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Welcome to 2018 Western Regional Gas
Conference
IR FREE COUPONS – A
TECHNOLOGY REVIEW
◼ Presented by:
Jonathan Loomis,
CP Specialist &
Scott Smith, CP
Specialist
◼ Farwest Corrosion
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IR FREE COUPONS – A
TECHNOLOGY REVIEW
◼ What’s Out There
◼ The Industry Buzz
◼ Typical Applications
◼ Conclusions
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Comparison of CP Coupons & Soil
Corrosion Probes
CP Coupons Soil Corrosion Probes
Measure CP potential (-mV) using
reference electrodes
Measure corrosion rate with CP applied
(mils / yr.)
Used for “off” potential (e.g. minimum -
850 mV) or 100 mV polarization
criterion
Used as corrosion rate measurements as
an alternative to the CP potential
criterion
Buried pipelines where alternative CP
criteria (‘off” potentials, 100 mV
depolarization criterion) is used the
assess effectiveness of CP
Typically used for buried pipelines at
locations where potentials can not be
measured accurately or are not
dependable
Can be used for measuring high ‘off”
potential (> -1200 mV) to determine if
coating or pipe damage could occur
Can be used for congested plant piping,
under storage tanks, internal casings
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What’s Out There
◼ IR Free Coupon
by MC Miller Co
◆ Double leads
◆ PVC Monitoring
tube
◆ 1.374 sq. in of
metal (8.862 sq.
cm)
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What’s Out There
◼UC Underground
Coupon by EDI
⧫ Split Steel Coupon
⧫ 10 sq. cm surface
area
⧫ Inner backfill for
potentials through
split
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What’s Out There
◼ Stelth 7
by Borin Mfg.
◆ Will not dry out in desert soil
◆ Local copper sulfate electrode to coupon
◆ Available in 1, 5, 10, up to 100 cm2 surface
area mild steel coupon
◆ 26 sq. in sensing surface
◆ Chloride ion trap
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What’s Out There
◼ Fink Probe by
Cott Mfg.
◆ Steel Ring Coupon
◆ 0.01 sq. ft. (1.44 sq.
in) surface area
◆ Potential Access
Tube
◆ Jumper bond plugs
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What’s Out There
▪ Farwest Hemi-10 & Dual Hemi-10
Steel Coupons
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What’s Out There
▪ Farwest Flathead-10 & Cyclone-10
Steel Coupons
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What’s Out There
◼ AC-10
Portable
Current
Density
Coupon /
Probe
◼ 10 cm²
size
◼ 25 mA =
25 A / m²
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What’s Out
There
◼ Farwest
Rapid-
Check Test
Station
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What’s Out There
◼ Typical
Test
Station
Wiring
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What’s Out There
◼Wireless Coupon Test-Station
by OmniMetrix
◆ Dual coupons – 1 Native, 1 Polarized
◆ Automatically reads Native & I-Off,
followed by depol from 1-6 days
◆ Wireless to web
◆ 10-yr, field replaceable battery
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What’s Out There
◼ Soil Corrosion
Rate Probes
◆ Various models /
different
measurement
methods, all require
an instrument for
measurement
⧫ ER, LPR, others
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What’s Out There
◼ ER Probe ▪ LPR Probe
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What’s Out There
◼DIP-1 & CSP-1
by Tinker & Rasor
◆ ER Probes measuring
mpy
◆ Measurement area 1
sq. in (6.5 sq. cm)
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What’s Out There
◼Metal Samples
CT-10 ER Probe
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Industry Buzz
◼ Paper 98666 - Presented in CORROSION ‘98
◆ THE USE OF IR DROP COUPONS AS A
PRACTICAL & EFFECTIVE TEST
METHOD
⧫ by Jeff Didas, Columbia Gas
(now at Matcor, Inc.)
