GP 06-70 - Corrosion Monitoring

Document No.
GP 06-70
Applicability Group
Date 17 June 2009
GP 06-70
Corrosion Monitoring
Group Practice
BP GROUP
ENGINEERING TECHNICAL PRACTICES
17 June 2009 GP 06-70
Foreword
This issue of Engineering Technical Practice (ETP) GP 06-70 is a complete revision that includes:
• New sections on corrosion monitoring philosophy and design principles, which are
common to all segments.
• A section with a system-by-system approach to corrosion monitoring selection, most of
which are segment specific.
• Reference to an underpinning GN covering detailed technical information on corrosion
monitoring techniques.
Changes and reorganization are so extensive that revisions are not marked by bars in the margin as is
normal practice.
Copyright © 2009 BP International Ltd. All rights reserved.

This document and any data or information generated from its use are classified, as a
minimum, BP Internal. Distribution is intended for BP authorized recipients only. The
information contained in this document is subject to the terms and conditions of the
agreement or contract under which this document was supplied to the recipient's
organization. None of the information contained in this document shall be disclosed
outside the recipient's own organization, unless the terms of such agreement or contract
expressly allow, or unless disclosure is required by law.
In the event of a conflict between this document and a relevant law or regulation, the
relevant law or regulation shall be followed. If the document creates a higher obligation, it
shall be followed as long as this also achieves full compliance with the law or regulation.
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17 June 2009 GP 06-70
Table of Contents
Page
Foreword ........................................................................................................................................ 2
1. Scope .................................................................................................................................... 4
2. Normative references............................................................................................................. 4
3. Terms and definitions............................................................................................................. 5
4. Symbols and abbreviations .................................................................................................... 7
5. Corrosion monitoring philosophy............................................................................................ 8
6. Principles of corrosion monitoring system design................................................................. 10
6.1. General..................................................................................................................... 10
6.2. Device selection and placement................................................................................ 11
6.3. Corrosion data quality ............................................................................................... 14
6.4. Data management .................................................................................................... 14
7. Corrosion monitoring principles............................................................................................ 15
7.1. Direct intrusive monitoring techniques....................................................................... 15
7.2. Direct non-intrusive monitoring techniques................................................................ 19
7.3. Indirect online monitoring techniques ........................................................................ 20
7.4. Indirect offline monitoring techniques ........................................................................ 21
8. Corrosion monitoring selection............................................................................................. 24
8.1. General..................................................................................................................... 24
8.2. Oil and gas systems.................................................................................................. 26
8.3. Refinery systems ...................................................................................................... 30
Bibliography .................................................................................................................................. 37
List of Tables
Table 1 - General guide for application of corrosion monitoring techniques................................... 25
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17 June 2009 GP 06-70
1. Scope
a. This GP provides requirements for the selection, installation, and use of technologies for
monitoring of internal corrosion within in service piping and equipment.
Corrosion monitoring is a key component of corrosion management, which in turn is
a key component of integrity management, mandated by the Group Integrity
Management Standard and the Operating Management System (OMS). Detailed
technical information on corrosion monitoring techniques can be found in
GN 06-012.
b. This GP is applicable to oil refineries, petrochemical and chemical plants, onshore and
offshore (including subsea) oil and gas production facilities, liquefied natural gas plants,
pipelines, and distribution facilities.
c. Equipment that is subject to deterioration from exposure to a production or process
environment is within the scope of this GP. Typical equipment includes the following:
1. Process and utility piping, risers, pressure vessels, boilers, fired heaters, heat
exchangers, valves, pumps, compressors, and flowlines.
2. Atmospheric and low pressure storage tanks.
3. Pipelines.
d. Equipment inspections are not included in the scope of this document.
The broad definition of corrosion monitoring is the use of any method that enables
an estimate or measurement of the corrosion rate occurring in an item of a facility
or of a process stream. On that basis, corrosion monitoring comprises coupons and
probes, online monitoring, inspection, fluid analyses, analysis of process streams,
and operational history assessments. Equipment inspection is a vital component of
the corrosion monitoring activity, since it measures the in-situ pipe wall, whereas
other techniques typically measure the fluid corrosivity. Because detailed technical
requirements for equipment specific inspection and testing are available in
GP 32-40, discussion of inspection practices is not included in this GP.
e. The scope of this GP does not include techniques for:
1. Downhole monitoring of tubing and casing.
2. Monitoring of cathodic and anodic protection systems.
3. Monitoring of corrosion under insulation (CUI).
f. Additional specific requirements on corrosion monitoring may be given where appropriate
in other business segment specific documents.
2. Normative references
The following referenced documents may, to the extent specified in subsequent clauses and normative
annexes, be required for full compliance with this GP:
• For dated references, only the edition cited applies.

• For undated references, the latest edition (including any amendments) applies.
BP
GN 06-012 Guideline on the Selection and Application of Corrosion Monitoring
Techniques and Systems.
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17 June 2009 GP 06-70
GP 32-40 In Service Inspection and Testing - Common Requirements.
American Petroleum Institute (API)

API RP 38 Biological Analysis of Subsurface Injection Water.
API RP 45 Analysis of Oilfield Waters.
American Society for Testing and Materials (ASTM)

ASTM D664 Standard Test Method for Acid Number of Petroleum Products by
Potentiometric Titration.
ASTM D974 Standard Test Method for Acid and Base Number by Color-Indicator
Titration.
ASTM D1066 Standard Practice for Sampling Steam.
ASTM D3228 Standard Test Method for Total Nitrogen in Lubricating Oils and Fuel
Oils by Modified Kjeldahl Method.
ASTM D3230 Standard Test Method for Salts in Crude Oil (Electrometric Method).
ASTM D3370 Standard Practices for Sampling Water from Closed Conduits.
ASTM D4294 Standard Test Method for Sulfur in Petroleum and Petroleum Products by
Energy Dispersive X-ray Fluorescence Spectrometry.
ASTM D4929 Standard Test Methods for Determination of Organic Chloride Content in
Crude Oil.
ASTM D6470 Standard Test Method for Salt in Crude Oils (Potentiometric Method).
Institute of Petroleum (IP)

IP 265 Determination of total salts content of crude oil - Conductivity method.
NACE International (NACE)

NACE RP0497 Field Corrosion Evaluation Using Metallic Test Specimens.
NACE RP0775 Preparation, Installation, Analysis, and Interpretation of Corrosion
Coupons in Oil Field Operations.
NACE TM0194 Field Monitoring of Bacterial Growth in Oil and Gas Systems.
3. Terms and definitions
For the purpose of this GP, the following terms and definitions apply:
Accuracy
Amount of uncertainty that exists in a measurement with respect to the relevant true value.
Corrosion monitoring
Corrosion monitoring refers to acquiring data under operating conditions that can be used to estimate
or measure the rate of in-service material degradation of a facility or of a process stream.
Corrosion monitoring is more complex than monitoring most other process

parameters because: there are a number of different types of corrosion mechanisms;
corrosion may be uniform or localized; corrosion rates may vary substantially even
within relatively short distance; and there is no single measurement technique
capable of accurately considering all of these aspects. Most monitoring techniques
described in this document can be used to measure general corrosion but only a few
can be used for localized corrosion.
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17 June 2009 GP 06-70
Direct monitoring techniques

Techniques that measure parameters directly related to metal loss or corrosion. May be either intrusive
or non-intrusive.
Flush mounted probes or coupons

Corrosion probes or coupons that are installed flush with the internal surface of the facility, not
interfering with the process stream or cleaning activities such as pigging.
Indirect monitoring techniques

Techniques that measure parameters that either affect or are affected by the corrosiveness of the
environment or the products of the corrosion process. May be either online or offline.
Intrusive monitoring techniques

Any monitoring technique that requires access through the pipe or vessel wall for measurements to be
made. May be either online or offline.
Intrusive probes or coupons

Corrosion probes or coupons that extend into the process stream, in contrast with flush mounted
coupons or probes.
Inspection
The process of examining a pipe or vessel using a non-destructive testing technique to measure wall
thickness or evaluate the presence of other anomalies.
Non-intrusive monitoring techniques

Any monitoring techniques that do not require access through the pipe or vessel wall for
measurements to be made. May be either online or offline.
Online monitoring
Monitoring equipment installed for continuous or near continuous measurement of metal loss,
corrosion rate, or other parameters in an operating system. The majority of the monitoring techniques
in this category are intrusive. Data are obtained without removing the monitoring device.
Offline monitoring
Monitoring methods in which a sample is taken for subsequent analysis.
Planktonic bacteria
Bacteria that are freely floating in brine. Planktonic bacteria can become sessile bacteria by adhering
to a surface.
Real-time measurements
Measurements that can detect a change in the parameter under investigation essentially as it occurs.
The changes can be detected because the technique is sufficiently sensitive, and can be made
continuously or with sufficient frequency to follow the changes in the parameter.
Response time
Minimum time required for a corrosion monitoring system to detect a specified change in corrosion
rate.
Sensitivity
Smallest absolute amount of change of the stimulus (e.g., corrosion rate) that can be resolved by a
measurement with a given degree of confidence.
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17 June 2009 GP 06-70
Sessile bacteria
Bacteria that are attached to surfaces or live in biofilms.
Side stream
A by-pass loop or a direct outlet from the process stream. Fluid may or may not be at the same
velocity, temperature, and pressure as the main process stream.
Solid particle
Particulate inorganic matter that can cause erosion damage such as sand (e.g., silica), certain hard
scales (e.g., magnetite, mill scale), proppants, and catalysts.
4. Symbols and abbreviations
For purposes of this GP, the following symbols and abbreviations apply:
CAD Computer aided design.
EDS Energy dispersive spectroscopy.
EN Electrochemical noise.
ER Electrical resistance (probe).
EFM Electrical field mapping (corrosion monitoring technique, also known as FSM).
FSM Field signature method (proprietary name of EFM corrosion monitoring system).
HAZ Heat affected zone.
HIC Hydrogen induced cracking.
ICM Inspection and corrosion monitoring (database).
LPR Linear polarization resistance (probe).
MIC Microbiologically influenced corrosion.
mm/y millimeters per year.
mpy mils per year (mil = 0,001 in).
NDE Non-destructive examination.
OMS Operating Management System.
ORP Oxidation reduction potential.
P&IDs Process and instrumentation diagrams.
PFD Process flow diagrams.
SEM Scanning electron microscopy.
SRB Sulfate reducing bacteria.
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TAN Total acid number.
TAR Turnaround.
TDS Total dissolved solids.
TLC Top of line corrosion.
TSS Total suspended solids.
WLC Weight loss coupon (or more properly mass loss coupon).
5. Corrosion monitoring philosophy
a. Each asset shall have a corrosion monitoring philosophy, aligned with the corrosion
management strategy.
Corrosion monitoring is a vital element of the corrosion management system
implementation process. GP 06-10 (Bibliographic ref.[26]) outlines the system for
management of corrosion and includes elements of corrosion monitoring system
design as well as allocation of responsibilities for its implementation.
The corrosion monitoring philosophy may be included as a section of the corrosion
management strategy.
b. The corrosion monitoring philosophy should define and document:
1. Monitoring objective.
The following three main objectives can be distinguished:
 Corrosion control management. Assure corrosion rates are low enough so that
corrosion allowance is not consumed before the end of service life, and assure
effectiveness of corrosion mitigation program, if there is one.
 Integrity management. Predict more accurately the worst case corrosion rate at
different locations of the system, which can be used to calculate remaining life
and define frequency of inspection.
 Corrosivity studies. Establish corrosion mechanism of a system, optimize
corrosion control (e.g. test corrosion inhibitors, adjust dosage), evaluate effect
of changing operational conditions (e.g., crude composition in a refinery, flow
velocities).
2. Corrosion mechanisms to be monitored based on corrosion risk analyses performed
on a system by system basis.
How corrosion occurs is essential information to estimate corrosion rates and to
select specific corrosion monitoring methods to be used to provide information on
these mechanisms.
The corrosion management strategy required by GP 06-10 (Bibliographic ref. [26])
includes a corrosion risk assessment and a combined mitigation, monitoring, and
inspection strategy to address the risks. This corrosion risk assessment identifies
corrosion mechanisms (e.g., CO2 corrosion, under deposit corrosion, MIC) or
modes of attack (e.g., general wastage, localized attack, pitting, cracking) likely to
occur in the facility, and process stream parameters (e.g., pressure, temperature,
production rate, fluid composition, production chemistry laboratory data, corrosion
product concentration, solids concentration, and chemical treatment) that influence
the corrosion rate.
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17 June 2009 GP 06-70
The corrosion risk assessment considers the materials of construction, corrosion

