Theory and Application of The Corrosometer

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
THEORY AND APPLICATION

OF THE CORROSOMETER
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Chapter : Corrosion For additional information on this subject, contact

File Reference: COE-102.03 PEDD Coordinator on 874-6556
Engineering Encyclopedia Corrosion Monitoring
Theory and Application of the Corrosometer
Content Page
PRINCIPLES OF CORROSOMETER OPERATION ..................................................... 2

History of Electrical Resistance Measurement Technique.................................. 2
Theory of Electrical Resistance Measurement ................................................... 2
Temperature Compensation ............................................................................... 4
Electrical Circuits ................................................................................................ 4
Types of Corrosometer Probes........................................................................... 6
Advantages of Probe Types ............................................................................... 7
Measuring Elements ........................................................................................... 7
Probe Selection .................................................................................................. 8
FIELD USE OF THE CORROSOMETER.................................................................... 11
Common Problems in Field Use ....................................................................... 11
Safety Precautions............................................................................................ 12
Interpretation of Corrosometer Data ................................................................. 13
Applications of the Corrosometer -- Advantages and Limitations ..................... 14
REFERENCE .............................................................................................................. 17
GLOSSARY................................................................................................................. 18
List of Figures
FIGURE 1. Typical Corrosometer Data ........................................................................ 3

FIGURE 2. Schematic of a Null Balance Circuit Used
in the Electrical Resistance Method for Corrosion Measurement.............. 5
FIGURE 3. Probe Selection for General Corrosion ...................................................... 9
FIGURE 4. Probe Selection for Process Upset Conditions ........................................ 10
FIGURE 5. Corrosion Rate Graph.............................................................................. 16
Saudi Aramco DeskTop Standards i

PRINCIPLES OF CORROSOMETER OPERATION
History of Electrical Resistance Measurement Technique
The measurement of corrosion by electrical resistance

technique, such as with a corrosometer, uses the principle that
resistance of a metal specimen increases as its cross-section
decreases. For years the technique was limited to occasional
laboratory use. In 1954, a paper by Dravnicks and Cataldi
stirred interest in developing a practical field tool using the
electrical resistance technique. However, unstable temperature
control made field measurements of electrical resistance
unreliable. Eventually, temperature compensation methods
were developed so that temperature variations in test
specimens were no longer as critical. Subsequent refinements
in both instruments and probes have made the electrical
resistance measurement technique an excellent tool for rapid
corrosion measurement.
Theory of Electrical Resistance Measurement
The electrical resistance of a specimen of metal can be

expressed mathematically by equation 1.
L
R = ρA (1)
where R = resistance (ohm)
ρ = resistivity (ohm-cm)
L = length (cm)
A = cross-section area (cm2)
Examples: Cross-sectional area of a strip = width x thickness

Cross-sectional area of a wire = π x diameter2
Cross-sectional area of a tube = π x (outside
diameter2 - inside diameter2)
Saudi Aramco DeskTop Standards 2

The electrical resistance of a fixed-length specimen depends on

its cross-sectional area. As the specimen corrodes, its cross-
sectional area decreases and its electrical resistance increases.
The resistance increase per unit time can be plotted on a graph.
The slope of the curve at any point in time represents the
corrosion rate. Figure 1 shows typical data recorded with a
corrosometer.
 ∆ Reading 
Rate (MPY) =   ∞ 0.365 ∞ Span
∆ Time (Days)
If probe = W40
Then span = 10 mils (0.010 in.)
Rate A = 7.3 MPY
Rate B = 0 MPY
Rate C = 44 MPY
FIGURE 1. Typical Corrosometer Data

Temperature Compensation
The effect of temperature can be expressed as follows:
RT = R0(1 + α[T - T0]) (2)
where RT = resistance at temperature T

