Corossion Coupon FullCatalog

KOROSI SPECINDO Corrosion Monitoring Equipment, Chemical injection, Sampling Systems and Services

iv

KOROSI SPECINDO

L ist of C ontent page COMPANY PROFILE 1. General Information 2. Quality Management System and Regulation Standard Compliance 3. Main Office and Manufacturing Workshop

i i ii

INTRODUCTION TO CORROSION MONITORING AND CONTROL 1. Philosophy of Corrosion Monitoring and Control 2. Corrosion Monitoring and Control Methods

ii iii

SECTION 1:TWO INCH SYSTEM CORROSION COUPON HOLDER ASSEMBLIES 1. Principle of Operation 2. Type of Corrosion Coupon and Holder 3. Length Calculation of Corrosion Coupon Holder 4. Ordering Procedures of Corrosion Coupon and Holder 5. Corrosion Rate Calculations 6. Material Option for Corrosion Coupons

1-1 1-2 1-3 1-5 1-6 1-7

SECTION 2:TWO INCH SYSTEM ELECTRICAL RESISTANCE (ER) PROBE AND DUAL ER/TEMPERATURE PROBE ASSEMBLIES 1. Principle of Operation 2. Probe Type, Length Calculation and Ordering Procedure l Tubular ER and Temperature Probe l Loop ER and Temperature Probe l Flush ER and Temperature Probe l Strip-band ER and Temperature Probe l Sand-erosion and Temperature Probe

2-1 2-1 2-4 2-6 2-8 2-10 1-12

SECTION 3: TWO INCH SYSTEM LINEAR POLARIZATION RESISTANCE (LPR) AND DUAL LPR/TEMPERATURE PROBE ASSEMBLIES 1. Principle of Operation 2. Probe Type, Length of Calculation and Ordering Procedure l Projecting LPR and Temperature Probe l Flush LPR and Temperature Probe

3-1 3-2 3-3 3-6

SECTION 4: DATA COLLECTION INSTRUMENT (DCI) FOR ER AND LPR MEASUREMENT 1. KSHHU-Handheld Data Logger and Up/down-loader 2. DCI-Field Mounted Data Logger and Transmitter 3. Extension Adapter, Probe Cable and Test Probe

4-1 4-4 4-9

SECTION 5: OTHER TWO INCH SYSTEM CORROSION MONITORING AND CONTROL EQUIPMENTS 1. Sand-erosion Monitoring Probe 2. Sulphate Reducing Bacteria (SRB) Monitoring Probe 3. Hydrogen Monitoring Probe 4. Chemical Injection/Sampling System 5. Tee-less Chemical Injection System

5-1 5-4 5-6 5-9 5-14

KS - CTG - MKT -03 REV .5

v

KOROSI SPECINDO

SECTION 6: MODEL KS6000 TWO INCH SYSTEM ACCESS FITTING ASSEMBLIES 1. Non-flange Access Fitting Assembly l Flarweld Access Fitting l Buttweld Access Fitting l Socketweld Access Fitting l NPT Access Fitting 2. F lange Access Fitting Assembly l ANSI RF Flange Access Fitting l ANSI RJ Flange Access Fitting l 2-1/16" API RJ Flange Access Fitting 3. Access Fitting Assembly Spare Parts 4. Hydraulic Non-flange Access Fitting Assembly l Flarweld Access Fitting l Buttweld Access Fitting l Socketweld Access Fitting l NPT Access Fitting 5. Hydraulic Access Fitting Assembly Spare Parts 6. Hydraulic Flange Access Fitting Assembly l ANSI RJ Flange Access Fitting l ANSI RF Flange Access Fitting l API RJ Flange Access Fitting

6-2 6-2 6-3 6-4 6-5 6-7 6-7 6-8 6-9 6-11 6-13 6-13 6-14 6-15 6-16 6-18 6-20 6-20 6-21 6-22

SECTION 7: TWO INCH SYSTEM RETRIEVAL TOOLS 1. TKS-R Retriever and Accessories 2. Service Valve and Accessories 3. TKS-THT Hot-tap Tool and Accessories 4. TKS-RP Mechanical Retriever 5. TKS6000-KHT Hot-tap Tool and Accessories

7-1 7-3 7-5 7-7 7-10

SECTION 8: ONE INCH RETRACTABLE CORROSION MONITORING AND CONTROL EQUIPMENTS 1. One Inch Retractable Access System General Overview l Retractable Corrosion Coupon Holder l Retractable Sampling and Injection Systems l Retractable ER Probe l Retractable LPT Probe l Retractor Tool and Accessories l Retractable Complete Assembly Series l KS500 Adapter l Laboratory and NPT Probe

8-1 8-2 8-4 8-7 8-11 8-14 8-15 8-17 8-18

SECTION 9: KS DOUBLE BLOCK AND BLEED VALVE 1. Model KSDBB 6000 Series Double Block and Bleed Valve 2. KSDBB Accessories for Sampling and Chemical Injection Ordering Procedure 3. KSDBB Spare Parts Ordering Procedure

9-1 9-4 9-5

APPENDIX Guide to Material Codes for Use With ER/LPR Probe


KOROSI SPECINDO

C OMPANY P ROFILE 1. General Information KOROSI SPECINDO was founded in 1994 to provide a complete range of internal corrosion monitoring equipments and services to the Oil & Gas, Petrochemical Plant and Water Treatment industries. The company manufactures intrusive types of corrosion monitoring equipments, i.e., weight loss coupon, ER/LPR probe complete with data collection instrument, sampling system for chemical analysis and other supporting equipments, viz., access fittings and retrieval tools. Our products are completely interchangeable to existing two-inch and one-inch systems. Employing qualified specialist and engineers committed to corrosion management, we are capable of providing total supply of equipments and services including: l Custom Design, Engineering and Manufacturing l Field Survey and Assessment l Installation, Commissioning and Maintenance l Corrosion Monitoring, Inspection and Control l Tools Training and Certification l Tools Repair and Rental l Laboratory Analysis

2. Quality Management System and Regulation Standard Compliance KOROSI SPECINDO adopts Total Quality Management in our business flow while concerns about Environmental Sustainability and Occupational Safety by acquiring the following stringent certifications: l ISO 9001:2008 l ISO 14001: 2004 l OHSAS 18001:2007 l EUROPEAN COUNCIL DIRECTIVE 94/9/EC