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Industry Buzz
◼ Paper 98666 – Major Points
◆ Locate anomalies (CIS Survey) then remediate, and only then locate IR Free coupons at location with:
⧫ Anomalies
⧫ High IR Drop
⧫ Poor / no coating
⧫ Most aggressive soils
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Industry Buzz
◼ Paper 98666 – Major Points
◆ ICCP Pipe – IR Free Coupon Station Frequency:
⧫ No more than 5-mile spacing
◆ Galvanic CP Pipe – IR Free Coupon Station Frequency:
⧫ No more than 1-mile spacing
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Industry Buzz
◼ Paper 05039 – Presented in CORROSION ‘05
◆ FIELD TESTS ON AN ADVANCED CATHODIC PROTECTION COUPON
⧫ by Frank J. Ansuini, Electrochemical Devices, Inc. & James R. Dimond, Dimondale Co., Inc.
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Industry Buzz
◼ Paper 05039 – Major Points
◆ Excellent problem statement
⧫ IR Drop & Measurement errors
◆ References NACE Publication 35201 by TCC Task Group 210
◆ Gives arguments against other shapes (not flat)
◆ Centered sensing membrane eliminates the IR Drop of the first 5 cm where 90% of IR Drop can occur (Gummow)
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Industry Buzz
◼ Paper 05039 – Major Points
SHAPE Tests IR Drop elimination during ON testing.
◆Rod shaped coupon-disconnect potentials still contain
residual voltage drop error in the presence of a current
field.
◆Concentric CP coupons during ON testing have minor
(2-10 mV) voltage drop error
⧫ Disconnecting coupon or interrupting rectifier will
substantially eliminate error when necessary
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Industry Buzz
◼ Paper 05039 – Major Points
Soil Resistivity Effects on Coupon Potential Measurements
◆ 90% IR Drop error eliminated in high resistivity environments
◆Virtually all IR Drop error eliminated in low resistivity environments
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Industry Buzz
◼ Paper 05039 – Major Points
Effects of Distance from Pipeline
◆ No effect of distance on the amount of error
eliminated but there was a distance effect in
the actual potential reported
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Industry Buzz
◼ Paper 05039 – Major Points
Coupon orientation contained error, mV (%) (from fixed 300 mV surface error)
◆ Facing structure, back to anode 35mv (12%)
◆ Perpendicular to structure and anode 56mv (19%)
◆ Back to structure, facing anode 67mv (22%)
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Industry Buzz
◼ Paper 07037 - Presented in CORROSION ‘07
Use of CP Coupons and Soil Corrosion Probes
in Application of Pipeline Cathodic
Protection Criteria
⧫ By Naeem A. Khan, Saudi Aramco
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Industry Buzz
◼ Paper 07037 – Major Points
Introduces “new” ISO/FDIS 15589-11, lists different CP
potential criteria for various soil resistivities.
◆ Both coupons and probes can be used to implement
corrosion control monitoring program
⧫ Coupons -> polarized potentials
⧫ SCPs (Soil Corrosion Probes) ->where polarization
insufficient, but where corrosion rate measurements
indicate effective protection on the structure
◼ (RP-0104-2004) -use of CP coupons for CP potential
measurements
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Industry Buzz
◼ Paper 07037 – Major Points
ISO/FDIS 15589-1:2003 CP PROTECTION CRITERIA
◼ Soil Type Soil ResistivityProtection Potential
◼ Aerobic <100 ohm-m -850
100 to 1000 -750
>1000 ohm-m -650
◼ Anaerobic conditions -950
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Industry Buzz
◼ Paper 07037 – Major Points
◼ NACE Committee TG-321 finalizing Technical Report on SCRPs (Soil Corrosion Rate Probes) mainly addresses applications for ER SCRPs on buried pipelines.
◆ Also includes information on Linear Polarization Resistance (LPR) probes used for assessing soil corrosiveness, and the use of corrosion probes for reinforced concrete structures.
◆ SCRPs typically used on buried or congested piping, where CP potentials cannot be reliably measured and corrosion rate measurements using ER probes are used as an alternative to conventional CP criteria for buried pipelines.