allowances and operating conditions. Changes in operating conditions in different
parts of the system during its service life should be considered, as they may
influence prevalent corrosion mechanisms.
3. Sensitivity and response time requirements.
The usefulness of a corrosion monitoring system for corrosion management can be
usually related to how well and how fast it can deliver warnings of undesirable
corrosion conditions, so that corrective actions can be taken before significant
corrosion damage occurs. This translates into two closely related properties:
 The sensitivity to detect a change in corrosion rate (measurement sensitivity
combined with elapsed time).
 The time required to detect such a change (i.e., response time).
Different monitoring objectives have different requirements for the same system,
which should be met by the techniques selected. For example, a corrosion control
management objective may have an application window with a 0,1 mm/y to 1 mm/y
(4 mpy to 40 mpy) sensitivity range and 1 day to 2 days response time, whereas an
integrity management objective may have the same application sensitivity range but
with much longer response time (1 month to 2 months).
Due to the measuring principle of many corrosion monitoring techniques, sensitivity
and response time have an inverse relation to each other. For example, the
sensitivity of thickness measurement in ER probes is determined by the instrument
(and technology) used and geometry of the probe, but the sensitivity of the system in
measuring corrosion rates increases with time elapsed between thickness
measurements.
Corrosion monitoring and inspection techniques typically represent opposite ends of
the measurement spectrum, although there is an overlap in the sensitivity of some of
the techniques. The more sensitive monitoring techniques can detect corrosion
related changes as they occur. Such information makes decisions regarding
remedial action possible before significant damage can occur. Inspection techniques
are generally less sensitive and/or require longer response time, but tend to be more
accurate. Sometimes significant damage can occur before the condition is detected
by inspection.
Apart from sensitivity limitations on short time scales, a monitoring system may not
measure accurately over long time scales, because of limitation in the system
stability (e.g., deterioration of the sensor, drift of the electronics).
4. Data communication and analysis requirements.
The following steps are involved in the actual response time of the monitoring
system:
 Data collection (e.g., process plant operator, batch, or on-line data
transmission).
 Data processing (e.g., corrosion monitoring specialist, software packages).
 Data interpretation (e.g., corrosion engineer).
 Remedial action plan (e.g., corrosion engineer).
 Implementation (e.g., operations or maintenance engineer)
The total sensor-to-desk response time (steps 1 to 3) needs to be defined based on
the criticality of the system and balanced with the response time of the corrosion
monitoring sensor.
5. Corrosion monitoring reliability, based on the criticality of the system.
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17 June 2009 GP 06-70
For example, high reliability is required if the corrosion monitoring system is

actively used to control the inhibitor program effectiveness of a pipeline with high
uninhibited corrosion rate.
6. Monitoring techniques.
The parameter(s) to be monitored and available technique(s) depend on the type of
application. Availability and cost should also be considered. Some methods are not
available for the expected operating conditions or their application may not be cost
effective. Detailed technical information on corrosion monitoring techniques can be
found in GN 06-012.
c. Projects should define monitoring philosophy during early (Define) stage and shall include
the development of corrosion monitoring in detailed design of plants and facilities.
Implementation of an effective corrosion monitoring design may be difficult or not
cost effective if not included in the design stage of the project. In particular,
installation of corrosion access fittings and availability of sufficient space for on-
line retrieval of probes and coupons.
6. Principles of corrosion monitoring system design
6.1. General
a. The primary objective of the corrosion monitoring system design process is to establish the
type, location, and orientation of monitoring devices and sampling ports in the facility.
The selection of the appropriate monitoring location(s), orientation(s), and
technique(s) is critical for successful corrosion monitoring. Selection of the wrong
location or technique results in a large amount of effort and expense only to
generate inappropriate or even misleading information, which is often not
questioned.
b. Key considerations are:
1. Locations of monitoring devices should allow optimal monitoring of corrosion
mechanisms of interest.
2. Orientation of monitoring device should position the probe or coupon at the location
in the optimal position to monitor the stream or the fluid phase where corrosion is
most severe.
3. A corrosion monitoring system should not rely on just one method.
The best results are obtained by using and correlating a number of different
techniques.
4. The corrosion monitoring system should be user-friendly. At least one of the outputs
should be sufficiently developed to be interpreted by system operators or interfaced to
alarms and controllers for taking proper and timely mitigation actions.
5. The monitoring system should be robust and maintainable, able to withstand normal
use and abuse.
a) Minimum required time between maintenance or replacement should be in
accordance with the application.
b) Periodic service and calibration should be simple.
6. The combination of monitoring element(s) or probe(s) should be accurate and
sensitive to the onset of a corrosion problem with adequate response time, in
accordance with the corrosion monitoring philosophy.
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False positives and negatives, or indications caused by process variable

interferences can seriously affect the credibility and usefulness of the corrosion
monitoring program.
6.2. Device selection and placement
6.2.1. Experience
Previous inspection and monitoring results as well as experience at other assets utilizing similar
facilities should be considered when selecting the most suitable locations and/or monitoring
techniques.
Inspection/shutdown reports as well as maintenance and repair lists can provide
valuable information on which parts of a facility have experienced the most severe
corrosion.
6.2.1. Location
a. The monitoring device shall be located in the corrosive phase. Predictive models may be
used to identify the most likely location for corrosion to occur in a given phase.
The corrosive phase is almost always an aqueous phase. Therefore, monitoring
devices should be located at positions most likely to have the presence of water.
Water holdup and water dropout effects are of central importance to device
location. Water dropout is most likely in long horizontal pipe runs and less likely in
vertical runs. If corrosion is expected to occur at the bottom of a horizontal line, the
monitoring device should be located in that position. If water condensation is
expected, locating monitoring devices on top of the line should also be considered.
In fluid streams that have suspended solids, if the access fitting is located in
positions between 3 o’clock and 9 o’clock, there is a risk of solids accumulating in
the fitting. Accumulated solids can cause potential probe shielding problems or
stuck probes.
b. The anticipated corrosion mechanisms (e.g., general or localized attack, under deposit
corrosion, erosion/corrosion) shall be considered.
c. Effects of flow rate and flow regime shall be considered, including:
1. Probes and coupons should be sited in a region where water drop out is more likely
and where hydrodynamics are uniform and representative of most of the system.
2. Access fittings should be located a minimum distance of seven pipe diameters
downstream and a minimum of three pipe diameters upstream of flow disturbances
(e.g., bends, reducers, valves, orifice plates, thermowells) for the measurement to be
representative of most of the system.
In some cases, locating probes or coupons near a flow disturbance should be
considered if these conditions are representative of a higher corrosion rate that is
possible in the system. For example, water hold-up or flow induced corrosion may
occur at an elbow.
3. If intrusive (not flush mounted) access fittings are installed in pairs, a minimum
distance of 1 m (3 ft) should be between each fitting.
4. If monitoring devices are intrusive and have a probe and a coupon holder, the probe
should be located in the upstream fitting to minimize turbulence around the second
monitoring device.
5. If space limitations (e.g., offshore platforms) do not allow meeting the location
criteria mentioned above, the hydrodynamic effects on corrosion rates should be
assessed.
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17 June 2009 GP 06-70
Hydrodynamically severe regions, such as bends, reducers, valves, elevation

changes, and pump outlets, can have an effect on local corrosion rates.
d. Chemical injection points shall be considered.
Injection of production chemicals, including corrosion inhibitors, scale inhibitors,
asphaltene and paraffin inhibitors, demulsifiers, oxygen scavengers, and biocides
can have a marked effect on corrosion.
1. Corrosion monitoring devices should be placed a minimum of five pipe diameters
downstream of treatment chemical injection points.
2. Depending on the monitoring philosophy, additional monitoring points upstream of
production chemical injection (e.g., corrosion inhibitor, asphaltene inhibitor) should
be considered.
Measuring corrosion rates before and after corrosion inhibitor injection is
important in assessing its efficiency. Some production chemicals can be corrosive to
certain steels and render corrosion inhibitors less effective if they are not fully
compatible.
e. Effects of process stream changes shall be considered.
Changes in pressure, temperature, flow rate, inputs/outputs, etc., as well as position
of equipment affecting process (e.g., vacuum/gas stripping towers in sea water
systems, pumps, heat exchangers) modify potential corrosivity of the fluids and
preferred monitoring locations.
f. Physical access should not dictate monitoring location. However, when a monitoring point
is identified, the location should allow routine access for probe maintenance, retrieval, etc.
g. Intrusive probes should be located where they can remain in place for extended periods.
h. Intrusive probes (not flush mounted) should be installed upstream of any pig launcher or
downstream of pig receivers. Otherwise, the probe requires retrieval prior to each pigging
operation to avoid damage to the probe and the possibility of the pig becoming trapped.
i. Practical factors limiting the choice of monitoring locations should be considered.
1. Coupons and probes require the line or equipment to be accessible for installation and
service.
2. Fluid sampling may not be safe (e.g., pressures, temperatures) or reliable without
contamination or blockage problems.
3. Adverse weather conditions or chance of vandalism may exclude the use of certain
techniques in some locations.
j. Corrosion monitoring locations shall be recorded on the relevant technical drawings.
1. This should include P&IDs and isometric PFDs.
2. On new facilities they should be included in the CAD system as this aids data analysis
and the development of control procedures.
3. The records should include:
a) Details on the system, item, and location.
b) Corrosion monitoring method.
c) Probe or sample valve orientation.
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17 June 2009 GP 06-70
6.2.2. Monitoring technique