3. Main Office and Manufacturing Workshop Jalan Pangeran Jayakarta No. 76 Jakarta 10730, Indonesia Tel : 62-21 6267576, 70307792 Fax : 62-21 6289918, 6598363 Website : www.korosispecindo.com

Email

: [email protected] / [email protected]


i

ii

KOROSI SPECINDO

INTRODUCTION 1. Philosophy of Corrosion Monitoring, Inspection and Control Corrosion is known as the degradation process of a material caused by environmental conditions where the material is in operation. Since corrosion is a natural phenomenon which would lead to economic lost, environmental damage and safety threat, it is one of major considerations in asset management and maintenance program. Corrosion monitoring and inspection are invaluable tools for assisting the asset management and maintenance program because corrosion monitoring enables detection of presence of corrosive substances and quantitative estimation of corrosion rate and prediction of remaining lifetime of an asset. In contrast, corrosion inspection allows access on the actual progress of corrosion. Furthermore, in a facility where corrosion monitoring and inspection are already practiced, the corrosion monitoring and inspection provide information on effectiveness of existing corrosion control program and suggestion on improving the corrosion control program. Corrosion is an electrochemical reaction, and corrosion control employs methods which inhibit the electrochemical reaction to proceed readily, viz., applying suitable material and modifying environment conditions result in reduction of ionic transfer rate, using protective coating prevents occurrence of anodic/cathodic half cell reaction and utilizing cathodic protection effectively alter direction of electron transfer. However, environment conditions continuously fluctuate, corrosion can thence be controlled in certain periods of time but aggressive in other periods of time. Ideally, corrosion control methods have then to be adjusted instantaneously according to the change in environment conditions in order to ensure the performance of these methods. Importantly, control of corrosion in constantly changing environment conditions is feasible with real-time corrosion monitoring. Figure A below shows a section of metal loss versus time data obtained from Electrical Resistance (ER) probe with approximately real-time corrosion monitoring configuration. The sharp peaks may originated from the changes in environmental conditions.

Figure A. Metal loss versus time data viewed using Korosi Monitoring System (KMS) software.


KOROSI SPECINDO

2. Corrosion Monitoring, Inspection and Control Methods Online (non-interupted) corrosion monitoring allows access to corrosion data as often as needed in a facility while it is on service without the necessity to shut-down the facility. Even, the installation and maintenance of online corrosion monitoring require no shut-down of the facility. In accordance to the fact that corrosion takes place at the interface of corroded material and corrosive substance (electrolyte), intrusive type of online corrosion monitoring method are proven to be powerful in the oil and gas, petrochemical and water treatment fields. KOROSI SPECINDO manufactures several intrusive type online corrosion monitoring equipments as follows: 1. Corrosion coupon 2. Electrical Resistance (ER) probe 3. Linear Polarization Resistance (LPR) probe KOROSI SPECINDO also offers several options of corrosion Data Collection Instrument (DCI) along with the ER/LPR probe, namely: i. Portable data logger ii. Field mounted data logger iii. Field mounted data transmitter In order to meet the field’s restrictions, these instruments are available with various configurations and they, along with their production process, have obtained certifications from ATEX and IEC for application in potentially explosive atmosphere. Ultrasonic thickness, dye penetrant and magnetic particle testings are types of non-destructive testings that KOROSI SPECINDO can offer for the corrosion inspection service. Due to practical and economical reasons, modifying environment conditions is favorable for mitigation of corrosion by means of chemical injection, i.e., oxygen scavenger, scale inhibitor, biocide and etc. Aside from the corrosion monitoring equipments listed above, We also supply online corrosion control equipment, namely, Chemical Injection and Sampling Systems.

It is to be noted that these corrosion monitoring methods have both advantages and disadvantages, which are elucidated in the remaining of this catalog, in term of capability to explain the causes and effects of progressing corrosion. Combination of several of these corrosion monitoring methods are often required by corrosion engineer to provide sound solution. Meanwhile, for enhancing the usefulness of corrosion data, KOROSI SPECINDO has developed our intrinsically safe data transmitter for the purpose of real-time corrosion monitoring as well as other types of Data Collection Instrument (DCI). The real-time corrosion monitoring coupled with processing parameters monitoring should be powerful tools for determining the cause of and then the solution for occurring corrosion at its earliest stage.


iii

S ECTION 1 TWO INCH SYSTEM CORROSION COUPON HOLDER ASSEMBLIES

KOROSI SPECINDO

MODEL KS200 SERIES-TWO INCH SYSTEM CORROSION COUPON HOLDER ASSEMBLIES 1. Principle of Operation Corrosion coupon is a method of online corrosion monitoring employing mass-loss measurement. A coupon is a metallic specimen which composition and condition of state are approximately similar to those of the facility being monitored. After exposure to various fluids and flow conditions for certain period of time, the coupon is later retrieved for examination and evaluation in order to determine the cause and extend of corrosion. The extend of corrosion is generally represented by corrosion rate. The cumulative corrosion rate throughout the exposure period is accordingly calculated using the equation as follows, corrosion rate = mloss/(r.t.A), where mloss is mass-loss, r is density, t is total exposure period and A is the exposed area. Furthermore, corrosion coupon accesses other additional information which other methods can not provides, viz., scale formation and types of corrosion, such as, pitting, galvanic, crevice and stress-related corrosion. In laboratory tests, corrosion coupons made of different materials are also commonly used for selection of appropriate material. Wide selection of corrosion coupon and holder as illustrated in Fig. 1-1 is available for comprehensive range of application and operational condition. Flush configuration is primarily used in locations where pigging is performed. Whereas, projecting configuration permits exposure of the coupon to the corrosive phase in a multi phase fluid. All design and processing of corrosion coupon and holder assembly meet NACE RP0775-2005 and NACE MR0175/ISO 15156 standards.

KS6000-two inch system access fitting assembly

Strip coupon holder with 3" coupon

Strip coupon holder with 6" coupon

Flush disc coupon holder

Multiple disc coupon holder

Ladder strip coupon holder

Fig. 1-1. Selection of corrosion coupons and holder assemblies.