R0 = resistance at temperature T0
∝ = coefficient of resistivity
T = temperature T
T0 = temperature T0
As corrosion takes place, extremely small changes in resistance

occur. Temperature, as defined in equation 2, can cause
changes in resistance that will obscure the changes resulting
from corrosion. Compensation for change of resistivity with
temperature is achieved with a reference element protected
from the corrosion process. As the resistance of the specimen
increases with temperature, so does the resistance of the
reference element. Since the resistance ratio of the specimen
and the reference element remains unchanged, automatic
compensation for temperature changes is provided.
Electrical Circuits
The circuitry of the corrosometer determines the resistance ratio

of the specimen to the reference element. Figure 2 is a
schematic of the circuitry. The design of the circuits makes the
corrosion readings directly proportional to the amount of metal
removed from the specimen. Each corrosion reading, therefore,
is a direct indication of the average reduction in thickness of the
specimen. To determine the rate of corrosion, the loss of metal
occurring between any two readings is divided by the time
interval between the two readings.

FIGURE 2. Schematic of a Null Balance Circuit Used in the Electrical Resistance

Method for Corrosion Measurement

CORROSOMETER PROBES
Types of Corrosometer Probes
The probe is the heart of the corrosometer system. It functions

as a local sensor accumulating the corrosion history of the
environment and displaying or recording the corrosion data.
The probe is sometimes called an “electrical coupon”.
A variety of corrosometer probes are available to match various

applications. The following is a description of the major types of
corrosometer probes.
• Internal process monitoring probes
• Removable under system pressure
• Retractable system (for pressures up to

1,500 psi). Retractable process probes are
introduced into the system through a stuffing
box mounting external to a valve. A
retracting device is used to insert or remove
probes at pressures too high for safe
operation by hand.
• Retrievable system (for pressures up to

6,000 psi). Retrievable process probes are
sealed into the system in an access fitting.
A separate service valve and retriever is
used for insertion and removal of the probes
under system pressures.
• Non-removable under system pressure (fixed type)
Fixed-type probes are available as flange

mounting, fixed thread mounting, or adjustable
thread mounting.
• Laboratory probes
Laboratory probes have glass epoxy bodies that can be

used in low pressure systems. They are either clamped
over an open vessel or inserted through a rubber
stopper.

• Atmospheric corrosion probes
Atmospheric corrosion probes monitor the corrosivity of

the air or atmosphere in plant control rooms, near
exhaust stacks, or critical locations in a refinery or plant.
Advantages of Probe Types
• Probes that are removable under system pressure permit

inspection or change out of probes without shutting down
or isolating the system.
• Probes that are not removable under system pressure

are used for reasons of economy, safety, or special
process limitations.
Measuring Elements
There are four forms of corrosion measurement elements.
• Strip, tube, and wire loop elements
The strip, tube, and wire loop elements are more

economical and available in a wider range of alloys than
for other element forms. Two forms of element seals
protect the reference element within the probe body.
Glass-to-metal seals provide the highest seal integrity.

They are suitable for process fluid ranging between 0
and 9 pH and temperatures up to 500 °F. They are not
suitable for fluids containing fluoride ions, which attack
glass, ceramics, and epoxies.
Teflon coating and ceramic fill provide the alternative

seal of the reference element in loop elements.

• Cylindrical elements
Cylindrical elements are directly welded to the probe

body, providing the highest integrity seal for aggressive
environments. They provide a large surface area for
measurement and have the fastest dynamic response to
temperature transients. Cylindrical elements are the
least susceptible to the effects of conductive deposits
such as iron sulfide. Probes with cylindrical elements are
suitable in environments with pH 0 to 14 and
temperatures up to 500 °F. For high temperature
applications (above 500 °F), probes with specially
designed elements are available.
• Flush elements
Flush element probes monitor localized wall effects and

situations where protrusion into the line would damage
the probe, for example, during scraping operations.
• High sensitivity elements
High sensitivity element probes are used in minimally

corrosive environments where quick detection of
increased corrosion is important.
Probe Selection
Probe selection is very important for the collection of reliable