a. A combination of monitoring techniques described in 7 should be selected for each system,
aligned with the corrosion monitoring philosophy and based on the selection criteria
described in 8.
Each monitoring technique gives only a limited amount of information. It is
therefore good practice to use a selection of techniques (direct and/or indirect) to
give overall confidence in the results.
If only one probe-based method can be used then the first choice should be weight
loss coupons as this technique gives both general and localized corrosion
information.
b. The monitoring technique(s) selected should provide information relating to the actual
corrosion mechanisms.
c. Corrosion monitoring information should be supported by inspection programs, which
provide information on actual equipment conditions. GP 32-40 provides detailed technical
requirements for equipment specific inspection and testing.
The utility of inspection based methods is tempered by the fact that they are
“lagging” indicators of corrosion. If inspection data indicates a bad situation, then
it may be too late to do anything about it because the damage has already been
done. Monitoring methods are usually considered “leading” indicators of
corrosion. They show the fluid corrosivity at a particular moment, potentially before
any significant damage has occurred.
6.2.3. Monitoring device access

a. The monitoring devices should be available and maintainable ideally without the need to
shut down the facility.
b. Use of extraction tools to install or remove probes/coupons at high pressures is a
potentially dangerous activity that shall only be carried out by specifically trained and
competent personnel following sound operating procedures.
1. Mechanical retrievals instead of hydraulic retrievals should be preferred.
2. Detailed procedure for field use of an extraction tool shall include competency
requirements for technicians assigned on its use and a checklist to be followed.
3. Competency of technicians assigned to extraction activities shall be reviewed to
ensure they meet required levels of experience and competency.
c. The total pressure of the system shall be considered for selecting access fittings.
1. For systems of less than 10 bar(g) (150 psig), low pressure DN 25 (NPS 1) access
fittings may be used.
2. For high pressure systems from 10 bar(g) (150 psig) to 137 bar(g) (2 000 psig),
proprietary DN 50 (NPS 2) access fittings shall be used.
3. For pressures higher than 137 bar(g) (2 000 psig), proprietary access fittings shall be
selected based on their rating and subject to a case by case safety review.
Virtually all conventional probe and coupon monitoring devices are capable of
being installed and retrieved from pressurized systems by means of the proprietary
DN 50 (NPS 2) 137 bar(g) (2 000 psig) rated access fittings. These fittings are
frequently used in any system, regardless of operating pressure because of the
greater variety of available monitoring devices. Access fittings are usually installed
in the construction phase or during a subsequent plant shutdown. Therefore, it is
important that the corrosion monitoring requirements are well thought out during
the project design stage. Otherwise, subsequent installations can be difficult and
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costly. Although access fittings can be installed during plant operations, in some
circumstances, in general safety concerns normally preclude such activities.
d. The selected location shall have adequate clearance for the operation of the retrieval tool.
Without adequate clearance, the access fitting is unusable.
e. If possible, fittings should also be located in places of easy and safe access to personnel.
Permanent platforms should be provided for access to fittings more than 2 m (6,6 ft) above
grade or deck level.
6.3. Corrosion data quality

a. Information from a single type of corrosion monitoring method should not be relied upon
to provide a full understanding of the corrosion environment of interest.
b. For any monitoring program, some of the following control checks should be included to
ensure reliability of the data:
1. Comparing results from duplicate or redundant devices.
2. Correlation with inspection results.
3. Comparisons between direct and indirect monitoring data.
4. Correlating data with visual inspection results for equipment taken out of service.
c. Corrosion data produced should be validated to ensure that monitoring techniques used are
sufficiently reliable, sensitive, and responsive to conditions being monitored.
Validation is a process of reviewing whether the corrosion monitoring devices and
processes are measuring the actual system corrosion phenomena. If important
damage mechanisms are transient, does the monitoring device identify and/or
record them? If timely awareness of excessive corrosion rates or excessive metal
loss is needed, is the monitoring device providing information in the right time
period? Is the monitoring system identifying the morphology of interest?
6.4. Data management

a. To maximize utility of data provided by a corrosion monitoring program, information
should be universally and readily available in a convenient format that facilitates
application of appropriate analytical tools.
b. A corrosion monitoring database should include chemical treatment information and be co-
resident with or compatible with the ICM database.
c. ICM database should have as many of the following features as are practical:
1. Electronic storage of ICM related data and information in an easily retrievable and
secure format (preferably through the web).
2. Electronic data to include multimedia files.
3. Inspection results from a variety of NDE techniques.
4. Corrosion monitoring data from probes and coupons.
5. Chemical injection data.
6. Basic process parameters (e.g., flow, pressure, temperature, water chemistry, gas
composition, materials of construction).
7. Compatible with engineering data and information stored in other electronic
document databases.
8. Compatible with OMS.
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9. Support the analysis and trending of ICM related data.

10. Automatic analysis against preset limits.
11. Projections of remaining life, based on design code.
12. Trending and comparison of data from different sources.
13. Support analysis of fitness for service of piping and vessels.
14. Support non-numerical or semi-quantitative analysis.
15. Perform custom or ad hoc queries of data in the ICM database.
16. Support workflow of ICM functions.
17. Interface with work planning and scheduling tools.
18. Data are auto analysed against predefined rules.
The standard electronic work planning and scheduling software in many locations is
Maximo. There are several commercial software systems with the capability to
provide most of the features listed above.
7. Corrosion monitoring principles
This clause defines general requirements for the different corrosion monitoring
techniques currently available. Additional technical information on these techniques
is included in GN 06-012 and in NACE International Publication 3T199
(Bibliographic Ref.[22])
7.1. Direct intrusive monitoring techniques

Direct intrusive monitoring techniques measure parameters directly affected by the
corrosion process and require introducing a probe or coupon inside the pipe or
vessel.
7.1.1. Flush mounted probes and coupons

Flush mounted monitoring devices are designed such that the coupon or probe
element is flush with the inside of pipe or vessel wall.
a. These devices should be used for monitoring specific metal loss processes that occur
preferentially at the wall surface (e.g., low water cut situations, water dropout or
condensation, under deposit corrosion).
b. Flush mounted devices should be considered where pigging is required or where debris
may damage an intrusive device.
c. Location of devices should ensure that any fouling is minimized.
Flush mounted probes are susceptible to fouling, but this can be mitigated somewhat
by placement in turbulent locations.
d. A back pressure procedure should be implemented for retrieving flush mounted devices
located at the bottom of the pipe, to prevent plugging or getting stuck.
7.1.2. Intrusive probes or coupons

Intrusive devices protrude well into the process stream and are suited to measure
the overall corrosivity of the stream rather than the more specific phenomena that
are targets of flush mounted probes.
a. Intrusive devices should be considered to monitor process upsets in single phase, high wall
shear stresses, “worst case” situations, or in systems where fouling is likely.
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b. In piggable pipelines, intrusive probes should be installed upstream of any pig launcher or
downstream of pig receivers. Otherwise, the probe shall be retrieved prior to each pigging
operation.
7.1.3. Weight loss coupons

a. Weight loss coupons (also known as mass loss coupons) should be selected based on the
specific requirements of the system to be monitored. GN 06-012 provides further
information.
b. Coupons shall be manufactured from similar material to the pipe or vessel, unless a
different material is under evaluation.
c. Metallic coupons should be installed, analyzed, and interpreted and data should be
recorded in accordance with GN 06-012, NACE RP0497, and NACE RP0775.
d. If pre-weighed commercial coupons are used,
1. Coupons should be solvent cleaned prior to insertion in the line, to remove the vapour
phase inhibitor.
2. Coupons should be reweighed after cleaning to confirm listed weight.
ASTM standards G4 and G46 (Bibliographic refs. [7] and [8]) give full details of
coupon testing, preparation, cleaning, inspection, and reporting of information.
Coupons cannot be used to provide rapid response data.
e. Coupons should be mounted either:
1. In coupon holders inserted into and retrieved from the process fluid by means of a
high pressure DN 50 (NPS 2) welded access fitting and a special retrieval tool.
2. On test racks attached to suitable locations inside equipment for retrieval and
examination at a TAR.
Typical coupon configurations retrievable from piping are shown in GN 06-012.
Coupons can be installed and retrieved from vessels in a similar fashion.
f. Pitting should be reported as maximum pitting corrosion rate, based on pit depth and
exposure time, and indication of pitting frequency (e.g., isolated, numerous).
Surface analyses of the coupon after cleaning, using 3D profilometer techniques,
can provide quantitative information regarding the nature and extent of localized
corrosion.
g. Special coupons and analysis should be used to assess susceptibility to corrosion in
weldments or weld HAZ, hydrogen embrittlement, or stress corrosion cracking.
h. Corrosion products present on retrieved coupons should be subjected to chemical and
biofilm analyses to provide further insight into corrosion mechanisms.
Laboratory analysis of films and deposits on coupons prior to cleaning using SEM
and EDS techniques can also provide valuable information regarding the corrosive
agents involved.
Some corrosion products degrade over time of exposure to the external environment
(e.g., react with oxygen) and special storage procedures may be required to
maintain their in situ composition immediate to a coupon’s recovery.
i. For pressure retrievable coupons, default exposure time should be 3 months. However,
exposure times should be adjusted to circumstances.
For general corrosion, NACE RP0497 and ASTM G31 suggest a minimum exposure
duration in hours that is approximately 50 divided by the expected corrosion rate in
Page 16 of 38
17 June 2009 GP 06-70
mm/y (2 000 divided by the expected corrosion rate in mpy). Optimum exposure
depends on conditions encountered in the system.
j. Exposure periods should be as consistent as practical. A tolerance of ±7% is satisfactory
for most applications.
The effect of exposure time in interpreting corrosion coupon data is described in
NACE RP0775.
k. If direct assessment of corrosion on the process stream piping is required, spool pieces
(short length of flanged piping) should be considered in accordance with the guidance
available within GN 06-012.
The disadvantage of this approach is that unless the spool piece is in a side stream,
the system needs to be shut down and made safe before removal.
7.1.4. Electrical resistance (ER) probes

a. ER probes should be used to provide real-time uniform corrosion rates in conductive and
non-conductive system. ER probes should not be used if:
1. Localized corrosion is predominant.
2. Corrosion products are conductive (e.g., iron sulfides may short-circuit elements or
indicate metal gain).
3. Environment is electrically conductive (e.g., molten salts, liquid metals).
b. Wire elements should not be used. Guidance on selecting tubular and flush mounted
elements is available within GN 06-012.
c. Velocity shields should not be employed unless all the risks of their use have been
evaluated, see GN 06-012 for further advice.
d. Seal materials used in the construction of the device should be evaluated against the
process streams to ensure long term integrity.
e. The sensor element should be selected to provide the required sensitivity and response time
with a reasonable life time.
ER probe manufacturers provide guidelines showing the trade-off between improved
sensitivity and reduced sensor life for different geometries.
f. Hard-wired monitoring connections, dedicated data loggers, and wireless data transmission
should be considered.
Hardwiring minimizes signal noise associated with probe connection. A dedicated
type of data logger allows repetitive measurements to be taken. Taking data more
frequently can filter signal noise associated with thermal oscillation of the probe or
electrical noise. Emerging wireless technologies can simplify the data transmission
system and reduce the installed cost associated with wiring.
g. ER probe data should be recorded as sensor thickness as a function of exposure time and
the corrosion rate should be subsequently calculated in mm/y or mpy from the slope of the
resulting plot.
Raw probe and reference element data, along with probe characteristics should also
be stored.
Depending on the probe sensitivity, several days may be required to provide a clear
indication of small changes in corrosion rate.
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17 June 2009 GP 06-70
7.1.5. High sensitivity ER probes