1-1

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KOROSI SPECINDO

2. Type of Corrosion Coupon and Holder (a)

(b)

( c)

(d)

( i)

(e)

(f)

(j)

(g)

(h)

(k)

Fig. 1-2. Various types of corrosion coupon, i.e., (b)/(d) 6"/3" scale coupon, (c)/(e) 6"/3" strip coupon, (f )/(g) retractable scale/strip coupon, (h) ladder strip coupon, (i) rod coupon, (j) flush disc coupon and (k) multiple disc coupon, preserved in Vapor Corrosion Inhibitor (VCI) envelop as shown in (a).

Corrosion coupon is available in many different shapes and materials for diverse objectives. Strip coupon is mounted in pair and immersed in the phase of interest within a multi phase fluid. The strip coupon comes in 3" or 6" in height to ensure adequate observation area for good analysis. Scale coupon has a strip shape and different size holes so that scaling tendency can be monitored. Flush disc coupon is positioned flush to the surrounding surface and, hence, closely represents the actual surface condition. Multiple disc coupon allows comparison of corrosiveness of different phases simultaneously. Ladder strip coupon functions similarly to the multiple disc coupon but it is installed in pairs, as demonstrated in Fig. 1-1. Rod coupon serves the same purpose with the strip coupon however the more number of coupon installed enhances result accuracy. Model KS200 series-corrosion coupon holders are used in conjunction with Model KS6000-two inch access fittings for high pressure application. For safety reason, we offer non-weld type design and AISI 316 SS as standard material. All coupon holders are furnished with insulator to avoid contact between the coupon and the holder. Model KS200-strip coupon holder is for holding a pair of 3" or 6" strip or scale coupon. Length is available from minimum 2.50" and beyond. Model KS201-adjustable disc coupon holder is intended for usage with only 5.25" height flarweld and buttweld type access fittings. The adjustable disc coupon accommodates many pipe wall thickness for flush mounting. Fig. 1-3. KS200-strip coupon holder.


KOROSI SPECINDO Model KS202-fixed disc coupon holder is opted for flush mounting where a longer coupon holder than the adjustable disc coupon holder is required, namely, above 3.50". Model KS203-multiple disc coupon holder is appropriate for pipe with outer diameter of 6" and greater. Multiple disc coupon holder enables coupons to be placed at specific levels in a multi phase fluid.

Fig. 1-4. KS201-adjustable disc coupon holder

Model KS204-ladder strip coupon holder is suitable for pipe outer diameter of 8" and above. The ladder strip coupon allows pairs of coupon to be positioned at several heights simultaneously. Model KS205-rod coupon holder permits application of more number of coupon than a strip coupon holder does.

3. Length Calculation Procedure of Corrosion Coupon Holder NON FLANGE

Length calculations of all corrosion coupon holders in inch unit are demonstrated in the followings:

FLANGE

LA

l FG

MF

LA

WG

WG TOP OF LINE

PW

MIDDLE OF LINE

POD

BOTTOM OF LINE

Remark LA : height of access fitting WG : weld gap=0.0625" (ANSI B31.1.1973) PW : pipe wall thickness FG : flange face-to-face gap

Model KS200-strip coupon holder

NON-FLANGE ACCESS FITTING Top of line monitoring (LA+PW+WG)-2.50" Middle of line monitoring (LA+0.5POD+WG)-(2.50"+0.5LC) Bottom of line monitoring (LA+POD+WG)-(3.00"+PW+LC) FLANGE ACCESS FITTING Top of line monitoring (LA+FG+MF+WG+PW)-2.50" Middle of line monitoring (LA+FG+MF+WG+0.5POD)-(2.50"+0.5LC) Bottom of line monitoring (LA+FG+MF+WG+POD)-(3.00"+PW+LC) MF POD LC

: mating flange height : pipe outer diameter : effective height of coupon (LC=1.625" or 4.75" for 3" or 6" strip coupon)


1-3

1-4

KOROSI SPECINDO l

Model KS201-adjustable disc coupon holder

The adjustable disc coupon holder is used with only 5.25" height flarweld and buttweld type access fittings and fixed order length of 2.75". l

Model KS202-fixed disc coupon holder

NON-FLANGE ACCESS FITTING Top of line monitoring (LA+PW+WG)-2.82" Middle of line monitoring (LA+0.5POD+WG)-2.625" Bottom of line monitoring (LA+POD+WG)-(3.32"+PW) NON FLANGE

FLANGE ACCESS FITTING Top of line monitoring (LA+FG+MF+WG+PW)-2.82" Middle of line monitoring (LA+FG+MF+WG+0.5POD)-2.625" Bottom of line monitoring (LA+FG+MF+WG+POD)-(3.32"+PW)

FLANGE

LA

FG

MF

LA

l

WG

TOP OF LINE

PW

MIDDLE OF LINE

POD

BOTTOM OF LINE

l

Remark LA : height of access fitting WG : weld gap=0.0625" (ANSI B31.1 2010) PW : pipe wall thickness FG : flange face-to-face gap MF : mating flange height POD : pipe outer diameter

Model KS203-multiple disc coupon holder (Note: pipe outer diameter must be 6" and beyond)

NON-FLANGE ACCESS FITTING (LA+POD+WG)-(3.00"+PW) FLANGE ACCESS FITTING (LA+FG+MF+WG+POD)-(3.00"+PW)

Model-KS204-ladder strip coupon holder (note: pipe outer diameter is at least 8" and above)

Length of ladder strip coupon holder is calculated in the same manner as that of multiple disc coupon holder above for non-flange and flange access fittings. l

Model-KS205-rod coupon holder

The length calculation of rod coupon holder is similar to that of strip coupon holder for non-flange and flange access fittings while using LC=2.5".


