Corrosion Coupon For Pipeline Testing

Description

EMT-CI Corrosion Coupon is used to monitor the corrosion rates of the sample (coupon) in the pipe or container. By observing the mils-per-year corrosion rate of an exposed coupon, valuable information can be provided regarding the material’s life expectancy.

1.  Prepare

Protective equipment: positive pressure air respirator, protective glasses, protective gloves, portable hydrogen sulfide tester.

Tools:

29mm explosion-proof wrench, 1 “mechanical wrench, 11 / 4” mechanical wrench, 12 “adjustable wrench
60-90mm explosion-proof hook head wrench, 105mm explosion-proof wrench, plastic hammer
Take and place the device, manual pump, safety gas tank (lye), and connecting hose
Cleaning tools, 8mm and 5mm flat screwdriver, operation record card.

Materials: grease, acetone, filler, polytetrafluoroethylene.

2.  Operation inspection

1. Installation inspection with pipeline under pressure

1) First of all, make sure that there is enough space for use of the pick-and-place device.
2) Secondly, confirm the pipeline pressure and estimate the pressure fluctuation range.
3) Then confirm that the hydraulic fixing device is intact.
4) Confirm that the safety cover is fully tightened.
5) Screw out the locking pin for inspection every time. One at a time.
6) Check the O-ring of the locking pin for cuts and wear. Replace if necessary.
7) Then check and clean the surface of the fittings and 0-ring.
8) Check the locking pin and tighten it.
9) Check the condition of the hanging piece and hanging piece holder. If there is oil or other compounds on it, we must remove it with acetone

2. Installation procedure of corrosion coupon of pressure pipeline

• Wear safety glasses when using the dispenser.
• Let’s open the dispenser upward. And connect the extractor and the pump with a hose. We set the pump to the installation position. Press until the connecting rod is extended.
• Screw the plug-in and hanging piece on the connecting rod. We turn the pump to the “retrieve” position. Then relieve the pressure until all the hanging pieces return to the retrieval device. Remove the safety cap and install the maintenance valve on the fixing device
• Lift the retrieval device and place it on the maintenance valve. Screw the impact nut on the maintenance valve and tighten it.
• Turn the pump to the “installation position”.
• Balance the pressure on both sides of the maintenance valve by:

Standard maintenance valve:

Slowly open the bypass valve. The pressure in the retrieval device will rise to the same as that in the pipe. (We can read it on the pressure gauge).
Double ball seal maintenance valve: slowly open the bypass valve of the upper ball valve. Then open the upper ball valve. Slowly open the bypass valve of the lower ball valve. The pressure in the retrieval device will rise to the same level as the pipeline pressure.
If the pressure on both sides cannot be balanced. It is most likely that there is dirt in the bypass valve. Which makes it difficult to open the maintenance valve. When the pipeline pressure is too high (higher than 50bar), it may be necessary to pump flat pressure.

To balance the pressure with a pump, use the following steps:

① Turn the pump to the “retrieve” position. Release the pressure until the hanging film yard enters the retrieval device.
② Install the quick return pressure connection assembly on the pressure relief valve. At this time, make sure that the pressure relief valve is open;
③ Keep the pump in the “retrieve” position. Boost the pressure until the pressure in the retrieval device is equal to or exceeds the pipeline pressure.
④ Take the hose from the pressure relief valve and open it back to its original position.

• We can observe the pipeline pressure in the take-out and release devices. Check the leakage between the retrieval device and the maintenance valve. If there is no leakage, open the maintenance valve.
• Turn the pump to the “installation” position. Increase the pressure until the solid cock and hanging piece enter the position inside the device. The number of times depends on the pipeline pressure and the size of the retrieval device. The pump matched with the retrieval device is a two-stage pump. The first stage to the second stage is about 30 bars. Therefore, if the pressure is lower than 30bar, press it about 30 ~ 60 times. If the pressure is higher than 30bar, press 400 ~ 600 times.
• Carefully open the pressure relief valve of the extractor. Reduce the pressure in the service valve. Use a hose with a safety relief tank to connect the relief valve and the safety relief tank
  It is used to hold the outflow gas or fluid. Drain as much liquid as possible from the retrieval device before removing the hose.
  Note: When acid gas or other dangerous gas or fluid leaks out. It must be connected with hoses and necessary precautions shall be taken to ensure the safety of operators