High sensitivity ER probes should be considered as alternative to conventional ER probes (same
applications, restrictions, and analyses) if:
a. Real time corrosion rate information has high value.
b. Increased sensitivity, decreased response time or increased life time is required.
These probes are useful in performing corrosion inhibitor dosage optimization
programs because corrosion rates outside of acceptable limits can be detected
before damage to the system occurs.
7.1.6. Ring pair corrosion monitoring spools

a. This proprietary device should be considered if ER technology is required for 360 degree
monitoring in pipelines.
b. Full pipe diameter sensing rings cut from a representative pipe section should be specified
dependent on the expected corrosion mechanism, corrosion rate, and design life.
High sensitivity rings can detect pitting but may not last long; full thickness rings
can easily distinguish location of corrosion on circumference of pipe and have the
same design life as the pipe; rings manufactured from circumferential welds can be
used to detect preferential weld corrosion.
c. The device incorporates temperature compensation. However, adequate shielding or
placement away from heat sources is required to ensure stable readings.
7.1.7. Intrusive solid particle monitoring

a. Real-time solid particle measurements should be employed if solid particle erosion is
considered a threat.
Field experience with sand monitoring in production operations has shown that
sand is often not produced at a constant rate but in intermittent bursts. Erosion can
be rapid on some equipment, in which failures have occurred in minutes to a few
hours.
Refer to the GP 32-40 for guidelines for designing and operating a sand detection
system and see Bibliographic ref. [2] for a summary of field experience with sand
detection systems.
Also refer to acoustic solid particle detectors (see 7.3.2).
b. The intrusive type of solid particle detector, based on ER technology, shall be installed at a
location where the produced solid particle is expected to impact the probe element.
c. The probe should preferably be located in a vertical section of piping, at least 10 diameters
from a bend and preferably with vertical up-flow, where the solid particles will be
distributed across the pipe.
Installation downstream of a choke valve is common, but choke valves that become
damaged, e.g., by solid particles, may cause the flow to be directed to one side of the
pipe and solid particles may, therefore, miss the probe.
d. Particle detectors shall be constructed from corrosion resistant materials.
7.1.8. Electrochemical probes
7.1.8.1. General
The use of electrochemical probes shall only be considered in aqueous or substantially aqueous
systems.
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17 June 2009 GP 06-70
7.1.8.2. LPR probes

a. LPR should be considered primarily where instantaneous corrosivity readings are required.
b. Probes may become fouled with deposits or hydrocarbon phases and this should be taken
into account when analyzing data.
7.1.8.3. Galvanic probes

a. Galvanic probe should be considered for monitoring changes in corrosivity of aqueous
systems in which dissolved oxygen may be present.
The probe can discriminate dissolved oxygen levels in the 0 ppb to 50 ppb range
typically required for injection quality sea water.
b. Galvanic probes provide real time measurements and should be used where a rapid
response to changing operational conditions is required. However, the measuring
electrodes can be susceptible to fouling especially when subject to long term exposure and
this should be taken into account when analyzing probe data.
7.1.8.4. Coupled multi-electrode array system

The use of coupled multi-electrode array system should only be considered for localized
corrosion monitoring in special cases.
This technology is relatively new and more field experience is required before
considering for routine use. A primary application is monitoring for preferential
weld corrosion.
7.1.8.5. Advanced electrochemical techniques

Advanced electrochemical techniques (e.g., electrochemical impedance spectroscopy,
electrochemical noise) should be considered only under special circumstances such as research
projects or high value, one-of-a-kind applications. Specialist (SME) advice and guidance should
be sought before use.
7.2. Direct non-intrusive monitoring techniques
7.2.1. Electrical field mapping

EFM technology that utilizes the field signature methodology (FSM) should not be used without
previous approval by the relevant BP Engineering or SPU Technical Authority.
A series of recent experiences have highlighted a number of issues with this
technology: Detecting corrosion where none had occurred, not detecting significant
metal loss, sensitivity of measurements exaggerated, faulty wiring leading to
artificial results, questionable interpretation of data.
Alternative technologies based on the same principle have been developed by other
suppliers, but not enough field experience is available.
7.2.2. NDT methods

NDT techniques generally do not provide real-time data.
For purposes of this GP, NDT methods are classified as inspection techniques and
are outside its scope. Detailed technical requirements for equipment specific
inspection and testing are available in GP 32-40.
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7.3. Indirect online monitoring techniques
7.3.1. Hydrogen monitoring

a. Hydrogen monitoring should be considered if the combined conditions of a corrosive
environment and susceptible materials can result in blistering, HIC, and, with high strength
steels, sulfide stress cracking, or hydrogen embrittlement.
b. A hydrogen monitoring system shall not be used under the following conditions:
1. If the cathodic element of the overall corrosion reaction does not involve hydrogen
reduction (e.g., oxygenated seawater systems, alkaline systems).
2. With nickel or copper based alloys in which atomic hydrogen is insoluble in the metal
structure.
3. With titanium.
Titanium forms stable hydrides and limits the diffusion of hydrogen.
c. The rate of diffusion of atomic hydrogen into structural materials should be measured by
one of the following real time measurement methods:
1. Thin wall tubular probes inserted directly into the process stream.
2. Patch detectors clamped or welded to the outer pipe or vessel wall.
3. Portable or permanent hydrogen ‘collector plate’ technology.
7.3.2. Acoustic solid particle detectors

Acoustic solid particle detectors should be the preferred technology for subsea installations that
require real time data.
Sensors require recalibration at regular intervals to ensure their continuing utility
although evolving technology developments in this area suggest a single calibration
for life of the detector is now possible.
7.3.3. On-line water chemistry analyses

Water chemistry probes should be limited to low pressure (<25 bar (360 psig)) and temperatures
up to 150°C (300°F).
7.3.3.1. pH and ORP probes

a. Online pH monitoring should be used in preference to offline sample analysis in cases
where pH control is critical to corrosion.
b. pH probes should be easily isolatable from the process stream to allow for routine
maintenance and calibration.
c. Other flow monitors and controllers should be placed downstream of the pH probe
location, to avoid exposing the pH probe to excessive pressure drops or flow perturbations.
d. In water treatment process streams, ORP should be measured to closely control the
addition of oxidizing biocides, such as chlorine.
e. The pH electrodes should be calibrated at the sample temperature.
7.3.3.2. Dissolved oxygen

a. Continuous online monitoring should be used for process monitoring of water systems if
the presence of oxygen is possible.
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17 June 2009 GP 06-70
b. Dissolved oxygen probes should not normally be inserted directly into the process stream,
but fitted into a small flow chamber connected to a side stream or process fluid off take
point.
1. Oxygen monitors should be calibrated weekly.
2. The calibration setting requires correcting for the presence of other dissolved gases
such as CO2 and H2S.
3. Probe readings should, if possible, be routinely compared against dissolved gas
measurements on fluid samples - see 7.4.1.3. Significant and systematic differences
should be resolved.
7.3.3.3. Conductivity probes

Conductivity probes should be used where the presence of an electrolyte containing dissolved
solids in excess of established limits can result in corrosion in the system or in a related process.
This technique can be used to measure the salt content of crude oil and TDS build-
up in cooling water.
7.3.4. Process variables

Process parameters (e.g., pressure, temperature, flow rate, dew point) should be routinely
measured as elements of a corrosion monitoring program.
These parameters are normally available in real-time as routine process control and
monitoring data. They are mathematically related to corrosion through algorithms
that estimate corrosion rates. Therefore, a fast response “virtual corrosion
monitoring” technique can be implemented by feeding real-time process parameters
along with additional indirect monitoring techniques into corrosion prediction
models.
7.3.5. Side streams

a. Installation of instrumented side streams should be considered for special circumstances
such as research projects, chemical evaluation, or high value, one-of-a-kind applications.
Side streams may be used for simulating and measuring corrosion activity or
chemical analysis within a process stream.
b. Side stream systems may be modular to permit disassembly and reassembly and adapt the
simulator to different applications, and may include:
1. A small pressure vessel or a series of modular vessels and pipes coupled to a process
stream source and a process stream discharge point.
2. A cooling coil/medium to simulate condensing/dew point or a heat exchanger to
control the temperature.
3. Different types of corrosion probes.
4. Temperature, pressure, and flow sensors.
5. Online chemical sensors (e.g., pH, dissolved oxygen, conductivity).
7.4. Indirect offline monitoring techniques
7.4.1. Water chemistry parameters
7.4.1.1. Dissolved solids analysis

a. Dissolved solid analysis should be carried out on produced water in accordance with
API RP 45.
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17 June 2009 GP 06-70
b. Organic acid concentrations in solution should be measured (e.g. acetic acid, propionic
acid, and butyric acid).
c. In commingled process streams or water the potential for formation of inorganic scales
should evaluated.
d. Routine water analyses should be considered for boiler feed water and cooling water.
7.4.1.2. Metal ion corrosion

a. Measurement of dissolved metal ions in a process stream should only be used as a general
indication of system corrosivity or as an indication of corrosion trends.
To have any value, measurements need to be carried out regularly and over an
extended period of time to ensure a change in metal ion concentration from a given
baseline or threshold is not a direct result of or corrupted by the measurement
regime being applied (e.g., varying periodicity of measurements).
The source of metal ions may be from localized or general corrosion within the
system so using such measurements to compute corrosion rates should not be
undertaken. Furthermore, the inherent background level of metal ions in the
produced or processed fluids should be accounted for in the measured values. A
clearer picture can sometimes be gained by looking at the ratio of selected metal
ions (e.g., iron and manganese, iron and chromium) to reflect the ratio at which they
are present in the alloy material in use within a system.
b. Corrosivity changes should be based on production or process flow rates rather than ion
concentrations.
The technique is not reliable in sulfide containing fluids or with high activity of
sulfate reducing bacteria because of precipitation of iron sulfide, or in alkaline
solutions because of precipitation of ferric hydroxide. This can also be a problem if
CO2 corrosion is prevalent for conditions where formation of iron carbonate films is
possible (typically at higher temperatures - > about 60°C (140°F) and pH > about
5,5).
7.4.1.3. Dissolved gas analysis

a. Proprietary gas analysis kits are available for rapid on-site determination of O2, CO2, and
H2S in aqueous process streams and should be used regularly as a quality control check for
online monitoring systems.
b. If kits are not available for a species of interest or greater precision is required, laboratory
analysis should be used.
7.4.2. Bacteria analysis