KOROSI SPECINDO

4. Ordering Procedures of Corrosion Coupon and Holder Ordering procedure of corrosion coupon CODE 3SC 3SS 3SL 6SC 6SL LSC FDC MDC 3RC RSC RSL

DIMENSION

SURFACE AREA (sq.in)

2-7/8"x7/8"x1/8" 3"x3/4"x1/8" 2-7/8"x7/8"x1/8" 6"x7/8"x1/8" 6"x7/8"x1/8" 2"x7/8"x1/8" Dia: 1.25", Height: 0.125" Dia: 1.25", Height: 0.125" Dia: 0.25", Height: 3" 3"x1/2"x1/16" 3"x1/2"x1/16"

5.2 4.7 5.2 11.4 11.4 3.4 2.2 2.2 2.4 3.6 3.6

COUPON TYPE 3" Strip Coupon 3" Special Strip Coupon 3" Scale Coupon 6" Strip Coupon 6" Scale Coupon Ladder Strip Coupon Flush Disc Coupon Multiple Disc Coupon 3" Rod Coupon Retractable Strip Coupon Retractable Scale Coupon

CODE CS02 CS10 CS33 SA03 S A 04

MATERIALS SELECTION

AISI 1018 Carbon Steel ASTM A105 Carbon Steel ASTM A106 Grade B Carbon Steel AISI 316 Stainless Steel AISI 316L Stainless Steel For other materials option consult KS

CODE

STAMP

0 S

No stamp Serial number stamp

CODE

CS02

S

INSULATOR No insulator Standard nylon insulator Teflon insulator

0 1 2

3SC

Coupon comes complete with: F Pre-weighed F Vapor Corrosion Inhibitor (VCI) envelope F Water proof bag F Silica Gel

1

Example: 3SC-CS02-S-1

3" strip coupon of AISI 1018 CS complete with pre-weighed, serial number stamp, standard nylon insulator & VCI envelope.

Ordering procedure of corrosion coupon holder CODE

COUPON TYPE

KS200

3" or 6" strip or scale coupon

KS201

Adjustable disc coupon

KS202

Fixed disc coupon

KS203

Multiple disc coupon

KS204

Ladder strip coupon

KS 205

Rod coupon

Corrosion coupon holder comes complete with: F Mounting kit for strip/scale coupon (part no: 6002MK-500316) F Mounting kit for disc coupon (part no: 16224C) F Insulator for disc coupon (part no: 16223C)

LENGTH Lenght in inch, see previous calculation method

KS200

12.00

Example: KS200-12.00

Strip coupon holder with length of 12" complete with mounting kit


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1-6

KOROSI SPECINDO CORROSION RATE CALCULATIONS: Weight Loss Coupons To calculate average corrosion rate as uniform rate of thickness loss per unit time mils per year (mpy), use the following equations : CR =

W x 365 x 1.000 3 ATD x (2,54)

=

22274 x W ATD

Where : ''CR'' ''W'' ''A'' ''T'' ''D''

is Average Corrosion Rate, mils per year (mpy) is the weight loss due to corrosion and is determined by subtracting the weight after cleaning from the initial weigh, grams (g) is the surface area of the coupon that is exposed to the corroding process, 2 square inches (in ) is the period in days between installation and removal of the coupon, days (d) 3 is the density of the coupon or coupon alloy from the table in the next page (g/cm )

The above equations is used for calculation of corrosion rate in mpy (mils per year) when the area of the coupon is in inches and the time of exposure is in days. For other units of measure example in millimeter per year (mmpy), use the following equation:

CR =

W x 365 x 1000 ATD

=

365 x 103 W ATD

Where : ''CR'' ''W'' ''A'' ''T'' ''D''

is Average Corrosion Rate, mils per year (mmpy) is the weight loss due to corrosion and is determined by subtracting the weight after cleaning from the initial weigh, grams (g) is the surface area of the coupon that is exposed to the corroding process, 2 square millimeter (mm ) is the period in days between installation and removal of the coupon, days (d) 3 is the density of the coupon or coupon alloy from the chart next page (g/cm )

To calculate of the maximum Pitting Rate (PR), use the following equation PR (mmpy) =

Depth of pit (mm) x 365 Exposure time (Days)

EXAMPLE A mild steel coupon weighing 10.9265 grams and having an exposed area of 2.96 square inches was th th installed in a process on August 27 and on November 13 , After 78 days in the process, it was removed, cleaned and weight found to be 10.5560 grams. From the chart on the next page the 3 density was found to be 7.86 g/cm . The corrosion rate calculation for this period is: 2.227 x 104 x (10.9262 - 10.5560) 2.96 x 78 x 7.86


= CR (mpy)

KOROSI SPECINDO

MATERIAL OPTION FOR CORROSION COUPONS ALUMINUM ALLOYS MATERIAL AL 1100 AL 2024

STAINLESS STEELS Part Number AL 04 AL 05

DENSITY (gr/cm3)

Part Number

Part Number

DENSITY (gr/cm3)

2.71

304 SS

SA01

7.94

2.77

304 L SS

SA02

7.94

316 SS

SA03

7.85

316 L SS

SA04

7.98

Duplex 2205 (UNS S31803)

SA05

7.80

Nitronic 60

SA15

7.62

COPPER ALLOYS & BRASS MATERIAL

MATERIAL

NICKEL ALLOYS DENSITY (gr/cm3)

MATERIAL

Part Number

DENSITY (gr/cm3)

Copper

C002

8.91

Nickel 200

SA13

8.89

CDA 443 Admiralty Brass

B001

8.52

Monel 400

SA23

8.84

CDA 445 Phos. Admiralty

B002

8.52

Monel K-500

SA36

8.47

7.69

Inconel 600

SA16

8.51

SA37

7.94

SA38

8.14

CDA 642 AI Bronze

B003

CDA 687 AI Brass

B004

8.33

Inconel 800

Cu-Ni (90/10)

CN04

8.94

Inconel 825

Cu-Ni (70/30)

CN02

8.94

CARBON & ALLOYS STEEL MATERIAL

Part Number

OTHERS DENSITY (gr/cm3)

MATERIAL

Part Number

DENSITY (gr/cm3)

AlSI 1010

CS01

7.86

Carpenter 20-Cb3

SA12

8.08

AISI 1018

CS02

7.86

Lead

L001

11.34

AISI 1020

CS03

7.86

Zinc

Z001

7.13

AISI 1022

CS36

7.86

A 106 Gr B

CS33

7.85

A 105

CS10

8.00

A 350 LF2

CS05

8.00

API 5 L Gr B

CS18

7.78

Cast Iron, Gray

I001

7.19

Other material options, see guide to material codes on Appendix or consult Marketing KS.