corrosion data. Probe selection depends on many factors:
metallurgy, pressure, temperature, corrosion level. Generally, a
probe should have an element thickness to allow for about 0.5
percent of the element's useful life to be consumed per day at
the average corrosion rate expected. For critical applications,
more sensitive probes should be chosen.
When corrosion probes are used to monitor general corrosion

rates and speed of response is less critical, Figure 3 should be
used as a selection guide. When corrosion probes are used in
process applications where speed of response to upset
conditions is of primary importance, probes should be selected
according to the response time in Figure 4.

With a corrosometer probe, 1 percent of the probe life (10

divisions of 1000 divisions) is a practical detection level. Probe
life, however, is not necessarily 100 times the response time,
because the upset corrosion rates are normally rather brief.
FIGURE 3. Probe Selection for General Corrosion

FIGURE 4. Probe Selection for Process Upset Conditions

FIELD USE OF THE CORROSOMETER
Common Problems in Field Use
• Poor location of corrosometer probes
In principle, corrosometer probes will give readings

anywhere. An electrically conductive environment is not
required. However, probes should be located where
corrosive conditions exists. For example, probes located
in the gas-filled upper portion of a line will gather no
information about the corrosion damage occurring in the
water-covered bottom section of the line. Probes should
be located at sites where corrosive conditions are
dynamic. Dead legs are not good sites.
• Inadequate monitoring points
Most applications require multiple corrosometer probes

to monitor various points in the system. Probes should
be located at critical points (velocity, turbulence,
temperature, and mixing), at points where upset may
occur, at points where abrupt changes occur, and “worst
case” points as determined by prior operating
experience.
• Fluctuating temperature
Although the effect of varying temperature has been

canceled by probe design, fluctuating temperature may
still affect measurements. Since the probe's reference
element is either coated or embedded, it responds more
slowly to temperature changes than the exposed test
element. Readings may go backward or jump
unrealistically. Under such conditions, plotting the
readings over a period of time will determine the best
curve to fit the data points.
• Build up of corrosion products on probe elements
Conductive corrosion products such as iron sulfide can

affect corrosometer measurements. Sometimes these
products have a conductivity approaching that of the
metal lost. Such conditions may cause measured

electrical resistance to indicate no loss of metal even

though the metal has been replaced by another material.
• Fatigue failure of the probe element
In a fast flowing stream, probe elements can fail from

fatigue. In such environments, a stronger, heavier
element or a shielded element is recommended.
• Corrosion of the probe housing
Corrosion of the probe housing occurs when the probe

selected is not the right one for the conditions. Examples
of this problem include the use of an austenitic stainless
probe in conditions that cause rapid stress corrosion
cracking or use of seals and other materials that would
not withstand the process temperature.
• Probe sensitivity
A high sensitivity probe in an aggressive environment will

not last long and will require frequent replacement. If the
probe is a fixed type, the system will have to be
depressurized or shut down to replace the probe.
A probe with sensitivity insufficient for the environment

being monitored will not provide useful data. To
determine which probe is appropriate, several probes
with varying sensitivity are sometimes installed in a new
environment.
Safety Precautions
• Only use probes that are compatible to the system being

monitored.
An improperly selected probe can be a serious safety

hazard. Probes should have the correct metallurgy and
appropriate pressure and temperature ratings for the
system to be monitored.

