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9/2/2017 Corrosion Monitoring & Corrosion Coupons - Global Water Technology
Corrosion rates should be viewed in relative, not absolute, measurements. Many variables affect corrosion, but
the type of application will ultimately determine what an acceptable corrosion rate is. A system that is subjected
to severe use, such as a process loop in a nuclear cooling system, will have higher corrosion rate expectations
than a less abused system, such as a commercial HVAC system. Use corrosion data to compare stability of the
loop over time. Improvements or regressions can be determined through monitoring.
http://www.gwt-inc.com/resources/corrosion-monitoring/ 2/7
9/2/2017 Corrosion Monitoring & Corrosion Coupons - Global Water Technology
Corrosion
coupons
are the
simplest
and most
commonly
used form
of
corrosion
measurement today. Corrosion coupons are small bars of various metals or alloys that are introduced into the
system through a side stream coupon rack. The coupon alloy selection should be representative of system
metals.
Coupons are pre-weighed and measured by a manufacturer and left in place for a fixed amount of time. After
exposure, coupons are usually returned to the supplier for analysis by an independent laboratory.
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9/2/2017 Corrosion Monitoring & Corrosion Coupons - Global Water Technology
Metal Alloys:
Physical Configurations:
Strips
Rods
Flush Discs
Discs
A corrosion rate is determined in mills per year (MPY) from the weight of material lost over its time in place.
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9/2/2017 Corrosion Monitoring & Corrosion Coupons - Global Water Technology
Evaluating a 30 day coupon interval versus a 90 day will be of less use than a 90 to 90 where you can see if your
system is stable or not. A coupon will have the most metal loss in the first 30 days and typically a lower loss rate
in the last 60 days of a test. This is due to 30 days being too soon for a passivating layer to develop on the
coupon.
Pitting: Depressions on the metal surface from corrosion. Pits vary in size, depth, and density. Pitting is typically
caused by one of the following: low inhibitor levels, high chlorides, copper plating, pH variations, and under-
deposit corrosion.
Localized Corrosion: Caused from under-deposit corrosion. Could be caused by a low flow rate through the
rack or necessity for better deposit control.
Copper Plating: Soluble copper attaches to non-copper alloy samples. Can cause severe galvanic corrosion and
metal failure due to pitting.
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9/2/2017 Corrosion Monitoring & Corrosion Coupons - Global Water Technology
Coupons need flow to work. Some no flow areas such as by-pass lines, future lines, lead and lag
equipment, or out of service equipment are the most susceptible to corrosion.
Coupons are brand new samples of metal alloy. The surfaces are smooth and polished. These
surfaces may differ from the surfaces of older piping systems which might be worn or pitted.
This difference could create a source of error.
Model Equipment Model equipment can be installed in parallel with actual equipment or in a pilot plant. All
variables must be identical to the actual plant.
Instrumental Test Methods Electrical resistance and polarization scans are valuable, and can generate a
continuous record of corrosion rate.
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