1-7

S ECTION 2 TWO INCH SYSTEM ELECTRICAL RESISTANCE (ER) PROBE AND DUAL ER/TEMPERATURE PROBE

KOROSI SPECINDO

TWO INCH SYSTEM ELECTRICAL RESISTANCE (ER) PROBE AND DUAL ER/TEMPERATURE PROBE 1. Principle of Operation Electrical Resistance (ER) probe is analogues to corrosion coupon that these corrosion monitoring methods require sacrificial elements to be corroded prior to determination of corrosion rate. However, unlike the corrosion coupon which must be retrieved periodically, the ER probe needs no retrieval through out the life time of the element. Using a Data Collection Instrument (DCI), which will be presented in Section 4, electrical resistance of the element with fixed length and cross-sectional area is monitored at specific time. Since the electrical resistance of a material is explained by the following equation, R=r.l/A, where r, l and A are resistivity, length and cross-sectional area of the material, respectively, the change in instantaneous cross-sectional area of the element is easily obtained. Metal loss during exposure period can then be calculated from reduction of the cross-sectional area and, hence, the corrosion rate can be derived from graph of the metal loss and exposure period. Furthermore, the corrosion rate commonly represents the result of general corrosion since the ER probe is generally not sensitive enough to detect localized increase of the electrical resistance due to pitting corrosion. It is obvious that the ER probe is not suitable for application in a medium which is conductive and susceptible to scale formation. Therefore, the application of the ER probe is limited to a low conductive medium or intermittent conductive medium and, notably, the usage of the ER probe is preferably accompanied with the usage of other corrosion monitoring method. Temperature is one of important processing parameters. As the resistivity of a material depends on temperature, its variation thence contributes to alteration of electrical resistance reading of the ER probe. However, the effect of temperature on the resistivity of the probe’s element can be compensated by having a reference element of identical material to the probe’s element protected from corrosion. The change of the cross-sectional area of the probe’s element due to corrosion then can be calculated from the ratio of the probe’s element resistance and the reference element resistance. Moreover, temperature also strongly influence corrosion process, hence, it is often advantageous to have temperature data available along with corrosion data. In addition to the ER probe, KOROSI SPECINDO therefore also offers dual ER/temperature probe for simultaneous measurements of corrosion rate and temperature. The temperature measurement is based on Resistance Temperature Detector (RTD) which working principle is briefly mentioned above.


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KOROSI SPECINDO

2. Probe Type, Length Calculation and Ordering Procedure KOROSI SPECINDO manufactures various types of ER probe based on shape of the sacrificial element, i.e, tubular, wire/tube loop and flush, designed for different purposes and wide range operating conditions. Installation of the two inch system ER probe is done in combination with the KS6000-two inch access fittings. Material design of the ER probe follows NACE MR0175/ISO15156, and the standard materials of the probe body are mild steel or AISI 316 stainless steel. The sacrificial element of designated material is connected to the ER probe body by sealant. Epoxy, glass and weld sealants are commonly used for exposure to various temperatures, pressures and chemicals. As protective measure in case that the sealant fails, filler made of alumina is employed. The present schematic drawing shows several installation configurations of ER probe, viz., flush/top, middle and bottom, with non-flange and flange access fittings.

Remark LA : height of access fitting WG : weld gap=0.0625" (ANSI B31.1 2010) PW : pipe wall thickness FG : flange face-to-face gap MF : mating flange height POD : pipe outer diameter LE : height of sacrificial element (LE=2" for short tubular element, LE=4" for long tubular element, LE=1.5 for wire/tube loop element, LE=0.95" for stripband element) Sensitivity and life time are determining factors for selection of ER probe. Sensitivity is a measure of the probe readiness to detect corrosion. Sensitivity increases with decrease of the probe’s element thickness. In contrary, the probe’s life time is shortened with the decrease of the probe’s element thickness. Table 2-1 on the next page provides information on sensitivity and life time for several ER probes. The remaining of this section will explain the various types of ER probe in more detail along with length calculation and ordering procedures. Furthermore, existence of sand causes erosion problem. Similar to corrosion rate, erosion rate can be monitored using the electrical resistance method. Sand-erosion probe is purposely developed for monitoring erosion rate, and it will also be explained later in this section. KS - CTG - MKT -03 REV .5


24

12

3

3

12

6

6

6

6

HIGH

3

Note: 24 = 2 year ; 12 = 1 year ; 6 = 6 month ; 3 = 3 month life time at stated corrosion rate

Wl80 WIRE LOOP

24

12

24

Tw20 TUBULAR

Wl40 WIRE LOOP

12

6

6

3

24

6

3

FL20 FLUSH

12

24

Tw10 TUBULAR

12

6

12

24

12

MEDIUM

CORROSION RATE IN MIL PER YEAR (MPY)

24

24

LOW

Fl10 FLUSH

WT8 TUBE LOOP

WT4 TUBE LOOP

CODE/DESCRIPTION

PROBE ELEMENT

(0.500)

0.020 0.080 (2.00)

(0.250)

0.010 (1.00)

0.040

(0.250)

0.010

0.020 (0.500)

(0.250)

0.010

0.020 (0.500)

(0125)

0.005

0.010 (0.250)

(0.125)

0.005 0.010 (0.250)

(0.100)

(0.200)

0.004

0.008

0.002

0.004 (0.050)

( M M )

(MM)

(0.100)

I N C H

INCH

USEFUL L I F E

NESS

THICK

TABLE 2-1. ELECTRICAL RESISTANCE PROBE SELECTION GUIDELINE

20

10

10

10

5

5

4

2

100 MPY RATE

OF LIFE AT

IN HOURS TO 1%

RESPOND SPEED

KOROSI SPECINDO

2-3

2-4

KOROSI SPECINDO

MODEL T6200 AND T6200T TUBULAR ER PROBE AND TUBULAR DUAL ER/TEMPERATURE PROBE

3.62

1.18

0.94

Fig. 2-1. Model T6200/T6200T probe and velocity shield.

Specifications Ø Mounting Ø Ø Ø Ø Ø

Ø

: Model KS6000- Two Inch Access Fittings Temperature Rating : 2600C (standard, glass or weld sealant) 0 520 C (high temperature, weld sealant) Pressure Rating : 3600 psi Element’s Sealant : Glass Weld Filler Material : Alumina Probe Body Material : Mild steel, AISI 316 SS 0 0 0 Temperature Reading : -40 C to 260 C (1 C reading step)

Model T6200-ER probe and T6200T-dual ER/temperature probe are manufactured for strength and reliability in extreme operating conditions. All probe body is machined from a single piece of mild steel or AISI 316 SS. The sacrificial element of either different or similar material is joined to the probe body by glass sealant or weld, respectively. Alternative probe body and sacrificial element materials are available for ordering. The sacrificial element is offered in two lengths, short and long. The long tubular element is used when more sensitivity to corrosion is needed. Velocity shield is equipped to provide protection on the element against collision damage. All probe is factory tested for compatibility with wide range of instrumentation. Probe extension adapter is required to make cable connection to the probe, and it is ordered additionally.


