Specialized Corrosion Monitoring Probes from Metal Samples Company
Specialized Corrosion Monitoring Probes from Metal Samples Company
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Specialized Monitoring Probes
Biofilm Activity Monitoring System
Metal Samples in cooperation with Structural Integrity Associates, Inc., now offers the BIoGEORGE system - a simple, rugged, dependable system for real-time monitoring of:
Microbiologically influenced corrosion (MIC)
Microbiologically Influenced Corrosion (MIC) is a significant degradation mechanism in nuclear and fossil-fueled power plants, chemical processing, refineries, pulp and paper, oil and gas production and distribution and the armed services. Essentially all cooling water and process water applications may be susceptible to MIC. Further, biological fouling, which is always a precursor to MIC, can reduce the efficiency of heat exchangers and fluid distribution systems and can interfere with water-based processes.
The most common approach to mitigation of MIC is chemical treatment. Chemical costs for a large process plant are often on the order of $1,000,000 per year. Chemical toxicity is always a concern for plant personnel and the environment. This results in close scrutiny and control of effluents and chemical inventories by regulators, environmental agencies, and plant owners.
The BIoGEORGE system was developed to provide online and real-time indications of biofilm activity on typical metallic surfaces. The probe is designed and operated so that microorganisms in the environment are encouraged to settle on probe surfaces well before they settle on heat exchanger tubes or piping.
Probe status is indicated on the integrated electronics enclosure by an LED display (red light/green light).
By closely tracking biofilm activity on the probe, the operator is alerted to the need to treat the system, to assess the effectiveness of a treatment, to schedule maintenance activities, or to optimize chemical treatments.
The system consists of a probe, its integrated electronics, interconnecting cable, display software, User's manual, and product support.
The probe is installed into a piping system, heat exchanger water box, cooling tower, or side stream via a 2-inch threaded connection. Special probes can also be built for "hot tap type fittings or flow-through probes.
The unit operates on a 110 or 220 VAC and has built-in battery backup.
System data can be downloaded to the user's PC. Software is included with the system for analyzing the data and creating detailed trend plots.
Model HCA200 bio-probe is used to collect samples of bacteria in gas and oil producing systems. The bacterial population on a systems metal surface is more relevant to corrosion than the bacterial population in the systems fluids. This is because only surface or sessile bacteria cause corrosion. Thus a corrosion control program is ineffective unless it kills those bacteria which have formed attached biomasses.
The same bacteria which cause problems in gas pipelines, tanks, vessels, oil wells and water handling systems attach to the bio-probes sample element. And since the bio-probe is designed for high pressure access systems, common throughout the oil field, it becomes a convenient and economical way for sampling corrosion-causing biological activity.
Bacteria and other microorganisms can be found in almost any process medium, from cooling water to crude oil. These organisms can lead to the formation of biofilm which can have a severely negative impact on plant operations. Biofilm is a serious threat with financial, environmental, and health & safety implications.
Corrosion Coupons - BioFilm
Biofilm formation can greatly reduce the efficiency of systems such as heat exchangers through biofouling. It may also lead to microbiologically influenced corrosion (MIC) which can cause physical damage to piping and equipment, resulting in leaks and premature failures. These risks make it essential to monitor for biofilm formation in your system.
Metal Samples offers the Biofilm Coupon to monitor for biofilm formation in piping and plant equipment. The biofilm coupon is constructed from a stainless steel mesh which provides an ideal surface for the growth of biofilm, while resisting corrosion. This allows the biofilm, if present, to be cultured for quantification and identification.
The biofilm coupon is manufactured to the same size as our common weight-loss corrosion coupons, which allows it to be mounted using our standard coupon holders. Its small size allows it to be installed in almost any access point.
Model ER0600 Corrosion Under Insulation (CUI) probe is designed for measuring corrosion behavior under the insulation of jacketed pipes where corrosion may go undetected for long periods of time, resulting in unsafe operating conditions, equipment failures, and costly repairs.
Unlike other CUI probes which are retrospective and only alert you after a certain level of corrosion has been reached, the model ER0600 is a true ER corrosion probe which provides continual, real time corrosion data (metal loss). Being a standard ER probe, it can be measured with any standard ER meter.
The ER0600 CUI probe utilizes a flush ER element which can be inserted through the outer pipe jacket and insulation layer, and located adjacent to the pipe surface where corrosion may occur. The unique castle-top design helps to facilitate installation and set the proper spacing for the element, while preventing contact between the probe element and the pipe wall.
The probe is provided with the necessary sheet metal mounting flange and compression fitting. Installation requires a single hole to be cut in the pipe jacket and insulation. Then the mounting flange is secured to the pipe jacket with standard sheet metal screws. The compression fitting holds the probe in place after it has been set to the desired depth.