Corrosion

• Tighten all locking pins of the fixture. The locking pin of the upper locking fixture must be tightened evenly. Avoid pushing the solid cock to one side of the fixture. Until the locking pin touches the solid plug, tighten it by a quarter turn at a time. Tighten one by one until all locking pins are tightened.
  If it is jammed or easily twisted (4-5 turns) after only one-third of a turn, there is no resistance. This means that the position of the solid plug is incorrect.
  Loosen all pins and reinstall solid cocks and hanging pieces. And check the damage caused during installation.
• When the solid cock is fixed by the locking pin, the pressure in the retrieval device is released. Turn the pump to the “take back” position and operate the pump 1 ~ 2 times. The pressure gauge reads 0.
• Close the pressure relief valve and wait for 1 ~ 2 minutes. Then open the pressure relief valve again. Check whether there is pressure in the retrieval valve. If there is pressure, it indicates that the solid insert is not well sealed in the fixing device. If this happens, pump to make the pressure in the pick-up and release device at least 10 bar higher than the pipeline pressure. Then loosen and tighten the locking pin to check whether there is any leakage. If so, the solid insert must be taken out for inspection or the main packing replaced.

Pipeline Corrosion

• If there is no leakage, remove the extractor. Specifically, loosen the impact nut and remove the take-out, and place the device from the maintenance valve. (be careful that there is liquid flowing out when disassembling the dispenser.). Turn the pump to the “installation” position and press until the connecting rod is fully inserted. Continue to press until the pressure gauge reads at least 20 bar. Then close the head valve of the pick-up and release the device to release the pressure in the pump and pipe. Disconnect the hose of the extractor and remove the connection of the extractor from the plug-in
  Rod.
• Clean the bottom of the plug-in and the hole of the plug-in. Remove all dirt and water.
• Check and lubricate the threads of each connecting device.
• Install the complete cover and tighten it with a 105 mm wrench. This can relieve the pressure of the locking pin.

3. Inspection before removal of corrosion coupon on pressure pipeline

(1) Ensure that there is enough space for the pick-and-place device.
(2) Confirm the pipeline pressure and estimate the pressure fluctuation range.
(3) Check the O-ring at the bottom of the maintenance valve.
(4) Clean and lubricate the exposed threads of the fixture.

4. Disassembly steps of corrosion hanging piece on pressure pipeline

• Remove the safety cover on the retaining device. Use soapy water to check for leaks around the solid plug and around the locking pin. If there is leakage, install and tighten the safety cover. Wait for the next full inspection when the piping system is shut down.
• Install the maintenance valve on the fixture. And smash it tightly with a plastic hammer.
• Connect the retrieval device to the pump with a hose. Before starting the pump, check the rotation direction of the directional valve handle.\
• Open the valve of the pick and place the head (it can be opened after 1-2 turns). Check that the return valve on the manual pump is closed. Set the manual pump to the “installation” position, and do not start pressing until the connecting rod is fully extended. Continue pressing until the pressure on the take-off and release device reaches 20bar. Then close the head valve. Remove the pipe. Connect the take-off and release device with the maintenance valve. Align the connecting rod of the take-off and release a device with the center of the maintenance valve, and extend the connecting rod into the maintenance valve. Rotate to connect. The rod and the solid cock are connected together. Be careful not to be too tight.

Corrosion Coupon For Pipeline Testing

• Connect the pump and the extractor with a hose. Turn the pick and place the device to the “retrieve” position. Open the head valve and press it 1 ~ 2 times to make the take-off and release device face the maintenance valve
• Connect the maintenance valve with the impact nut, tighten it as required, and screw it down with a plastic hammer.
• When the pressure relief valve of the take-off/release device is closed. Turn the directional valve on the pump to “installation”. Boost the pressure until the pressure of the retrieval device is at least 30 ~ 50bar higher than that in the pipeline.
• Loosen all locking pins on the fixture. We must loosen the locking pin. If it is not easy to tighten, the locking pin must be tightened again to increase the pressure.
  Note: screw out all the locking pins until the locking pins are flush with the outer surface of the fixture. If it spins out too much. When the solid plug is taken out, there will be a leakage
• Ensure that the maintenance valve is fully open. The ball valves on both sides of the maintenance valve are fully open.

• Step of retrieving the hanging piece from the pipeline to the maintenance valve.

