Microcor® High Speed Internal Corrosion Monitoring Systems

The Microcor® corrosion monitoring technology has been developed to substantially increase the speed of response over conventional corrosion monitoring techniques, such as coupons, electrical resistance (ER) probes, and linear polarization resistance (LPR), and is functional in all environments. Microcor® high speed corrosion monitoring is the result of patented technology which combines the rapid response of LPR and the universal applicability of ER. The figure below compares the real world response of various internal corrosion monitoring methods to the Microcor® system. Corrosion rate on a logarithmic scale is plotted against time, also on a logarithmic scale. At 10 mpy, the common W40 electrical resistance probe takes nearly 3 days to show a clear response. A Microcor® internal corrosion monitoring probe with the same useful probe life will show a clear response in 1 hour, and the trend is visible in 15 minutes. Even an LPR corrosion monitoring probe in water will take 5 to 10 minutes to produce a steady corrosion rate reading. This means that the Microcor® corrosion monitoring system is 50 to 100 times more sensitive and faster in response than ER systems. The absolute resolution of the Microcor® electronics is 256 times more sensitive than ER system electronics.

For information on protecting you resources from corrosion, contact Rohrback Cosasco Systems. Our experience in corrosion monitoring equipment means we can tailor a specific solution for your corrosion protection needs. Our corrosion monitoring field services will help you integrate and manage your new system.

Microcor Wireless Corrosion Monitoring System

Microcor® Corrosion Probes

Microcor® Corrosion Instrumentation

Microcor System Rapid Monitoring of Corrosion Rates

Applies to any environment just as CORROSOMETER® but due to the high resolution and the rapid response it affords, its' greatest benefit is for online monitoring where prompt corrective actions (chemical inhibition or modification of process parameter) can be made.

Microcor Online Corrosion Monitoring

Benefits

Microcor Online Corrosion Rate Monitor

Microcor Systems:

Reduces inhibitor evaluation times saving time and money
Rapidly detects small corrosion upsets in systems with little or no corrosion allowance – e.g. gas pipelines
Allows detection of corrosion upsets in batch processes with short cycle times – e.g. refineries
Probes can be used in any environment, even in sour service
Increase the speed of response and give “real-time” monitoring

Cost Savings

Inhibitor screening trials were conducted at an onshore oil field operated by a major oil
company in 2004 using a Microcor data logging system. Prior to the use of Microcor, standard electrical resistance technology had been employed. The following table compares the results achieved with both.

TRIAL DESCRIPTION:	Before	After

Technology employed	Standard ER	Microcor

Number of probes	Three	One

Test duration required to achieve adequate results	36 days	4 days

Data frequency	10 minute intervals	2 minute intervals

Data results	Analysis only practical at full inhibition	Analysis of entire curve

Number of concentrations tested	3 in 36 days	5 in 4 days

Percent of tests completed without interruption	30%	93%

Volume of chemical used	75 gallons	5 gallons

ECONOMICS:

Cost of chemicals at $10/gallon (estimated)	$750	$50

Estimated man-hours used	60	8

Cost per man-hour (estimated)	$40	$40

Labor cost per trial	$2,400	$320

Cost of trials for just chemicals plus labor	$750 + $2,400 = $3,150	$50 + $320 = $370

Savings achieved by Microcor	$3,150 - $370 = $2,780

Cost of CM technology per monitoring point including access fittings	$2,100	$5,000

Additional capital cost of Microcor	$5,000 - $2,100 = $2,900

FINDINGS:

Although this is a small, discrete application, it vividly demonstrates cost savings enabled by Microcor, savings that can be extended on a larger scale:

The higher capital cost of Microcor can be recovered very quickly. In the Case Study the extra investment of $2,900 is nearly recovered in the first trial, which lasted only four days.
Those savings may be dramatically scaled upward on larger production and operating systems where inhibitor volumes are high.
Microcor enables the user to analyze lower concentrations, an area of great interest when looking for cost reductions.
In online systems, process upsets can be detected and managed quickly, enabling asset preservation and extended life.
In online systems, much faster speed of response and higher resolution permit corrosion data to be incorporated into the DCS and used as a process control parameter.

In chemical screening trials additional benefits not evaluated above include:

More concentrations can be analyzed in a shorter time.
Faster speed of response enables finer control.
Increased speed of trials permits more efficient use of equipment.
The significant reduction in chemical volume reduces shipping and deployment costs, and leaves no leftover chemical to be handled.

Industries Served

Corrosion Monitoring Industries

Oil & Gas
- Production
- Refining
- Pipelines
Water
- Cooling Waters
- Process Waters
- Potable Waters
- Boiler Waters
- Effluent
Chemical
Petrochemical
Pulp & Paper