Analyzers & Probes for Real-Time & Online Localized Corrosion Monitoring and Electrochemical Studies
Used with CorrVisual software, a wide range of multielectrode probes, and innovative seals, QueonTM, the nanoCorrTM analyzer makes the online and real-time monitoring of localized corrosion and most types of general corrosions quick, easy and reliable in liquids, soils, concrete, and humid gases under normal temperature and pressure or high-temperature and high-pressure conditions.
Our nanoCorr analyzers were developed on the basis of the coupled multielectrode array sensor technology patented by a major international research organization, and backed by several other U.S. and international pending patents. They are highly sensitive and reliable for all types of non-uniform corrosions including localized corrosions. They are also the only type of corrosion instruments in the world that have ever been claimed to be quantitative for monitoring localized corrosion below mill-per-year or micron-per-year levels.
Principle of Coupled Multielectrode Sensor Analyzers
When a metal undergoes non-uniform corrosion, particularly localized corrosion such as pitting corrosion or crevice corrosion, electrons are released from the anodic sites where the metal corrodes and travel to the cathodic sites where the metal corrodes less or does not corrode. In a coupled multielectrode sensor, there are multiple miniature electrodes made of materials identical to the engineering component of interest. Statistically, some of the electrodes have the properties that are close to the anodic sites and others have the properties that are close to the cathodic sites of the corroding metal.
When the miniature electrodes are electrically isolated from each other but coupled together by connecting each of them to a common joint through an external circuit, the electrodes that have the properties close to the anodic sites simulate the anodic areas, and the electrodes that have the properties close to the cathodic sites simulate the cathodic areas of the corroding metal. The electrons released from the anodic electrodes are forced to flow through the external circuit to the cathodic electrodes. Thus there are anodic currents flowing into the more corroding electrodes and cathodic current flowing out of the less corroding or non-corroding electrodes. The resulting electrical currents are measured and the localized or non-uniform corrosion rates are determined by nanoCorr analyzers.
Sand Probe for High Pressure (HP and MH) Access Systems
Model SP7000 sand probes are used to detect erosion in flow lines caused by abrasive particles such as sand. One end of the probe is attached to a tee-type, high pressure access fitting with a solid plug by means of a sand probe nut. The other end is a sealed, thin-walled tube placed within the process stream to be exposed to particulate flowing through the system. (To minimize the effects of corrosion and thus more accurately detect erosion within the stream, the exposed element is made of stainless steel.) As particulate impinges on the surface of the sensing element, a hole is eventually eroded through the element. Once penetration has occurred, the system pressure then travels up the tube, into the access fitting body, and through a nipple and valve to a pressure gauge assembly. The pressure gauge detects that the element has been breached. If required, electronic pressure sensors can be connected to alarm systems to signal the exact moment when failure occurs.
The Hydrogen Penetration Monitoring System provides a method for directly measuring the rate of hydrogen migration through a vessel or pipe wall. This method actually measures the penetration current set up by the hydrogen as it moves through the steel. By sensing and recording this data directly from the pipe wall, this system offers valuable data which can only be indirectly inferred by other methods.
The Hydrogen Patch Probe (see below) can be mounted directly to the outside of the pipe wall by simple mechanical straps tightened with a screwdriver. No welding or tapping is required. The patch probe can be installed or moved to a new location in less than one hour.
One of the common corrosion products of iron or steel in a neutral or acidic medium is atomic hydrogen. Normally, these highly reactive species combine with other hydrogen atoms to produce a relatively harmless molecule, hydrogen gas (H2). In the presence of some catalysts such as sulfur, arsenic, or tin, the hydrogen atoms dissolve into the steel to a significant degree.
The Hydrogen Penetration Monitoring System measures hydrogen moving through a pipe or vessel wall. Since the hydrogen produced by the corrosion reaction occurring inside the pipe or vessel often produces severe structural damage to steel, especially in highly stressed or high strength alloys, it is valuable to be able to monitor the hydrogen penetration rate.
The MS3112 instrument and the HYY00330100 Hydrogen Patch Probe are quickly and easily installed at virtually any corrosion monitoring site. The pipe to be monitored is first surface cleaned. Then a transfer medium (paraffin wax) and a small piece of .010" palladium foil are placed on the pipe to be monitored. The electrochemical patch probe is then mounted over the foil. A pair of gaskets and an insert, shaped to the general contours of the pipe, provide a leak-tight seal against the foil. The cell is then filled with a suitable electrolyte. When the palladium foil is polarized by the MS3112 instrument, the foil acts as a working electrode, quantitatively oxidizing the hydrogen as it emerges from the pipe wall. After an initial pumpdown period, the current indicated by the instrument is directly equivalent to the real-time hydrogen penetration rate.
Since the instrument/probe is measuring the hydrogen penetration rate, the user gets fast response to changes in the system being monitored. Significant changes can be seen in less than two hours. The instrument instantaneously measures and records penetration current from a low of 10 microamps full scale to a high of 5000 microamps full scale. Its digital recorder charts the hydrogen penetration rate on-screen, and stores the data to a microSD flash memory card. Data can be reviewed on-screen and can be downloaded to a PC for printing and analysis.