• Use common sense and established procedures for

installing and retrieving probes.
Improper installation can mechanically damage a probe

and its hardware. Improper alignment of the probe
during service could allow excessive erosion or
corrosion. A mechanically damaged probe may be
unsafe to retrieve while the system is pressurized.
Before a damaged probe is removed, the system should
be shut down or depressurized to a low level.
• Use applicable safety devices.
The probe retractor is a device used to install and

remove probes in pressurized systems. Safety clamps
should also be used to secure retractable probes and to
prevent accidental ejection of the probe after installation,
especially when pressures exceed 100 psi.
In electrically hazardous locations, safety barriers should

be used to provide electrical isolation between line-
powered instruments and probes. The barriers isolate
the probes from power surges and electrical fault
conditions.
Protective shields should be used to prevent damage to

the exposed measuring element of the probe. High
velocity shields should be used with probes with loop
elements exposed to flow rates above 10 feet per second
or when there is significant particulate matter or viscosity
in the product stream.
Interpretation of Corrosometer Data
Interpretation of data from corrosometers is subject to the same

general limitations as data from coupons. Deposits on the
probe surface can shield the element from the corrosive
environment. In some cases, iron sulfide scale on the probe is
electrically conductive, causing an apparent increase in the
cross-section of the exposed element. These deposits result in
a lower corrosion rate measurement, zero apparent corrosion,
or a negative reading.

Pitting corrosion requires special consideration. Most element

readings are proportional to minimum, not average, element
thickness. Pitting, on the other hand, is a random occurrence
on probes. If nucleation occurs on one element but not on
another, a comparison of indicated corrosion will lead to false
conclusions. Therefore, probe elements should always be
examined when removed from service. Wire, tube, or strip
elements that experience pitting will indicate a corrosion rate
many times higher than elements without pitting. Although this
effect is not as serious in the wider flush-mounted and
cylindrical elements, they should still be carefully examined.
Applications of the Corrosometer -- Advantages and Limitations
The corrosometer has many applications. In the laboratory, the

corrosometer is invaluable for studying the mechanism of
corrosion and evaluating inhibitor tests. In refineries,
corrosometers primarily monitor and evaluate inhibitor
effectiveness in distillation units, geothermal systems, and
cooling towers. Other corrosometer applications include
marine, automotive, and oil field installations.
More recently, corrosometers have been used as monitoring

and alarm systems for rapid detection of extremely corrosive
conditions in chemical process streams. In certain chemicals,
the presence of moisture makes the difference between an
extremely corrosive environment and a noncorrosive
environment. Typical applications include hydrofluoric acid and
sulfuric acid alkylation units and chlorinated solvents where
hydrolysis with moisture can generate hydrochloric acid.
Corrosometers have the following advantages.
• Measurements of metal loss can be made frequently

without having to see or remove the specimen. Because
the sensor stays in place, gathering corrosion data for a
history is easy.
• Corrosion measurements can be made in just a few

minutes or monitored continuously. Continuous
monitoring can reveal changes in corrosion as they
occur. In some cases, it is then possible to modify the
process and decrease the corrosion rate.

• The corrodent can be either conductive or

nonconductive (gas, liquid, or solid).
• Sensitive corrosometer probes can detect corrosive

conditions that might have gone undetected for a long
time using weight-loss coupons.
Corrosometers have the following limitations.
• Pitting characteristics will not necessarily be evident

from corrosometer measurements. Pitting of the probe
element may cause no detectable change during the
early life of the probe. However, as the probe element
approaches the end of its useful life, very rapid changes
may occur. If high rates of corrosion are measured near
the end of the probe's anticipated life, the probe should
be visually inspected for uniformity of corrosion and for
pitting or velocity effects.
• Conductive corrosion products can adversely affect

corrosometer measurements.
• Fluctuating temperatures can affect the accuracy of

measurements. Wire and strip elements are more likely
to have this problem since their reference elements are
embedded in the body of the probe. Embedded
reference elements respond more slowly to temperature
changes than exposed test elements.