If bacteria are suspected in a system, tests for quantifying the presence of bacteria in both
planktonic and sessile forms should be performed.
The importance of quantifying both sessile and planktonic bacteria and their
relation to corrosion are discussed in GN 06-012. Care should be exercised if only
planktonic bacteria are measured as it is only in the sessile state that they are able
to induce corrosion. Many systems have a level of planktonic bacteria detectable but
there is considerable debate about this being a certain sign of bacterially related
corrosion occurring even at high concentrations.
a. Water samples should be examined for evidence of (planktonic) SRB using the serial
dilution test method described in NACE TM0194 and API RP 38.
b. Enumeration of the sessile population should be assessed by use of a biofilm probe
exposed to the process stream through a standard DN 50 (NPS 2) access fitting.
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17 June 2009 GP 06-70
Swabbing and analyzing films on weight loss coupons for sessile bacteria is
sometimes used in the absence of a bio-probe. In such cases extra care needs to be
exercised in readiness to conduct such an analysis and expert guidance should be
sought.
7.4.3. Chemical analysis of process samples
7.4.3.1. General
a. Samples should be taken, stored, and maintained at the pressures of their original
conditions for subsequent analysis.
b. Analyses of the samples should be performed under the pressure conditions of the process
system if a change in pressure would alter the nature or concentration of the constituents.
7.4.3.1. Oil and gas production

a. Samples of crude oil and gas condensate should be analysed for organic nitrogen, organic
acid, and sulphur compounds.
b. Samples of produced and processed natural gas and natural gas liquids should be regularly
analysed for the following:
1. Hydrogen sulphide.
2. Carbon dioxide.
3. Water.
4. Carbonyl sulphide.
5. Carbon disulphide.
6. Mercury.
7. Mercaptans.
8. Oxygen.
7.4.3.2. Refining operations

a. Crude oil samples should be analysed for organic (naphthenic) acid, nitrogen, sulphur, salt
content, and organic chlorides (if suspected).
Establishing the concentrations of the above compounds and elements can give an
indication of the potential corrosiveness of a crude oil during refinery processing.
This can be used to help establish suitable materials of construction and also help
predict potential corrosion rates of different materials.
b. ASTM D664 and ASTM D974 should be used to determine the TAN. UOP Methods 565
and 587 give procedures for removing molecules, compounds, and additives that can
potentially interfere with these measurements.
TAN can provide some predictive indication of the potential naphthenic Acid
corrosiveness of a crude oil primarily in crude and vacuum distillation units. A more
accurate assessment of corrosivity can be determined by measuring the actual NAN
(naphthenic acid number).
c. Nitrogen content should be analyzed according to ASTM D3228.
The presence of nitrogen above certain levels is not tolerable because it is a catalyst
poison. If organic nitrogen is in sufficient concentration, cyanide, and ammonia can
form during refining, which dissolve in water phase and become corrosive to
common materials of construction. This can also lead to the formation of ammonium
chloride salts and resultant salt deposition and under deposit pitting corrosion.
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17 June 2009 GP 06-70
d. Sulphur content should be analyzed according to ASTM D4294.

Sulphur content can be used to help establish suitable materials of construction and
also help predict potential corrosion rates of different materials.
e. Total salts should be measured following either ASTM D6470 or IP 265. ASTM D3230 is
not recommended.
Salt can cause corrosion in refinery equipment by forming hydrochloric acid. It can
also precipitate as scale in heaters and heat exchangers, causing accelerated under
deposit corrosion and hot spots.
f. Inextractable chlorides should be assessed separately, since they are not readily measured
by most chloride measurement techniques because they are not extracted into the aqueous
phase by standard test methods.
In general, chloride compounds that cause problems in refining are those that are
not extracted by the desalting process. These ‘inextractable chloride’ compounds
may be either inorganic or organic. They may break down later in the refining
process, causing problems such as acid corrosion of pipework and fouling (chloride
salt precipitation).
1. Organic chlorides should be measured using ASTM D4929, which is a multi-step
process.
2. The following method should be used for accurate measurement of inorganic
encapsulated chlorides:
a) Mix 50 g light oil or10 to 25 g heavy oil with the same mass of toluene.
b) Filter through a 0,45 micron Millipore filter paper and measure total chloride in
crude before and after filtration.
c) Weigh the sediment, wash with hot water to remove chloride salts and re-weigh.
The filtrate from the water wash can be tested for chlorides by ion
chromatography.
This gives a measurement of inorganic chlorides in the crude. For a true measurement
of inextractable chlorides the amount of chlorides removed by this procedure should
be compared with the amount of chlorides removed without the toluene addition.
8. Corrosion monitoring selection
8.1. General
a. This clause should be used as a general guide for selecting monitoring techniques for
different systems.
There are no fixed rules governing which methods are most suited for a given system
because conditions using each method can vary. Table 1 summarizes the possible
application of the various monitoring techniques on a system by system approach.
Not all monitoring techniques discussed in clause 7 and in GN 06-012 are included
in this clause. Some of the available monitoring techniques are not widely used in
the field for a variety of reasons, including cost, complexity, required operator
expertise, required field support, suitability for field use, and lack of wide
applicability.
b. Corrosion environment (e.g., aqueous, non aqueous, chemistry) should be considered, as
this often precludes many techniques (e.g., electrochemical methods are not suitable in low
water cut or low conductivity situations).
c. Anticipated corrosion mechanisms should be considered.
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17 June 2009 GP 06-70
An understanding of possible corrosion mechanisms (e.g., general, pitting, cracking,

under deposits, etc.) gives insight into the most suitable monitoring technique(s) and
eliminates many that are unsuitable (e.g. pitting cannot be detected using ER
probes).
d. Accessibility of monitoring locations should be considered.
e. The suite of monitoring techniques should be consistent with the system criticality, which
can be defined based on a risk assessment.
For example, a low risk pipeline may only require WLCs located at one end of the
pipe and annual water analysis. At the other end of the spectrum, a high risk
pipeline may require several WLC and ER probes located at different sections of the
pipe, in addition to weekly water analysis and daily review of operation parameters.
f. Condition changes along the system length (e.g., pressures, temperatures, flow pattern,
new entrants, connections) should be considered.
Table 1 - General guide for application of corrosion monitoring techniques

Weight loss coupons
Bacteria monitoring
Hydrogen probes/
Dissolved gasses
Sand monitoring
Dissolved solids
Galvanic probes
LPR probes
ER probes
devices
patch
pH(6)
EFM
Seawater injection and cooling systems   (5)  (4)      O2  

Produced water treatment and injection         O2, CO2,  
systems H2S
Aquifer water    (1)      CO2, H2S  
Effluent water       (2)   O2  
Boiler feedwater and steam       (2)   O2  
condensate
Multiphase flow (gas/oil/ water)    (3)        
Unstabilised crude oil         CO2, H2S  
Produced gas           
Crude distillation units, overhead         O2  
systems
Fluidised catalytic cracker units,           
distillation columns, gas plants
Amine/caustic treaters and piping         O2  
Vacuum units, and pipework         O2  
Storage vessels/tanks with separated         CO2, H2S  
water bottoms
 Possible application.
 Not applicable.
1. Depends on water quality. LPR unsuitable if there is low ion content, strong scaling tendency, or other forms of electrode
contamination are possible.
2. May be used if oxygen content is high.
3. Only in water cuts above approximately 10% to 20% and flow is stratified
4. Depends on water quality. LPR unsuitable if there is biofilming tendency.
5. Intrusive probe preferred. Flush mounted probe unsuitable if there is biofilming tendency.
6. Only if aqueous phase is present.
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8.2. Oil and gas systems
8.2.1. Seawater injection systems

Recommended practices for monitoring seawater injection systems are available in
NACE SP0499 (Bibliographic ref. [16]).
a. Seawater systems should use, as a minimum, corrosion coupons to monitor accumulated
uniform and localized corrosion.
Intrusive probes protruding into the process stream are well suited and can be
inserted from the top quadrant of the pipeline. However, they cannot be used in lines
that are pigged, or they need to be withdrawn before pigging operations are
undertaken. Flush mounted coupons should be installed at 6 O’clock position in
lines that are pigged.
b. Seawater injection systems that rely on a combination of mechanical deaeration and
oxygen scavenging should have continuous monitoring using on-line dissolved oxygen,
galvanic probes, or LPR probes. ER probes may also be used, but they are less sensitive to
short changes in oxygen concentration.
1. Specialist (SME) advice and guidance should be sought before using electrochemical
probes (galvanic or LPR). They should not be used in systems with biofilming
tendency.
2. Water samples should be periodically taken to measure dissolved oxygen and pH.
3. On-line oxygen monitors should be calibrated weekly.
c. The effectiveness of biocide treatment should be monitored by means of bacteria cultures
at a suitable location or bioprobes, and dissolved H2S.
The most significant risks are fouling resulting in plugging (injection wells) and
under deposit corrosion. In the former case very tight control can be required,
justifying the use of bio-probes. In the latter case routine cleaning such as regular
mechanical pigging is essential and hence measures for routine pigging control
apply.
d. The following process parameters should also be monitored (if applicable):
1. Oxygen scavenger availability (e.g., pump on/off percentage, frequency of chemical
dosage below recommended values, tank levels).
2. Biocide availability (e.g., biocide injection batch treatment compliance, biocide tank
levels, total biocide consumption compared to projected use).
3. Flow rate.
4. Water analysis (pH, total suspended solids, particle size, and distribution).
5. Completed pig runs.
8.2.2. Produced water injection systems

a. Produced water systems should use, as a minimum, corrosion coupons to monitor
accumulated uniform and localized corrosion.
1. Intrusive coupons should not be used in lines that are pigged, or they need to be
withdrawn before pigging operations are undertaken.
2. If corrosion under deposits is possible, flush mounted coupons located at the bottom
of the pipe and ideally at low spots should be considered.
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17 June 2009 GP 06-70
Probes located between 3 O’clock and 9 O’clock may have the tendency to get stuck
by accumulated solids, in which case a back flush procedure should be performed
prior to retrieval.
b. Produced water injection systems prone to oxygen ingress should consider continuous
monitoring using galvanic or LPR probes although long term reliability can be
questionable and care should be exercised.
Electrochemical probes may not be effective if the electrodes are filmed or covered
by non-conductive deposits. In these cases, ER probes are recommended.
1. Regular inspection and maintenance of potential ingress locations should be
performed.
2. Water samples should be periodically taken to measure dissolved oxygen and pH.
On-line oxygen measurements can be considered, but are complicated by probe
contamination challenges.
c. The effectiveness of biocide treatment should be monitored by means of bacteria cultures
at a suitable location, bioprobes, or scrapping off corrosion coupons.
The most significant risks are fouling resulting in plugging (injection wells) and
under deposit corrosion. In the former case very tight control can be required,
justifying the use of bio-probes. In the latter case routine cleaning such as regular
pigging is essential and hence the measures for routine pigging control apply.
d. The following process parameters should also be monitored (if applicable):
1. Water chemistry (including pH, iron, alkalinity, scaling tendency, TSS, organic acids)
and dissolved gases (CO2, H2S, O2).
2. Oxygen scavenger availability (e.g., pump on/off percentage, frequency of chemical
dosage below recommended values, tank levels).
3. Biocide availability (e.g., Biocide injection batch treatment compliance, biocide tank
4. Inhibitor residuals, carried over from upstream operations.
5. Flow rate.
8.2.3. Multiphase gas/oil/water pipeline