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Industry Buzz
◼ Paper 07037 – Major Points
◼ CP Coupons
◆ Measure CP Potential (-mV) using CSE’s
◆ Used for “OFF” or 100 mV criterion
◆ Also used for measuring high (>-1200 mV) “OFF”
potential for coating or pipe damage evaluation
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Industry Buzz
◼ Paper 07037 – Major Points
◼ SCRP (Soil Corrosion Rate Probes)
◆ Corrosion rate with CP applied (mils/year)
◆ Used as an alternative to the CP potential criterion
◆ Typically used at locations where potentials cannot be
measured accurately or are not dependable
◆ Can also be used for congested plant piping or under
storage tanks
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Industry Buzz
◼ RP0104-04
The Use of Coupons for Cathodic Protection
Monitoring Applications
◼ Depol testing without interrupting rectifiers
◼ May be differences between polarized pipe & coupon P/S
◼ High IR Drop locations can cause stray current corrosion
on coupons
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Typical Applications
◼ Stray Current – Static (Pipeline)
◼ Stray Current – Dynamic (Light Rail)
◼ Induced A.C.
◼ Distributed Anodes
◼ Congested Right-of-Way
◼ Shorted Casings
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Stray Current DC – Foreign Pipeline
Foreign
Pipe
Protected
Pipe
Voltage Gradients
Around the
Protected Pipe
Interference Current
DischargeInterference
Current
Pickup
PROFILE VIEW
+ -Rectifier
Impressed Current
Groundbed Remote from
Foreign Pipe
Interference
Current
Pickup
Foreign
Pipe
Protected
Pipe
Voltage Gradients
Around the
Protected Pipe
Interference Current
DischargeInterference
Current
Pickup
PROFILE VIEW
+ -Rectifier
Impressed Current
Groundbed Remote from
Foreign Pipe
Interference
Current
Pickup
◼ Cathodic Interference
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Stray Current DC – Foreign Pipeline
◼ Anodic Interference
Foreign
Pipe
Impressed
Current
Groundbed
Voltage Gradients
Around the
Groundbed
Interference
Current
Discharge
Interference
Current
Discharge
Interference
Current Pickup
TOP VIEW
- +Rectifier
Protected
Pipeline
Remote from
Foreign Pipe
Foreign
Pipe
Impressed
Current
Groundbed
Voltage Gradients
Around the
Groundbed
Interference
Current
Discharge
Interference
Current
Discharge
Interference
Current Pickup
TOP VIEW
- +Rectifier
Protected
Pipeline
Remote from
Foreign Pipe
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Transit
Systems – DC
Traction
◼ Stray DC Interference (dynamic)
800 VDC
+
-
Up to 3,000 A
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Stray Current DCdc
sub-station
ground
pick-up
IsIs
IL
Ie
IR
Ie
Is
discharge
metallic structure(e.g. watermain)
runningrails
O/H power conductor
▪ Pipe-to-soil potential shifts are dynamic
▪ Does short duration allow time for polarization decay?
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Induced AC
▪ No Corrosion Expected iac < 20 A/m2
▪ Corrosion Unpredictable 20 A/m2 < iac < 100 A/m2
▪ Corrosion Expected iac > 100 A/m2
I2
I1
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Induced AC Interference
AC Current Density:
I Density = 8*VAC /dρπ
d = diameter of holiday
ρ = soil resistivity (ohm-cm³)
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Distributed Anodes (Directly Connected)
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Potential Shielding – Multiple Lines in
R-O-W
• Multiple Rectifiers
• Cross Bonds
• Coating Condition
• Anodic Interference
• Cathodic Interference
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Monitoring Internal Corrosion –
Shorted Casings
◼ If a pipeline is in a casing within an HCA, it must be
assessed according to 192.921 (a) (1-3) – approved
methods are ILI, direct assessment, pressure test,
“other technology” such as guided wave
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Monitoring Internal Corrosion –
Shorted Casings
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Monitoring Internal Corrosion – Shorted
Casings
CorrTalk® RMU1-ER
Remote Monitor
Metal Samples CT-10 ER
Probe
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Conclusions
◼ CP coupons & ER probes can be used as an
alternative to pipeline potential measurements in
determining CP effectiveness.
◼ CP coupons are useful to measure polarized /
depolarized potentials on pipelines influenced by
foreign CP systems or where an operator’s CP
systems can not be simultaneously interrupted.
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Conclusions
◼ ER Probes can be used where required
polarization can not be achieved or measured
accurately, but can show effective protection
through corrosion rate measurements.
◼ Know your situation & pick the tool.
◼ An inexpensive tool can save years of headaches.
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Thank You!