FIGURE 5. Corrosion Rate Graph

REFERENCE
• Modern Electrical Methods for Determining Corrosion

Rates (NACE Publication 3D170)

GLOSSARY
access fitting A small pipe and valve used to connect a retractable probe
assembly into a line, tank, or process equipment.
corrodent A substance that causes a metal to corrode.
corrosion The process by which metal is lost to the solution it

contains. This process can be one or a combination of
chemical and electrochemical action.
electrical resistance That property of an electrically conductive material that

causes a portion of the energy of an electric current in a
circuit to be converted into heat.
erosion The process that removes solids by the flow of gas,

liquids, solids, or any combination of the three.
flange mounting A type of mounting that uses pipe coupling made in two
halves. Each half is screwed or welded to a length of pipe
and the two halves are then bolted together, joining the
two lengths of pipe.
nucleation Initiation of localized corrosion or pitting.
pitting Highly localized corrosion resulting in deep penetration.
probe A device placed in a system to monitor corrosion activity
probe element The sensing part of the probe; test specimen that is
available in a number of configurations (wire, tube, strip,
etc.) and alloys.
reference element A non-corroding portion of the probe element or test

specimen used to compensate for temperature changes.
retractable probe A type of probe that can be removed under system

pressure using a specially designed retracting device.
This probe has a lower pressure rating than a retrievable
probe.

Theory and Application of The Corrosometer

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Theory and Application of The Corrosometer

Hochgeladen von

Copyright:

Verfügbare Formate

Engineering Encyclopedia

Saudi Aramco DeskTop Standards

THEORY AND APPLICATION

Chapter : Corrosion For additional information on this subject, contact

Theory and Application of the Corrosometer

PRINCIPLES OF CORROSOMETER OPERATION ..................................................... 2

FIGURE 1. Typical Corrosometer Data ........................................................................ 3

Saudi Aramco DeskTop Standards i

Theory and Application of the Corrosometer

PRINCIPLES OF CORROSOMETER OPERATION

History of Electrical Resistance Measurement Technique

The measurement of corrosion by electrical resistance

Theory of Electrical Resistance Measurement

The electrical resistance of a specimen of metal can be

Examples: Cross-sectional area of a strip = width x thickness

Saudi Aramco DeskTop Standards 2

Theory and Application of the Corrosometer

The electrical resistance of a fixed-length specimen depends on

FIGURE 1. Typical Corrosometer Data

Saudi Aramco DeskTop Standards 3

Theory and Application of the Corrosometer

The effect of temperature can be expressed as follows:

RT = R0(1 + α[T - T0]) (2)

where RT = resistance at temperature T

As corrosion takes place, extremely small changes in resistance

The circuitry of the corrosometer determines the resistance ratio

Saudi Aramco DeskTop Standards 4

Theory and Application of the Corrosometer

FIGURE 2. Schematic of a Null Balance Circuit Used in the Electrical Resistance

Saudi Aramco DeskTop Standards 5

Theory and Application of the Corrosometer

Types of Corrosometer Probes

The probe is the heart of the corrosometer system. It functions

A variety of corrosometer probes are available to match various

• Internal process monitoring probes

• Removable under system pressure

• Retractable system (for pressures up to

• Retrievable system (for pressures up to

• Non-removable under system pressure (fixed type)

Fixed-type probes are available as flange

Laboratory probes have glass epoxy bodies that can be

Saudi Aramco DeskTop Standards 6

Theory and Application of the Corrosometer

• Atmospheric corrosion probes

Atmospheric corrosion probes monitor the corrosivity of

Advantages of Probe Types

• Probes that are removable under system pressure permit

• Probes that are not removable under system pressure

There are four forms of corrosion measurement elements.

• Strip, tube, and wire loop elements

The strip, tube, and wire loop elements are more

Glass-to-metal seals provide the highest seal integrity.

Teflon coating and ceramic fill provide the alternative

Saudi Aramco DeskTop Standards 7

Theory and Application of the Corrosometer

Cylindrical elements are directly welded to the probe

Flush element probes monitor localized wall effects and

• High sensitivity elements

High sensitivity element probes are used in minimally

Probe selection is very important for the collection of reliable

When corrosion probes are used to monitor general corrosion

Saudi Aramco DeskTop Standards 8

Theory and Application of the Corrosometer