KOROSI SPECINDO

LENGTH CALCULATION PROCEDURE NON-FLANGE ACCESS FITTING Top of line monitoring WG+PW+LE+1.25" Middle of line monitoring WG+PW+0.5PID+1.25" Bottom of line monitoring WG+PW+(PID-0.5")+1.25"

FLANGE ACCESS FITTING Top of line monitoring (LA+FG+MF+WG+PW+LE)-4.1" Middle of line monitoring (LA+FG+MF+WG+PW+0.5PID)-4.1" Bottom of line monitoring (LA+FG+MF+WG+PW+(PID-0.5"))-4.1"

Note: 1. Refer to the schematic drawing on page 2-2 for explanation of abbreviations used in length calculation. 2. For non-flange access fittings over 5.25", add the height increment to the length calculation.

ORDERING PROCEDURE MODEL

DESCRIPTION

T6200 Tubular ER probe T6200HT High temperature tubular ER probe T6200T Tubular dual ER/temperature probe CODE XXX

LENGTH ELEMENT Insert 3 digit length in inch ELEMENT CONFIGURATION CODE TW Long tubular element with wleld seal TV

TL

Short tubular element with weld seal Short tubular element with glass seal

TS

Short tubular element with glass seal ELEMENT DIMENSIONS CODE 0.010'' element thickness 10 20 40 80

0.020'' element thickness 0.040'' element thickness 0.080'' element thickness ELEMENT MATERIAL CODE CS01 Carbon steel 1010 For Other Materials Consult Material Code Data Sheet in The Appendix CODE 10 20

CONNECTOR TYPE Small Connector Standard Connector ACCESSORY VS Velocity shield option No device fitted OO

T6200

5.75

TV

20

CS01

20

VS

EXAMPLE OF CLIENT ORDERING PROCEDURE

Note: Two inch system ER probe requires probe extension adapter to connect to instruments. See Section 4 for ordering procedure of the extension adapter. KS - CTG - MKT -03 REV .5

2-5

2-6

KOROSI SPECINDO

MODEL W6211 AND W6211T LOOP ER PROBE AND LOOP DUAL ER/TEMPERATURE PROBE

3.62

1.18

0.94

Fig. 2-2. Model W6211/W6211T probe and velocity shield.


Ø

: Model KS6000- Two Inch Access Fittings Temperature Rating : 2600C Pressure Rating : 3600 psi Element’s Sealant : Glass Filler Material : Alumina Probe Body Material : AISI 316 SS 0 0 0 Temperature Reading : -40 C to 260 C (1 C reading step)

Model W6211 and W6211T probes are reliable to give accurate result. These probes are available with either wire loop or tube loop element. Tube loop element is exceptionally responsive to detect corrosion rate. Standard sealant is glass for isolation to prevent premature failure due to galvanic corrosion. All probe body is machined from a single piece of AISI 316 SS. Alternative probe body and sacrificial element materials are available for ordering. Velocity shield is equipped to provide protection on the element against collision damage. All probes are factory tested for compatibility with wide range of instrumentation. Probe extension adapter is required to make cable connection to the probe, and it is ordered additionally.


KOROSI SPECINDO




ORDERING PROCEDURE MODEL DESCRIPTION W6211 Loop ER probe W6211T Loop dual ER/temperature probe CODE XXX

LENGTH ELEMENT Insert 3 digit length in inch ELEMENT CONFIGURATION CODE WL Wire loop WT

Tube loop ELEMENT DIMENSIONS CODE 0.004'' element thickness 04 08 40 80

0.008'' element thickness 0.040'' element thickness 0.080'' element thickness ELEMENT MATERIAL CODE CS01 Carbon steel 1010 For Other Materials Consult Material Code Data Sheet in The Appendix CODE 10 20

CONNECTOR TYPE Small Connector Standard Connector ACCESSORY Velocity shield option No device fitted OO VS

W6211

5.75

WL

40

CS01

20

VS


Note: Two inch system ER probe requires probe extension adapter to connect to instruments. See Section 4 for ordering procedure of the extension adapter.


2-7

2-8

KOROSI SPECINDO

MODEL F6212 AND F6212T FLUSH ER PROBE AND FLUSH DUAL ER/TEMPERATURE PROBE

3.62

3.62

1.18

1.18

1.25

1.25

Fig. 2-3. Model F6211/F6211T probe.


Ø

: Model KS6000- Two Inch Access Fittings Temperature Rating : 1500C (FL & AF Element Configuration Code) 2600C (FG & AG Element Configuration Code) Pressure Rating : 3600 psi Element’s Sealant : Epoxy (FL & AF Element Configuration Code) Glass (FG & AG Element Configuration Code) Filler Material : Alumina Probe Body Material : AISI 316 SS 0 0 0 Thermocouple Reading : -40 C to 260 C (1 C reading step)

Model F6212 and F6212T probes enable corrosion monitoring close to actual the surface of pipeline/vessel conditions and do not interrupt pigging operation. These probes are available in two options, adjustable and fixed configurations. The probe with adjustable configuration has two standard probe’s lengths, 1.25" and 2.00", for usage in conjunction with 5.25" height access fittings and to cover all possible pipe sizes and schedules. While the probe with fixed configuration is intended for longer probe’s length requirement than that with adjustable configuration. Alternative probe body and sacrificial element materials are available for ordering. All probes are factory tested for compatibility with wide range of instrumentation. Probe extension adapter is required to make cable connection to the probe, and it is ordered additionally.


