for replacing e.g. corrosion probes under full line pressure without shutting down and depressurizing the pipe system. The Mechanical Retriever is supplied with a Service Valve with single isolation (one ball) as standard. For more safety, a Service Valve with double isolation (two separate balls) is also available. NOTE! Due to the increased height of the Double Isolation Service Valve, a special Double Acting Hydraulic Retriever is required for use with this valve. The retrieval tool and service valve allow the installation and the removal of any type of corrosion monitoring device under a pressurized system up to a maximum working pressure of 420 bars (6000 psi) and maximum operating temperature of +230 degrees Celsius (+392 degrees Fahrenheit) Operative data: Max working pressure: 420 bar Max/min Working temp: 230 degrees C / -40 degrees C Hydraulic test Pressure: 630 bar


75900050 Mechanical Retrieval Tool and Service Valve

Nitronic 50

Complete with Single Isolation Service Vavle in Nictronic 50, Accessories and field service Box. NOTE: High pressure retrieval tool operations shall be performed by properly trained and qualified personnel only.

Pos. Art. Nr. Description Material

2

(73100350)

Mechanical access fitting 2-inch flanged

150# RF


3 (75030316) Mechanical cover without hole Stainless steel 316

4 (70112316) Probe adapter for 2-inch probes with

Amphenol connector (M)

Stainless steel 316

5 (74600316) Hollow Plug Mechanical for Probe Stainless steel 316


2

(73100205)


150# RF

Duplex stainless steel ASTM A182

F51


5 (74600205) Hollow Plug Mechanical for Probe Duplex stainless steel 316

Above mentioned Assembly is without probe.

For probe selection, see chapter two of this manual

Assembly drawing: Mechanical Access Fitting Flanged with probe

Assembly Carbon Steel. Article nr. 89140911

Assembly Duplex Stainless Steel. Article nr. 89140912

Nr 1: Probe

of 49


1 (73000350) Mechanical access fitting 2-inch

flareweld


2 (74700316) Solid Plug Mechanical for Coupon Stainless steel 316

8 (72100316) Coupon holder disc Stainless steel 316

5 (75010042) Mechanical pressure retaining cover

for probe (with nanometer (12) and

bleed valve (13)



1 (73000205) Mechanical access fitting 2-inch

flareweld


ASTM A182 F512 (74700205) Solid Plug Mechanical for Coupon Duplex stainless steel 2205

8 (72100205) Coupon holder Duplex stainless steel 2205

5 (75010316) Mechanical pressure retaining cover


bleed valve (13)

Stainless steel 316

Above mentioned Assembly is without coupon

Assembly drawing: Mechanical Access Fitting Flareweld with coupon



Nr 9: Coupon

Above mentioned Assembly is without coupon

For coupon selection, see chapter five of this manual


3 (75100001) Primary Packing for

Mechanical/Hydraulic plug

PTFE with glass fibre

reinforcement4 Solid plug o-ring Viton

6 Set screw M6x6 SIS 2343

7 Pipe Plug Plastic

10 Insulators for Disc coupon PTFE

11 1/4" UNC screw SIS 2343

12 Pressure proof cover o-ring Viton

13 (75100006) ¼” NPTM-F Bleed Valve Stainless steel 316

14(75100005)

Manometer for pressure retaining

cover

Stainless steel 316

L= 54 + wall thickness

L= 72 + wall thickness of 49


2 Mechanical access fitting 2-inch flanged Carbon steel ASTM A350 LF2

3 (75030316) Stainless steel 316

4 (70112316) Probe adapter for 2-inch probes with

Amphenol connector (M)

Stainless steel 316



2

(73100205)


150# RF

Duplex stainless steel ASTM A182

F51



Above mentioned Assembly is without probe.

For probe selection, see chapter two of this manual

Assembly drawing: Mechanical Access Fitting Flanged with probe



Nr 1: Probe

(73110350) 300# RF

Mechanical cover with hole

of 49


1

(53400316)

Mechanical access fitting 2-inch 1-inch Tee

flanged 1.500# RTJStainless steel ASTM A182 F316


5

(54800316) Solid Plug Mechanical for Injection quillStainless steel 316

11 1/2" flangeolet 1500# RTJ Stainless steel ASTM A182 F316


1

(53400205)

Mechanical access fitting 2-inch 1-inch Tee

flanged 1.500# RTJDuplex stainless steel ASTM

A182 F51


5

(54800205) Solid Plug Mechanical for Injection quillDuplex stainless steel 2205

11 1/2" flangeolet 1500# RTJ Duplex stainless steel ASTM

A182 F51


Assembly drawing: Mechanical Access Fitting Flanged with injection tube

Assembly Stainless Steel. Article nr. 89115031


For Injection quill type (pos. 10) choose article:


10 52500316 Injection quill Stainless steel 316

10 52500205 Injection quill Duplex stainless steel 2205

10 52500900 Injection quill Customized


2 Pipe Plug Plastic

3 Solid Plug O-ring Viton

6 1/4" NPT injection nut AISI 316L

7 Injection nut O-ring Viton

8 Back up O-ring PTFE

9 (75100001) Primary packing for Mechanical/Hydraulic

plug

PTFE with glass fibr

reinforcement

L= 54 + wall thickness

of 49


1(73300350)

Mechanical access fitting 2-inch

flanged 900# RTJCarbon steel ASTM A350 LF2

4

(75010042)

Mechanical pressure retaining cover


bleed valve (10)




1(73300205)

Mechanical access fitting 2-inch

flanged 900# RTJ

Duplex stainless steel ASTM

A182 F514

(75010316)

Mechanical pressure retaining cover


bleed valve (10)

Stainless steel 316



11


Housing in stainless steel 316L

element in Carbon steel,

For Probe (pos. 11) choose article:

Assembly drawing: Mechanical Access Fitting for Sand probe



p max = 420 bar; ASME 2500# flanged fitting T max=180°C

70625316 ER probe tubular 2-inch element in Carbon steel,

0,5mm thickness11


Housing in duplex SS 2205

element in Carbon steel,

0,5mm thickness11



element in Carbon steel, 1 mm

thickness11


Housing in duplex SS 2205

element in Carbon steel, 1 mm

thickness11

70629900 ER probe tubular 2-inch Customized materials selection

11

70693316 ER Sand Probe tubular 2-inchHousing in stainless steel 316L

element in stainless steel 316L

1170694316 ER Sand Probe flush 45°


element in Monel K40011 70699900 ER Sand Probe Customized


2 Pipe Plug Plastic

3 (75100004) O-ring for pressure retaining cover

Mechanical

Viton

6 (75100009) Hollow plug nut mechanical AISI 316L

7 (75100007) Set screw, M5x5 SIS2343 (A4)

8 (75100001) Primary packing for


PTFE with glass fibr

reinforcement9 (75100005) Manometer for pressure retaining

cover

Stainless steel 316


of 49

Pos. Artikcle nr Description Material

1 (76000350) Hydraulic access fitting 2-inch

flareweld


6 (77600316) Hollow Plug Hydraulic for Probe Stainless steel 316

5 (78000042) Hydraulic pressure retaining cover for

probe (with nanometer (14) and

bleed valve (13)



1 (76000205) Hydraulic access fitting 2-inch

flareweld

Duplex stainless steel ASTM

A182 F516 (77600205) Hollow Plug Hydraulic for Probe Duplex stainless steel 2205

5 (78000316) Hydraulic pressure retaining cover for

probe (with nanometer (14) and

bleed valve (13)

Stainless steel 316L


2 70615316 ER probe flush strip 2-inch Housing in stainless steel 316,

element in carbon steel,

0,5mm thickness2 70615205 ER probe flush strip 2-inch Housing in duplex stainless

Assembly drawing: Hydraulic Access Fitting Flareweld with flush ER probe



For Probes (pos. 2) choose article:

2 70615205 ER probe flush strip 2-inch Housing in duplex stainless

steel 2205, element in carbon

steel, 0,5mm thickness

2 70616316 ER probe flush strip 2-inch Housing in stainless steel 316,

element in carbon steel, 1 mm

thickness2 70616205 ER probe flush strip 2-inch Housing in duplex stainless

steel 2205, element in carbon

steel, 1mm thickness2 70619900 ER probe flush strip 2-inch Customized


3 (78100005) Locking Pin Plastic

4 (78100004) O-ring for pressure retaining cover

Hydraulic

Viton

7 (75100001) Primary Packing for


PTFE with glass fibre

reinforcement8 (78100007) Wear ring for Hydraulic

10 (75100007) Set screw M5x5 SIS 2343

11 (70111110) Probe cable flexible. For Corrtran ER

probes with Amphenol connector (F)

Cable: HDPE - 6x24 AWB OK

5,9mm

12 Corrlog instrument 4-20 mA


14 (75100005) Manometer Stainless steel 316 of 49

Handbook Corrosion & Sand Monitoring - ironhaven.nl · Handbook Corrosion Monitoring Version: June...

Documents

Transcript of Handbook Corrosion & Sand Monitoring - ironhaven.nl · Handbook Corrosion Monitoring Version: June...