① Make sure the pressure relief valve is closed. Turn the pump to the “take back” position and relieve the pressure.
Suppose the gas pressure in the pipeline exceeds 200bar. Close the head valve before turning the pump to the “take back” position. When turning the rotary handle to the “take back” position, open the head valve and slowly depressurize.
② Pressurize with the pump until the pressure gauge on the pump shows that the pressure in the pick-up and release device reaches a certain value. This means that all the hanging pieces have been taken out. Check for leaks around the locking pin. In case of leakage, the hanging piece needs to be reinstalled. Reinstall the safety cover and recheck the “O” shape on the locking pin.
Note: when the pump is at the “take back” position, the pressure shall not exceed 100bar. This is to prevent the hanging piece from being ejected. If it is retrieved when the pressure is high, the dangling piece and retrieval device may be damaged. If it cannot be taken out at 100bar, the hanging piece shall be kept in the fixing device. We won’t take it out until the next time there is no pressure in the pipeline.
③ Close the maintenance valve. If a double ball seal maintenance valve is used, close the lower ball valve during this period. Do not close with force, otherwise, the following conditions may occur:

● There is large sand or debris in the separation valve. Hindering the rotation of the ball valve:
● The hanging piece is not completely taken out:
Make sure that the hanging piece has been completely taken back and pressurize the pump. The pressure in the retrieval device rises a little with each stroke.

Note:

if the maintenance valve cannot be closed, we must reinstall the hanging piece. Check the condition of the valve and find out the cause of the problem.

If the maintenance valve is closed, check whether the bypass valves on both sides of the maintenance valve are closed. If the bypass valve cannot be closed, the hanging piece must be reinstalled. And check the bypass system on the maintenance valve.

• Take out the pressure relief operation of the device. When the maintenance valve is closed, use the hydraulic cylinder relief valve to reduce the pressure of the takeoff and release device. Connect the relief valve with a safety relief tank with a hose. Fully drain the liquid in the trap before removing the hose.

• If the pressure in the take-out and release device drops to 0, check the sealing condition of the maintenance valve. Close the pressure relief valve and wait for 1-2 minutes. Then we open it to see if there is pressure in the loading/unloading device. If the maintenance valve leaks, check whether the maintenance valve is closed. Also, check whether the bypass valve is closed. If the leakage of the maintenance valve cannot be stopped, we must reinstall the hanging piece and solid cock. At the same time, we need to repair the maintenance valve.

Corrosion Coupon

If the hanging piece and solid cock have been completely retrieved, the pump must be set to the “installation” position. And the hanging piece and the solid cock are pumped toward the ball valve on the maintenance valve. Be very careful during air pressure to avoid the hanging piece hitting the ball valve. Otherwise, the ball valve and hanging piece may be damaged. Watch the pressure gauge carefully and stop pumping when the pressure starts to rise.
Open the pressure relief valve of the take-off and release device and turn the pump to the “take back” position for pressurization. Reduce the pressure in the retrieval device, which makes the ball valve in the maintenance valve return to its original position. If bleeding is not possible, close the pressure relief valve. Return the solid plug pump to the fixed device, tighten the locking pin, remove the maintenance valve and complete the maintenance work, and check whether the ball valve and sealing gasket are scratched.

• When the lower ball valve in the maintenance valve is closed and well-sealed, close the upper ball valve.
• After ensuring that the maintenance valve is well sealed, loosen the impact nut. Disassemble the take-out and place the device from the maintenance valve. The fixture is in the 12 o’clock position (facing up). When the extractor is removed from the maintenance valve, be careful that the liquid flows out.
• Place the opening of the take and place the device upward, and turn the pump to the “installation” position. Press the hanging piece, and plug it out of the extractor.

3. Precautions:

1. During operation, leakage occurs due to improper installation. So we must take protective measures. This can prevent people and equipment from being injured by leakage. If the leakage is flammable and explosive, fire and explosion prevention measures shall be taken.
2. We must use explosion-proof tools
3. The operator must ensure that the temperature and pressure do not exceed the limit value during operation. Otherwise, it will lead to leakage and associated danger.
4. The operator must send a signal to the personnel in the control room before each operation. Oil and gas leakage must be reported to the personnel in the control room.

Why Choose US?

1. Firstly, samples will be offered to attest to the quality and our services
2. And then the fastest delivery time.
3. At last, 24 hours,7 days online.

We cooperate with many express companies. So that could ensure the fastest delivery time and lowest shipping cost.

Packaging&Delivery

We use PLYWOOD CASE as packaging, it has the following advantages:

1.Lightweight,clear lines,insulation,high strength,not easy to deformation;

2.No fumigation is required.