KOROSI SPECINDO

LENGTH CALCULATION PROCEDURE Ø Adjustable Flush Probe (Note: to be used with 5.25" height access fittings) Order Length 1.25” (Short) AF All Schedules Schedule 5s to 160 Schedule 5s to 120 Schedule 5s to 100 Schedule 5s to 80 Schedule 5s to 80 Schedule 5s to XS Schedule 5s to XS Schedule 5s to 40 + Sched. XS

Nominal Pipe Size 3'' & 4'' 6'' 8'' 10'' 12'' 14'' 16'' 18'' 20''

2” (Long) AF N/A Schedule XXS Schedule 140 up Schedule 120 up Schedule 100 up Schedule 100 up Schedule 80 up Schedule 80 up Schedule 60 & 80 up

Ø Fixed Flush Probe (Note: to be used with access fittings with height above 5.25")

FLANGE ACCESS FITTING (LA+FG+MF+WG+PW)-4.1"

NON-FLANGE ACCESS FITTING WG+PW+1.25"


ORDERING PROCEDURE MODEL DESCRIPTION F6212 Flush ER probe F6212T Flush dual ER/thermocouple probe CODE XXX

LENGTH ELEMENT Insert 3 digit length in inch ELEMENT CONFIGURATION CODE FL Flush element with epoxy sealant and fixed configuration FG AF AG

Flush element with glass sealant and fixed configuration Flush element with epoxy sealant and adjustable configuration Flush element with glass sealant and adjustable configuration ELEMENT DIMENSIONS CODE 0.010'' element thickness 10 20 40

0.020'' element thickness 0.040'' element thickness ELEMENT MATERIAL CODE CS01 Carbon steel 1010 For Other Materials Consult Material Code Data Sheet in The Appendix CODE 10 20

F6212

3.00

FL

10

CS01

CONNECTOR TYPE Small Connector Standard Connector

20



2-9

2-10

KOROSI SPECINDO

MODEL B6215 AND B6215T STRIP-BAND ER PROBE AND STRIP-BAND DUAL ER/TEMPERATURE PROBE

3.62

1.18

1.25

Fig. 2-4. Model B6215/B6215T probe.


Ø

: Model KS6000- Two Inch Access Fittings 0 Temperature Rating : 150 C Pressure Rating : 3600 psi Element’s Sealant : Epoxy Filler Material : Alumina Probe Body Material : AISI 316 SS 0 0 0 Temperature Reading : -40 C to 260 C (1 C reading step)

Model B6215 and B6215T probes are suitable for corrosion monitoring in severe environments where pitting corrosion and scaling are expected. The probe has a narrow strip sacrificial element forming a circumferential band on a short cylindrical epoxy body. Alternative probe body and sacrificial element materials are available for ordering. All probes are factory tested for compatibility with wide range of instrumentation. Probe extension adapter is required to make cable connection to the probe, and it is ordered additionally.


KOROSI SPECINDO




ORDERING PROCEDURE MODEL DESCRIPTION B6215 Strip-band ER probe B6215T Strip-band dual ER/temperature probe CODE XXX

LENGTH ELEMENT Insert 3 digit length in inch ELEMENT CONFIGURATION CODE BE Circumferential strip-band element on cylindrical epoxy body ELEMENT DIMENSIONS CODE 0.004'' element thickness 04 06 10 20 40

0.006'' 0.010'' 0.020'' 0.040''

element thickness element thickness element thickness element thickness

ELEMENT MATERIAL CODE CS01 Carbon steel 1010 For Other Materials Consult Material Code Data Sheet in The Appendix CODE 10 20

B6215

3.95

BE

40

CS01


20


Note: Two inch system ER probe requires probe extension adapter to connect to instruments. See Section 4 for ordering procedure of the extension adapter.


2-11

2-12

KOROSI SPECINDO

MODEL S6400 AND S6400T SAND-EROSION PROBE AND DUAL SANDEROSION/TEMPERATURE PROBE

3.62

1.18

1.25

Fig. 2-5. Model S6200/S6200T probe.


Ø

: Model KS6000- Two Inch Access Fittings 0 Temperature Rating : 150 C Pressure Rating : 3600 psi Element’s Sealant : Epoxy Filler Material : Alumina Probe Body Material : AISI 316 SS 0 0 0 Temperature Reading : -40 C to 260 C (1 C reading step)

Model S6400 and S6400T probes monitor erosion rate due to sand existence in fluid flow. Erosion problem in oil and gas transmission usually occurs at locations where pipeline changes in direction and size. The sacrificial element of sand erosion probe is hence oriented to make some angle against the flow direction in order to simulate such pipeline locations. Corrosion resistant alloy is used as the sacrificial element, i.e, stainless steel, in order to ensure effect of erosion is distinguishable from effect of corrosion. Alternative probe body and sacrificial element materials are available for ordering. All probes are factory tested for compatibility with wide range of instrumentation. Probe extension adapter is required to make cable connection to the probe, and it is ordered additionally.


KOROSI SPECINDO

LENGTH CALCULATION PROCEDURE NON-FLANGE ACCESS FITTING Middle of line monitoring WG+PW+0.5PID+1.25"

FLANGE ACCESS FITTING Middle of line monitoring (LA+FG+MF+WG+PW+0.5PID)-4.1"

Note: 1. Refer to the schematic drawing on page 2-2 for explanation of abbreviations used in length calculation. 2. For non-flange access fittings over 5.25", add the height increment to the length calculation. 3. Sand erosion probe is proven effective to provide practical erosion monitoring at middle of line monitoring.

ORDERING PROCEDURE MODEL

DESCRIPTION

S6400

Sand Erosion Probe

S6400T

Dual sand erosion/temperature probe CODE LENGTH ELEMENT XXX Insert 3 digit length in inch ELEMENT CONFIGURATION CODE Gold thin film for sand erosion detection DG ELEMENT DIMENSION CODE SA03 AISI 316 SS CODE

S6400

XXX

DG

SA03

CONNECTOR TYPE

10

Small Connector

20

Standard Connector

20

EXAMPLE : CLIENT ORDERING PROCEDURE

Note: Two inch system sand-erosion probe requires probe extension adapter to connect to instruments. See Section 4 for ordering procedure of the extension adapter.


