AC Coupon

Test and Measurement

Guide

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 AC Coupon
Test and Measurement Guide

1 Purpose
The purpose of this document is to provide clear instructions on identifying corrosion and
determining weight loss on AC coupons deployed in the field. Key steps for the removal of AC
coupons from the field and subsequent preparation and testing of the coupon in a testing lab are
detailed.

2 Field Removal
The following steps should be taken for proper field removal of the coupon.

a) Remove the coupon from the earth with care.

b) Photographed the coupon once removed.

c) Scale, dirt, and other deposits should not be removed in the field.

d) Cut off excess cable leaving approximately 10 cm attached to the coupon.

e) Place the coupon in a moisture proof bag/envelope and ship to the designated laboratory for
analysis.

3 Laboratory Testing
The following steps should be taken to properly measure the mass of the coupon to determine
metal loss and to identify the type of corrosion.

a) The shrinkable sleeve, the connection cable, and any soil adhering to the coupon shall be
carefully removed to avoid damaging the coupon itself. Any deposit on the coupon that
doesn’t seem to be soil, shall be considered a corrosion product and treated as indicated in
step c). The photos of a new coupon and of the cable connection are shown below for
reference. A 5/64” Allen Wrench is required to remove the cable from the coupon.

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 AC Coupon
Test and Measurement Guide

Figure 3-1: AC Coupon General View

Figure 3-2: AC Coupon Cable Connection

b) The exposed coupon shall be weighed within +/- 0.1 mg and photographed before the
cleaning.

c) The coupon should be visually examined and the observations (i.e., type of corrosion) should
be recorded. Qualitative analysis of deposits should be performed using SEM/EDS and XRD
(Scanning Electron Microscopy/Energy Dispersive X-Ray Spectroscopy and X-Ray Diffraction)
analyses. Microscope photos of relevant features should be taken.

d) The coupon shall be carefully cleaned using chemical and mechanical methods as follows:

i) The coupon shall be immersed in 15% inhibited hydrochloric acid to remove mineral scale
and corrosion products. Ultrasonic agitation may be used to accelerate the cleaning
process. Numerous commercial inhibitors are available to protect the steel during acid
cleaning. SP0775-2013 recommends a stock solution made of 37.5% HCl with 10 g/l of
1,3-Dibutyl-2-thiourea added. Immediately prior to use, the stock solution is diluted by
slowly adding a measured volume of stock solution to an equal volume of distilled water
while stirring. If even longer immersion and ultrasonic agitation cannot remove the
deposits, the coupon may be mechanically cleaned by blasting with glass beads at 40 psi;

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 AC Coupon
Test and Measurement Guide

however, in this case the mass loss during blast cleaning shall be determined by subjecting
a pre-weighed blank (i.e., not exposed to corrosion) to the same cleaning process.

ii) After cleaning, immerse the coupon in a saturated solution of sodium bicarbonate for one
minute to neutralize the acid. Rinse with distilled water to remove the neutralizer.

e) Rinse the coupon immediately in isopropyl alcohol or acetone and dry in a steam of dry air.

f) The clean coupon shall be weighed within +/- 0.1 mg and photographed.

g) The coupon shall be inspected for pitting and any pits shall be measured and photographed.
This should be performed in accordance to ASTM G46 Standard.

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