a. Multiphase systems should use, as a minimum:
1. Corrosion coupons located in the corrosive phase(s) to monitor accumulated uniform
and localized corrosion.
2. On-line corrosion monitoring technique(s) with response time(s) consistent with the
defined corrosion philosophy.
b. ER probes should be used for on-line monitoring in favour of electrochemical probes.
Electrochemical probes (e.g., LPR, noise, impedance) can be used for special
studies (e.g., chemical evaluation or optimization) only if water cut is higher than
about 10% to 20% where the flow regime (e.g., stratified flow) favours formation of
a separate aqueous phase or above 30-40% where water can become the continuous
phase and probes can be totally immersed in the aqueous conductive phase.
c. Intrusive coupons/probes should not be used in lines that are pigged, or they need to be
withdrawn before pigging operations are undertaken.
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17 June 2009 GP 06-70
d. Flush mounted coupons should be considered in low water cut situation, under deposit
corrosion, areas of water dropout or condensation, and where maintenance pigging or well
debris could mechanically damage the coupon/probe.
e. Erosion probes should be considered if solids are expected.
1. ER based erosion probes should be favored for accessible applications, if only one
type of sensor is considered.
2. Acoustic solid particle detectors should be the preferred technology for subsea
installations.
Acoustic probes measure indirectly the amount of solids (e.g., sand) being
transported by the fluid, whereas ER base probes measure directly erosion produced
by the particles.
f. Monitoring location should be selected depending on the monitoring technique, expected
corrosion mechanism, and predicted corrosion rates at operating conditions:
1. At bottom of a pipeline operating under stratified flow.
2. At top of the pipeline if TLC is expected.
3. At sections of the line with highest predicted corrosion rate, such as:
a) Having highest pressures, temperatures, and velocities.
Special attention is required for lines having significant changes in conditions along
its length.
b) Hydrodynamically severe regions (e.g., bends, reducers, valves, elevation
changes where changes of flow pattern may occur).
c) Elevation/direction changes and low spots where solids may deposit.
g. If the monitoring location has been identified with certainty to be in an area of difficult
access (e.g., subsea), sensitive measurements using reliable probes or corrosion spools
Monitoring technologies available for subsea applications have to date exhibited
mixed performance and reference to current industry thinking and available
experience should always be consulted before a final decision is taken. Therefore, it
is not uncommon for subsea corrosion monitoring to be based on use (if possible) of
in-line inspection and inference from monitoring data obtained at the line terminus,
either topside or onshore.
h. Consideration should be given to other entrants to a pipeline system as these could
influence corrosivity considerably. This may include mixing of separate well streams,
through to third party entrants from other fields.
i. The effectiveness of biocide treatment should be monitored by means of bacteria cultures
at a suitable location, bioprobes, and/or dissolved H2S concentration (in non-sour
applications).
j. The following process parameters should also be monitored (if applicable):
1. Water chemistry (including pH, iron, alkalinity, scaling tendency, organic acids).
2. Corrosion inhibitor injection availability (e.g., pump on/off percentage, inhibition
levels, frequency of chemical dosage below recommended values, tank levels).
3. Biocide availability (e.g., biocide injection batch treatment compliance, biocide tank
4. Inhibitor residuals.
Page 28 of 38
17 June 2009 GP 06-70
Care needs to be taken to assure the technique being used is capable of detecting the
active component of the inhibitor and should be agreed with the chemical supplier
or Chemical Managed Services provider.
5. Flow rate, water cut, pressures, temperatures.
7. Solid content and analyses.
8.2.4. Export quality crude oil pipeline

a. Systems transporting crude oil which may contain water and sediments should use, as a
minimum, flush mounted coupons located at the bottom of the pipe, in areas where water
or solids may accumulate (e.g., low spots, long horizontal sections at low flow velocities).
Predictive models and LP-ICDA (Bibliographic Ref.[28]) approach can be used to
select appropriate monitoring locations.
b. If on-line measurements are deemed to be a requirement, flush mounted ER probes at
6 O’clock position should be used.
c. Erosion probes should be considered if solids and high velocities are expected. ER based
erosion probes should be favored if only one type of sensor is to be considered.
Refer to the GP 32-40 for guidelines for designing and operating a sand detection
system and see Bibliographic ref. [2] for a summary of field experience with sand
detection systems.
Field experience with sand monitoring in production operations has shown that
sand is often not produced at a constant rate but in intermittent bursts. Erosion can
be rapid on some equipment, in which failures have occurred in minutes to a few
hours. Real-time sand detection of transient rates greater than an established
threshold level can alert operators through control room alarms.
Sensors for the evaluation of erosion caused by solids entrained in fluid streams are
available from two competing technologies. One technique uses the principles of the
ER probe. The alternative technique monitors acoustic noise in the flowing stream.
d. If the monitoring location has been identified with certainty to be in an area of difficult
access (e.g., subsea), sensitive measurements using reliable probes or corrosion spools
e. Consideration should be given to other entrants to a pipeline system as these could
influence corrosivity considerably. This may include mixing of separate well streams,
through to third party entrants from other fields.
f. The effectiveness of biocide treatment should be monitored by means of bacteria cultures
at a suitable location, bioprobes, and/or dissolved H2S concentration (in non-sour
applications).
g. The following process parameters should also be monitored (if applicable):
1. Bottom solids and water (BS&W) analysis.
2. Water chemistry, if possible, (including pH, iron, alkalinity, scaling tendency, organic
acids, TDS, TSS).
3. Biocide availability (e.g., Biocide injection batch treatment compliance, biocide tank
5. Flow rate, pressures, temperatures.
Page 29 of 38
17 June 2009 GP 06-70
7. Solid content and analyses (sampling from process fluids and pigging deposits).
8.2.5. Gas pipeline

a. Systems transporting natural gas which may contain water (i.e., wet gas) should use, as a
minimum, flush mounted coupons or probes located at:
1. The bottom of the pipe, in areas where water may accumulate (e.g., low spots, long
horizontal sections) or
2. The top of line, in areas where water is predicted to condense onto the pipe wall.
Predictive models such as OLGA, MULTICORP, and those recommended by DG-
ICDA (Bibliographic Ref.[28]) can be used to select appropriate monitoring
locations.
b. Systems transporting dry (dehydrated) natural gas should have continuous monitoring of
dew point and records of process upsets and in so doing not require installation of
corrosion coupons or probes.
c. Consideration should be given to entrants to a pipeline system as these could influence
corrosivity considerably.
Mixing two non-corrosive streams (e.g., a dry gas containing high concentrations of
CO2 with a wet gas containing negligible concentration of acid gases) may produce
a highly corrosive stream.
d. The following process parameters should also be monitored (if applicable)
1. Water chemistry (including pH, iron, alkalinity, scaling tendency, organic acids).
2. Corrosion inhibitor injection availability (e.g., pump on/off percentage, inhibition
levels, frequency of chemical dosage below recommended values, tank levels).
4. Flow rate, process upsets that may introduce water, pressures, temperatures.
6. Gas analyses (CO2, H2S, water concentration or dew point).
8.3. Refinery systems
8.3.1. Boiler feed water and steam condensate

This clause outlines corrosion monitoring and sampling recommendations. For
details refer to Refining GN - Water Treatment BFW.
a. Water and steam samples should be taken using criteria based on ASTM D3370 and
ASTM D1066, respectively (technical, cost, performance).
1. Samples should be representative of the main body of water.
The most critical factors to achieve this are: the point of sampling, material
selection, system design, time of sampling, frequency of sampling, and proper
procedures to handle the sample until analysis.
2. Samples should be of sufficient volume and be taken frequently enough to permit
reproducibility of the test objective.
3. Properly cooled samples should be used, for safety and test accuracy.
Sample systems are recommended as opposed to sample coolers.
b. The following procedures should be used on samples withdrawn from the system to
measure control parameters:
Page 30 of 38
17 June 2009 GP 06-70
1. Alkalinity. A sample is titrated with a 0,02 N standard solution of sulphuric acid. P

