Report: Corrosion Coupon Installation in Online Pipeline

with Existing Access Point

1. Introduction

Corrosion is a major concern in pipeline integrity management. Corrosion coupons are a simple
and effective method for assessing the rate of corrosion within a pipeline. This report details the
successful installation of a new corrosion coupon in an online pipeline utilizing a pre-existing
access point.

2. Corrosion Coupons

A corrosion coupon is a small piece of metal, typically made from the same material as the
pipeline itself. The coupon is installed within the pipeline and exposed to the flowing fluid for a
predetermined period. After retrieval, the coupon is weighed and the thickness measured to
determine the amount of metal loss due to corrosion. This information can then be used to
calculate the corrosion rate and predict future pipeline life.

3. Installation Procedure

The following procedure outlines the steps taken to install a new corrosion coupon in the online
pipeline using a pre-existing access point:

3.1 Preparation

● Gather Equipment : Ensure all necessary tools and materials are readily available at
the worksite.
● System Isolation (Localized): Isolate the specific access point using valves upstream
and downstream of the coupon holder. This minimizes fluid release during the
procedure.
● Pre-Installation Inspection: Verify the integrity of the access point and coupon holder.
Ensure there are no leaks or damage.

3.2 Coupon Retrieval

● Open Access Point: Carefully remove the plug or cap from the coupon holder, allowing
any built-up pressure to vent slowly.
● Detach Existing Coupon: Use the appropriate retrieval mechanism (e.g., threaded rod)
to remove the existing coupon. Dispose of the used coupon appropriately.

3.3 Coupon Installation

● Clean the New Coupon: Ensure the new coupon is free of contaminants (dirt, oil, etc.)
using a clean solvent or wire brush.
● Attach the Coupon: Secure the new coupon to the retrieval mechanism using the
designated method (threads,fasteners).
● Re-installation: Carefully insert the retrieval tool with the new coupon into the access
point.
 ● Tighten and Seal: Screw the assembly back into the holder and tighten securely with
wrenches. Apply thread sealant if required.

3.4 Pressure Re-establishment

● Slowly Open Isolation Valves: Gradually re-introduce pressure into the isolated
section.
● Monitor for Leaks: Visually inspect the connection points for any leaks. Tighten
connections if necessary.

3.5 Tool Detachment

● Once pressure is restored, detach the retrieval tool from the coupon holder,
leaving the new coupon in place for monitoring.

3.6 Record Keeping: Document the following information:

● Coupon ID and Material

● Installation Date and Location
● Planned Retrieval Date

4. Calculation of Corrosion Rate

After coupon retrieval, the weight loss (ΔW) is measured, and the corrosion rate can be
calculated using the following formula:

Corrosion Rate (mpy) = (534 × ΔW) / (D × A × T)

Where:

● ΔW = Weight loss of the coupon (mg)

● D = Density of the coupon material (g/cm³)
● A = Surface area of the coupon (in²)
● T = Exposure time of the coupon (hours)

The factor 534 converts the units to mils per year (mpy). This calculated corrosion rate helps
assess the pipeline's overall corrosivity and predict future maintenance needs.

5. Advantages of Corrosion Coupons

● Simplicity and Reliability: Corrosion coupons are easy to use and provide reliable data
on the actual material loss due to corrosion within the pipeline.
● Direct Measurement: They offer a direct measurement of corrosion, unlike other
techniques that rely on estimations.
● Cost-Effective: Coupons are a relatively low-cost method for continuous corrosion
monitoring compared to more sophisticated techniques.

6. Limitations of Corrosion Coupons

● Time-Consuming: Obtaining meaningful data requires long-term exposure of the

coupon, making the process time-consuming.
 ● Surface-Specific: Coupons only measure corrosion at the specific location they are
installed and may not represent the entire pipeline system.
● Physical Handling: Improper handling and cleaning of the coupons can introduce errors
in the final weight loss measurement, affecting the calculated corrosion rate.

7. Applications of Corrosion Coupons

Corrosion coupons have various applications across industries, including:

● Oil and Gas Pipelines: Monitoring internal corrosion to prevent leaks and pipeline
failures.
● Water Treatment Plants: Assessing the effectiveness of corrosion inhibitors used in
water treatment systems.
● Industrial Cooling Systems: Ensuring the longevity and efficiency of cooling towers
and related infrastructure.

8. Equipment List

● Personal Protective Equipment (PPE): Safety glasses, gloves, hard hat, appropriate
clothing
● Cleaning Materials: Solvent or wire brush
● Wrenches/Socket Set
● Calibration Labels
● Existing Coupon Holder (pre-installed)
● New Corrosion Coupon
● Retrieval Mechanism (e.g., threaded rod)

9. Estimated Time

The total estimated time for installing a new corrosion coupon in an online pipeline with a pre-
existing access point is approximately 15 minutes. This timeframe can vary depending on
specific site conditions and unforeseen circumstances.

10. Conclusion

This report details the successful installation of a new corrosion coupon in an online pipeline
utilizing a pre-existing access point. By following this procedure and utilizing the proper
equipment, valuable data can be obtained on the pipeline's corrosivity, allowing for informed
decisions regarding maintenance and future pipeline integrity.