alkalinity is found by adding phenolphthalein as an indicator. Its end point is a pH of
8,3. The titration continues with determination of the M alkalinity. This is found by
adding methyl orange or methyl purple as an indicator. Methyl purple is easier to see
the end point versus the methyl orange indicator. The titration continues till the next
end point (pH of 4,3) is reached. This end point represents the complete neutralization
of the carbonate ions and any bicarbonate ions. The hydroxide alkalinity or O
alkalinity can be calculated as 2P-M. When using a 50 ml sample and 0,02 N
sulphuric acid, the alkalinity is equal to the milliliters of acid required to reach the
end point times 20.
2. Ammonia. Ammonia compounds combine with chlorine to form monochloramine
which in turn reacts with salicylate to form 5-aminosalicylate. The 5-aminosalicylate
is oxidized in the presence of sodium nitroprusside catalyst to form a blue coloured
compound. The blue colour is masked by the yellow colour from the excess reagent to
give a final green coloured solution. The intensity of the colour is then read in a
photometer and the amount of ammonia is determined from a calibration curve using
ammonium chloride in pure water. Concentrations of other ions interfere with the
results when above the following limits: calcium (>1000 ppm), magnesium
(>6000 ppm), nitrite (>40 ppm), nitrate (>440 ppm), orthophosphate (>300 ppm), and
sulphate (>300 ppm). Iron at any concentration interferes. Therefore, the calibration
water needs to have the same amount of iron as the sample. Sulphide, hydrazine, and
glycine in the sample intensify the sample’s colour. Extremely high or low pH
samples should be neutralized to a pH of about 7 with sodium hydroxide or sulphuric
acid. Turbidity and sample colour give erroneously high values. Samples with very
high amounts of interferences and albuminoid nitrogen may require distillation.
3. Carbon dioxide. Carbon dioxide reacts with sodium carbonate to form sodium
bicarbonate. At the equivalence point (pH = 8,3), phenolphthalein used as an indicator
turns pink. If free mineral acidity is present, it is measured along with the carbon
dioxide. This is corrected by titrating a second sample with sodium carbonate to a pH
of 4,3 (methyl orange/methyl purple end point). Subtraction of the two titration
results provides the corrected free carbon dioxide concentration. The CO2
concentration in mg/l is equal to the milliliters of N/22 sodium carbonate times 10.
Precaution in obtaining the sample is critical so that the water does not degas itself.
The titration is interfered with by free mineral acids, aluminium, chromium, copper,
amines, ammonia, borate, nitrite, sulphide, high total dissolved solids, and even
excessive indicator. If the colour of the water obscures the indicator’s end points, a
pH meter can be used.
4. Conductance. A conductivity meter is normally used. Conductivity is expressed in
micromho (mho) or the SI equivalent of microsiemens (S). For boiler water, the
hydroxide ions are often neutralized with a boric acid solution prior to measurement.
In neutralized boiler water, 1 mho is about 0,9 ppm of solids. In high purity waters
and condensate, the water should not be neutralized prior to testing. In this type of
water 1 mho is about 0,5 ppm to 0,6 ppm of solids. A correction factor is subtracted
from the measured conductivity reading to account for the dissolved gases, especially
carbon dioxide and ammonia.
5. Copper. The normal test method considers low levels (0,1 ppm to 5 ppm) of copper.
The sample is mixed with a bicinchoninate indicator and a reducing agent. The
reducing agent converts any Cu+2 ions to Cu+. This ion reacts with the indicator to
form a purple complex which is then used to measure the copper content by
photometer. Samples with a pH of less than 2 need to be neutralized with potassium
hydroxide. If the neutralization is still not clear, silver may be interfering. Cyanide
prevents enough colour from forming and can be eliminated by adding a small
amount of formaldehyde. A porphyrin reagent is used for lower copper concentrations
Page 31 of 38
17 June 2009 GP 06-70
(5 ppb to 210 ppb). Chelating agents interfere with this test as well as high or low pH
samples. Several other ions interfere with the results. They include aluminium,
cadmium, calcium, chloride, chromium, cobalt, fluoride, iron, lead, magnesium,
manganese, mercury, molybdenum, nickel, potassium, sodium, and zinc.
6. Hardness. Hardness is normally measured by titrating the sample with a standard
solution of chelant. A hardness buffer is added to adjust the sample pH (7 to 10) and
to complex potentially interfering ions. The indicator in the presence of hardness is
red but turns blue when the chelant complexes with all the hardness. Large amounts
of iron, copper, or zinc register as hardness. Polyphosphate also interferes. Low level
spectrophotometer methods are recommended for testing total hardness levels below
1 ppm. The low level flow through cell method is required if the total hardness is less
than 100 ppb.
7. Total iron. The iron testing method used in steam systems should be accurate in the
2 ppb to160 ppb range (e.g., Nalco Fe4 test or other spectrophotometer test having
low detection limits). Some spectrophotometer tests give wide detection limits. It is
recommended to take the maximum limit of the test and use 2% of scale as being
highly reliable and 1% of scale being the detection limit. This means that an iron test
with a 3 ppm maximum would be unreliable below 60 ppb. Many test procedures do
not detect hematite (Fe2O3) without digesting the sample. Samples need to be digested
for accurate results. The Nalco Fe4 test can be digested cold (24 hrs). There is also
the B&W filter test that can be used for particulate iron contamination levels. It filters
a 1 000 ml sample through a 0,45 micron filter and compares the filter colouring to
standard charts.
8. Soluble iron (Fe+2). Soluble iron testing shall be run in the field at the sample point
since any induction of oxygen converts the soluble Fe+2 to an insoluble oxide.
Detection limit is important because these values are generally in the low ppb range.
For example, the Nalco procedure (Fe2) has a detection limit of 2 ppb to160 ppb.
Other methods may be available from other water treatment testing vendors.
9. Dissolved oxygen. The method should be selected depending on the level of oxygen
present. Levels of ppm oxygen can be measured by the Winkler iodometric method or
by membrane detecting electrometric instruments. Levels of ppb oxygen requires
special sampling techniques, colourimetric methods and membrane detecting on-line
instruments. Using wet chemistry, a quantity of Rhodazine D dye greater than the
oxygen level is used in a Chemet. The colour of the dye in the presence of oxygen is
deep rose. The colour is then compared to a standard in graduated intervals to get an
approximate reading.
10. pH. pH should be measured using pH electrodes and instruments calibrated at the
sample temperature. The best practice method to measure pH is to have the sample at
a temperature of 25°C (77°F) but this may require a chilled cooling water sample. If
the sample can not be cooled to 25°C (77°F), the measured pH value needs to be
“corrected’ to 25°C (77°F) using correction tables included in the standard methods.
This correction can be very significant for high pressure boilers and condensate
control accuracy.
11. Phosphate. Both orthophosphate and total phosphates should be measured.
a) To measure orthophosphate it is necessary to acidify the sample and add
ammonium molybdate. This reacts to form molybdo-phosphoric acid. This
complex is then reduced by the amino acid reagent to yield a blue molybdenum
compound which is read in a spectrophotometer. Interferences include sulphides
and nitrites, chloride (>150 000 ppm), calcium (>10 000 ppm), magnesium
(>40 000 ppm). Reactions work best at room temperature. High salt levels in the
sample require the sample to be diluted until the dilution does not alter the
Page 32 of 38
17 June 2009 GP 06-70
results. This is shown by the initial sample changing form blue to green to
yellow to brown as the orthophosphate concentration increases.
b) Total phosphate is found by converting other phosphate forms to
orthophosphate. This can be done by using acid and heat to hydrolyze
metaphosphate, pyrophosphate, and other inorganic forms. If organic phosphates
and phosphonates need to be measured, they are heated with persulphate for
conversion to orthophosphate. The orthophosphate method is then used. High
concentrations of chromate may interfere. Organic phosphates interfere for a
simple inorganic measurement as some hydrolyze without the persulphate.
12. Silica. Silica and phosphate react with the molybdate ion under acidic conditions to
form yellow silicomolybdic and phosphomolybdic acid complexes. Citric acid is
added to break up the phosphomolybdic acid complex. For high silica levels, the
sample can be read in a photometer. For low concentrations, a reducing agent is
added to convert the sample to a dark blue species. A blank eliminates colour and
turbidity interferences. Sulphide and large amounts of iron interfere. The reaction of
some forms of silica can be quite slow. This can be accelerated by pretreating the
sample with sodium bicarbonate and sulphuric acid. The HACH bench top silica
analysis using a spectrophotometer has a detection limit of 17 ppb. Digital
spectrophotometers provide data that is below this detection limit.
13. Sulphate. Sulphate reacts with barium chloride to form insoluble barium sulphate.
The amount of turbidity formed is proportional to the amount of sulphate and can be
determined in a spectrophotometer. Silica (>500 ppm), calcium (>20 000 ppm),
magnesium (>10 000 ppm) and chloride (>40 000 ppm) can interfere.
14. Sulphite. Sulphite reacts with iodine in acidic conditions. A standard solution of
iodide/iodate is used to generate iodine in an acidic solution. At the end point of the
titration, the excess iodine combines with the phenolphthalein indicator to form a blue
colour. Any oxidizable substance in the sample interferes with the results. This
includes organic matter, sulphides, and nitrites, all of which yield high test results.
15. Suspended solids/turbidity. Turbidity or suspended solid matter in water is measured
optically. The solid particles in the sample causes light to be scattered or absorbed.
The amount of turbidity registered depends on the size, shape and refractive
properties of the particles. There is no correlation between turbidity and the weight of
the solids present. Two common units are used in measuring turbidity. They are FTU
(Formazin Turbidity Unit) and NTU (Nephelometer Turbidity Unit). A Nephelometer
unit measures the intensity of light scattered at an angle of 90 degrees to the incident
light. A photometer measuring the reduction in intensity of the light passing straight
through the sample is used with a Formazin turbidity standard to get readings in FTU.
c. On-line analytical instruments should be used as alternative means of measuring some of
the control parameters. Calibration of these instruments is critical to maintaining accuracy
in the result.
This is normally superior to manual chemical testing in that the analysis is done
nearly continuously and the delay in obtaining results is much shorter, so the results
can be immediately applied to control the system. These analyzers are often coupled
directly to the control device. Continuous data logging also allows for greatly
improved diagnostics. The disadvantage is that these systems are often expensive
both for initial purchase and maintenance.
d. The following monitoring techniques should be used to determine how much corrosion is
occurring in the condensate system and to determine how effective the chemical treatment
program is:
1. Weight loss corrosion coupons.
Page 33 of 38
17 June 2009 GP 06-70
2. Testing for corrosion products in condensate samples. Large volumes of condensate

sample should be taken to obtain enough corrosion products to make the analysis
representative, since these products may be present as insoluble species.
The amount of corrosion products in the condensate also is a treatment concern. If
few corrosion products are present, the condensate may be returned to the
deaerator to remove any dissolved gases present. If large amounts of corrosion
products are present, it may be necessary to polish the condensate. A condensate
polisher is an ion exchange device to remove iron and copper materials from the
condensate stream. It also tends to filter some of the larger particulates.
3. Monitoring residual oxygen scavengers and amines if possible. This provides a
measure of confidence that the system is being treated properly.
4. Selecting sample locations to insure that all areas of the system are being treated.
Variations in flow rates, temperatures, and amine compositions due to distribution
ratio differences make it hard to get adequate treatment everywhere in the system
without overtreating much of the rest of the system.
8.3.2. Crude distillation and vacuum units, overhead systems and NAP acid circuits
a. At least one traditional method of monitoring corrosion should be used in crude unit
overheads. These methods include the use of weight loss corrosion coupons and ER probes
as well as water analysis from the overhead accumulator.
b. Modern corrosion probes should be considered to obtain almost real time response to
changes in corrosivity. These probes include:
1. Electrochemical techniques (LPR, EN). Probes may have a variety of configurations
and the electrodes shall be in contact with the aqueous phase.
2. High sensitivity ER probes.
3. Hydrogen flux monitoring. Collector plate technology may be used in NAP acid
circuits.
c. Advice should be sought from the inspection and corrosion network prior to considering
installation of electrical field mapping systems (e.g., FSM) in NAP acid systems, due to
mixed experience with these devices.
d. The use of side stream systems should be considered for chemical analysis and corrosion
activity simulation.
The following systems have been successfully used in overhead systems:
 Advanced overhead corrosion simulator (AOCS) provides information pertinent
to corrosion control at the point of condensation and corrosion under salt
deposits.
 Condensate on-line analyzer (COLA) measures water dew point and analyses
water composition along the water condensation profile.
e. Advice should be sought from the inspection and corrosion network prior to using online
pH probes for monitoring overhead water pH. The experience is limited with mixed
results. Traditional pH probes have historically fouled regularly, losing signal.
f. The use of a chloride bench-top (or online) analyzer should be considered for ranking
chloride levels of crude oil, tracking desalting efficiencies, and in troubleshooting chloride
corrosion. The analyzer may also be used to screen out organic chlorides in crude, if they
are suspected.
g. Advice should be sought from the inspection and corrosion network for potential use of
online NDT techniques for monitoring corrosion.
Page 34 of 38
17 June 2009 GP 06-70
High temperature ultrasonic sensors have been developed by BP Refinery

Technology group and are capable of measuring spot wall thicknesses up to
temperatures of 700°C (1 300°F) with an accuracy of 0,1 mm (0,004 in).
8.3.3. FCCUs (fluidised catalytic cracker units), overhead systems, and FCC gas plants
a. ER corrosion probes should be installed in the overhead system between the main column
overhead condensers and the main column overhead receiver.
b. High sensitivity resistance probes should be considered instead of traditional ER probes.
c. Hydrogen flux sensors should be considered to assess the relative corrosion activity of the
liquid phase in the main column overhead system.
Guidelines on relative/acceptable flux rates may be obtained from some chemical
managed services providers and hydrogen flux sensor manufacturer.
d. Advice should be sought from the inspection and corrosion network for potential use of
online NDT techniques for monitoring corrosion.
High temperature ultrasonic sensors have been developed by BP RT and are
capable of measuring spot wall thicknesses up to temperatures of 700°C (1 300°F)
with an accuracy of 0,1 mm (0,004 in).
8.3.4. FCCU unsaturate gas plant (USGP)

Corrosion in downstream gas plants handling FCC gas streams is generally due to
the presence of moist hydrogen sulfide and cyanides; fouling is usually the result of
ammonium compounds.
a. Retractable ER probes shall be installed between the high-pressure coolers and the high-
pressure receiver and near the middle of the absorber tower.
b. Hydrogen flux monitoring should be considered at the following locations:
1. High-pressure receiver: Top of vessel and side of vessel just above liquid level.
2. Main absorber: Second manway from bottom, third manway from bottom at liquid
level, and second manway from top.
3. Stripper tower: Above top tray.
4. Debutanizer overhead receiver: Bottom boot and top of vessel.
c. Water samples drawn from the high-pressure receiver and debutanizer overhead
accumulator should be analyzed for cyanide and thiocyanate.
8.3.5. Amine treaters

a. The location of ER, guided wave ultrasonic, and WLCs should be chosen with care,
particularly if corrosion in the plant is highly localized.
1. New plants should have probe connections consisting of DN 40 (NPS 1-1/2) full port
gate valves installed in critical locations such as reboiler outlet vapour lines and the
rich amine piping between the rich/lean exchanger and the regenerator.
2. ER probes may not be satisfactory if corrosion occurs by pitting or if fluid velocities
and turbulence at the location are sufficient to cause the ER probe element to fail by
fatigue. If the best test location is a highly turbulent area such as the reboiler outlet
line, retractable WLCs should be used.
b. Hydrogen flux monitoring should be considered around the reboiler circuit and in hot
rich/lean amine systems.
Page 35 of 38
17 June 2009 GP 06-70
8.3.6. Isomerization units

a. Corrosion probe connections shall be provided in the following locations:
1. Suction line to isomerization gas compressor.
2. Downstream of the product neutralizers.
3. Suction of HCl absorber bottoms pump.
4. Suction of caustic wash circulation pump.
5. Suction of fuel gas scrubber circulation pump.
b. A moisture analyzer should be used to measure the moisture content of the recycle gas.
c. An oxygen analyzer should be used to check the oxygen content of the circulating gas
during nitrogen/air regeneration.
d. A conductivity meter, with alarm, should be installed in the condensate return line (HCl
stripper reboiler) to give warning of any leakage.
8.3.7. Sour water strippers

a. Corrosion and hydrogen probes should be used in the following areas:
1. In the liquid and vapour space above the top tray of the H guided wave ultrasonic
S/NH3 stripper tower.
2. In the liquid and vapour space of the reflux drum.
b. Corrosion probes should be used at the inlet and outlet of the H2S/NH3 overhead condenser
and in the H2S offgas stream.
8.3.8. Delayed cokers

Corrosion and hydrogen probes should be installed in the liquid phase of the overhead
accumulator to detect activity leading to corrosion, shell blistering, and weld cracking in the
fractionator overhead systems of coker units processing streams from high-nitrogen crudes.
Page 36 of 38
17 June 2009 GP 06-70
Bibliography
[1] J.W. Martin, J.M. Glenn, “Design and Operation Guidelines to Avoid Erosion Problems in Oil and Gas
Production Systems”, Topside Sand and Erosion Management Seminar, Nov. 24, 2004.
[2] A. Gyani, J. Glenn, T. Lockhart, “Sand Detection Bests Practices & Lessons Learnt for Subsea and
High Value Wells”, Report, BP Upstream Technology Report, Sunbury, Aug. 21, 2001.
[3] B. Hedges, A. Bodington, “A comparison of Monitoring Techniques for Improved Erosion Control: A
Field Study”, NACE Corrosion 2004, paper 04355.
[4] T.N. Evans, Y. Sun, E. Babian-Kibala, H.R. Bennett, Jr., J.W. Martin, J. Alvarez, “Studies of Inhibition
and Monitoring of Metal Loss in Gas Systems Containing Solids”, NACE Corrosion 2004, paper
04362.
[5] A. J. McMahon, D. M. Paisley, “Corrosion Prediction Modelling”, ESR.96.ER.066.
[6] J. Martin, “Guidelines for Selecting Downhole Tubular Materials with Particular Reference to Sour
Conditions”, ESR 94.ER.066.
[7] ASTM G4, “Conducting Corrosion Tests in Field Applications”.
[8] ASTM G46, “Examination and Evaluation of Pitting Corrosion”.
[9] R.J. Scanlan, R.M. Boothman, D.R. Clarida, “Corrosion Monitoring Experience in the Refinery
Industry Using the FSM Technology”, NACE Corrosion 2003, paper 03655.
[10] NACE 1C184, “Monitoring Internal Corrosion in Oil and Gas Production Operations with Hydrogen
Probes”.
[11] UOP 565, “Acid Number and Naphthenic Acids by Titration”.
[12] UOP 587, “Acid Number and Naphthenic Acids by Colorimetric Titration”.
[13] ASTM G31, “Laboratory Immersion Corrosion Testing of Metals”.
[14] NACE RP0192, “Monitoring Corrosion in Oil and Gas Production with Iron Counts”.
[15] NACE RP0189, “On-Line Monitoring of Cooling Waters”.
[16] NACE SP0499 (Formerly TM0299), “Corrosion Control and Monitoring in Seawater Injection
Systems”.
[17] ASTM D1068, “Iron in Water”.
[18] ASTM G1, “Preparing, Cleaning, and Evaluating Corrosion Test Specimens”.
[19] ASTM G96, “On-Line Monitoring of Corrosion in Plant Equipment (Electrical and Electrochemical
Methods)”.
[20] NACE 1C187, “Use of Galvanic Probe Corrosion Monitors in Oil and Gas Drilling and Production
Operations”.
[21] NACE 1D199, “Internal Corrosion Monitoring of Subsea Production and Injection Systems”.
Page 37 of 38
17 June 2009 GP 06-70
[22] NACE 3T199, “Techniques for Monitoring Corrosion and Related Parameters in Field Applications”.
[23] A. Groysman, A. Hiram, “Corrosion Monitoring and Control in Refinery Process Units”, NACE
Corrosion 1997, paper 97512.
[24] A. Bagdasarian, J. Feather, B. Hull, R. Stephenson, R. Strong, “Crude Unit Corrosion and Corrosion
Control”, NACE Corrosion 1996, paper 96615.
[25] ASTM D6350, “Mercury Sampling and Analysis in Natural Gas by Atomic Fluorescence
Spectroscopy”.
[26] GP 06-10, Guidance on Practice for Corrosion Management.
[27] M.J.J Simon Thomas and S. Terpstra. “Corrosion monitoring in Oil and Gas Production”. NACE
Corrosion 2003. Paper 03431.
[28] O. C. Moghissi, C. Mendez, W. Sun, J. R. Vera, T. Place “Internal Corrosion Direct Assessment
Methodology for Liquid Petroleum Pipelines” NACE Corrosion 2007, paper 07169.
[29] NACE SP0206 “Internal Corrosion Direct Assessment for Pipelines Carrying Normally Dry Gas (DG-
ICDA).
[30] P.R. Roberge. “Corrosion Inspection and Monitoring” .John Willey and Sons Eds (2007).
Page 38 of 38

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Copyright © 2009 BP International Ltd. All rights reserved.

Table 1 - General guide for application of corrosion monitoring techniques................................... 25

• For dated references, only the edition cited applies.

GP 32-40 In Service Inspection and Testing - Common Requirements.

American Petroleum Institute (API)

American Society for Testing and Materials (ASTM)

Institute of Petroleum (IP)

NACE International (NACE)

3. Terms and definitions

Corrosion monitoring is more complex than monitoring most other process

Direct monitoring techniques

Flush mounted probes or coupons

Indirect monitoring techniques

Intrusive monitoring techniques

Intrusive probes or coupons

Non-intrusive monitoring techniques

4. Symbols and abbreviations

CAD Computer aided design.

EDS Energy dispersive spectroscopy.

ER Electrical resistance (probe).

HAZ Heat affected zone.

HIC Hydrogen induced cracking.

ICM Inspection and corrosion monitoring (database).

LPR Linear polarization resistance (probe).

MIC Microbiologically influenced corrosion.

mm/y millimeters per year.

mpy mils per year (mil = 0,001 in).

NDE Non-destructive examination.

OMS Operating Management System.

ORP Oxidation reduction potential.

P&IDs Process and instrumentation diagrams.

PFD Process flow diagrams.

SEM Scanning electron microscopy.

SRB Sulfate reducing bacteria.

TAN Total acid number.

TDS Total dissolved solids.

TLC Top of line corrosion.

TSS Total suspended solids.

5. Corrosion monitoring philosophy

The corrosion risk assessment considers the materials of construction, corrosion

For example, high reliability is required if the corrosion monitoring system is

6. Principles of corrosion monitoring system design

False positives and negatives, or indications caused by process variable

6.2. Device selection and placement

Hydrodynamically severe regions, such as bends, reducers, valves, elevation

6.2.2. Monitoring technique

6.2.3. Monitoring device access

6.3. Corrosion data quality

6.4. Data management

9. Support the analysis and trending of ICM related data.

7. Corrosion monitoring principles

7.1. Direct intrusive monitoring techniques

7.1.1. Flush mounted probes and coupons

7.1.2. Intrusive probes or coupons

7.1.3. Weight loss coupons

7.1.4. Electrical resistance (ER) probes

7.1.5. High sensitivity ER probes

7.1.6. Ring pair corrosion monitoring spools

7.1.7. Intrusive solid particle monitoring

7.1.8. Electrochemical probes

7.1.8.2. LPR probes

7.1.8.3. Galvanic probes

7.1.8.4. Coupled multi-electrode array system