2-13

S ECTION 3 TWO INCH SYSTEM LINEAR POLARIZATION RESISTANCE (LPR) PROBE AND DUAL LPR/TEMPERATURE PROBE

KOROSI SPECINDO

TWO INCH SYSTEM LINEAR POLARIZATION RESISTANCE (LPR) PROBE AND DUAL LPR/TEMPERATURE PROBE 1. Principle of Operation Linear Polarization Resistance (LPR) probe measures corrosion rate in a different way from corrosion coupon and ER probe. Corrosion coupon and ER probe concern on change in physical property of the sacrificial element during corrosion process, namely, mass-loss and electrical resistance, respectively. Meanwhile, LPR probe focuses on change in electrochemical property of a material, particularly, corrosion current. It is a result of electron transfer from anodic half-cell to cathodic half-cell and directly proportional to corrosion rate. However, a satisfactory method to measure the corrosion current is still not available since locations of anodic and cathodic half-cells constantly change. One method to obtain an approximate value of corrosion current is by applying small potential difference on a material undergoing corrosion process and monitoring the resulting current. The material under such condition is termed in polarized state and, subsequently, the resistance calculated from the applied potential and measured current is named polarization resistance. The polarization resistance is inversely proportional to the corrosion current and, importantly, corrosion rate. LPR probe was developed for practical measurement of approximate polarization resistant, corrosion current and corrosion rate, successively. LPR probe employs two or three electrodes immersed in the solution of interest to convey current electrochemically through the solution from one electrode to another when small potential difference, 10-30 mV, is applied between the electrodes. The potential difference must overcome the polarization resistance of the first electrode, electrical resistance of the solution and the polarization resistance of the second electrode. In the case of LPR probe with two electrodes, electrical resistance of the solution is a major concern. When the solution resistance is low, the calculated resistance (applied potential difference/measured current) is comparable to the polarization resistance. In contrary, when the solution resistance is high, the calculated resistance is substantially larger than the polarization resistance and, consequently, the corrosion current and corrosion rate are underestimated. Hence, the two-electrode LPR probe is limited for usage in the solutions with high conductivity. In the case of LPR probe with three electrodes, the solution resistance is rendered less-influential due to the addition of the third electrode. When the potential difference is applied on the three-electrode LPR probe, a pair of electrode is used for measurement of voltage necessary for transmitting current through the solution, then, the required voltage is applied between the other pair of electrode for current measurement. Nevertheless, the three-electrode LPR probe is recommended for application in high conductive and continuous-flow solution for accurate determination of corrosion rate. KS - CTG - MKT -03 REV .5

3-1

3-2

KOROSI SPECINDO It is also to be noted that like ER probe, LPR probe does not perform well in a solution where scaling occurs and it gives only a uniform corrosion rate. But unlike ER probe, LPR probe responses rapidly to provide corrosion rate directly so that correlation to changes in the process can be made and, hence, it can point out when and why corrosion takes place. In addition to LPR probe, KOROSI SPECINDO also supplies dual LPR/temperature probe for comparison of corrosion rate and temperature.

2. Probe Type, Length Calculation and Ordering Procedure KOROSI SPECINDO offers two types of LPR probe, i.e, projecting and flush. The two inch system LPR probe is for usage in combination with the KS6000-two inch access fittings. Material design of the LPR probe complies to NACE MR0175/ISO15156, and the standard materials of the probe body is AISI 316 stainless steel. The electrodes of selected material are connected to the LPR probe body by glass, PEEK or epoxy sealant. Filler made of alumina is also employed to provide additional protection. The present schematic drawing shows several installation configurations of LPR probe, viz., flush/top, middle and bottom, along with non-flange and flange access fittings. Remark LA : height of access fitting WG : weld gap=0.0625" (ANSI B31.1 2010) PW : pipe wall thickness FG : flange face-to-face gap MF : mating flange height POD : pipe outer diameter LE : height of electrode (LE=1.6" for projecting electrode) The remaining of this section will explain the two types of LPR probe in more detail along with length calculation and ordering procedures.


KOROSI SPECINDO

MODEL P6100 AND P6100T PROJECTING LPR PROBE AND PROJECTING DUAL LPR/TEMPERATURE PROBE

3.62

1.18

1.25


Ø

: Model KS6000- Two Inch Access Fittings Temperature Rating : 2600C Pressure Rating : 3600 psi Element’s Sealant : Glass PEEK Filler Material : Alumina Probe Body Material : AISI 316 SS 0 0 0 Temperature Reading : -40 C to 260 C (1 C reading step)

Model P6100 and P6100T are designed to give fast and accurate result in conductive medium. Option of two-electrode or three-electrode LPR probe is available. All probe body is machined from a single piece of mild steel or AISI 316 SS. The electrodes made of material of interest is joined to the probe body by threading connection with glass or PEEK sealant. Alternative probe body and electrode materials are available for ordering. All probe is factory tested for compatibility with wide range of instrumentation. Probe extension adapter is required to make cable connection to the probe, and it is ordered additionally.


3-3

3-4

KOROSI SPECINDO




ORDERING PROCEDURE OF LPR PROBE MODEL DESCRIPTION P6100 Projecting electrodes P6100T Projecting electrodes with temperature detector CODE ORDER LENGTH XXX Insert 3 digit length in inch ELECTRODE CONFIGURATION CODE Projecting Glass sealed stud PF PK Projecting PEEK sealed stud ELECTRODE DIMENSIONS CODE S2 2 Standard electrodes (M3 thread) 3 Standard electrodes (M3 thread) S3 2 Reduced area electrodes (40UNC thread) R2 3 Reduced area electrodes (40UNC thread) R3 ELECTRODE MATERIAL CODE CS02 Carbon steel 1018 B001 Admiralty brass For Other Materials Consult Material Code Data Sheet in The Appendix CODE CONNECTOR TYPE 10 Small connector 20 Standard connector

P6100

7.00

PF

S3

CS02

20


Note: Two inch system LPR probe requires probe extension adapter to connect to instruments. See Section 4 for ordering procedure of the extension adapter.


KOROSI SPECINDO

ORDERING PROCEDURE OF SPARE ELECTRODES MODEL DESCRIPTION GMA General Mechanical Accessory CODE ELECTRODE Electrode set for LPR probe L ELECTRODE DIMENSIONS CODE S2 2 Standard Electrodes (M3 thread) S3 3 Standard Electrodes (M3 thread)) 2 Reduced area electrodes (40UNC thread) R2 3 Reduced area electrodes (40UNC thread) R3 ELECTRODE MATERIAL CODE CS02 Carbon steel 1018 B001 Admiralty brass For Other Materials Consult Material Code Data Sheet in The Appendix

GMA

L

S3

CS02 EXAMPLE : CLIENT ORDERING PROCEDURE


3-5

3-6

KOROSI SPECINDO

MODEL F6112 AND F6112T FLUSH LPR PROBE AND FLUSH DUAL LPR/TEMPERATURE PROBE

3.62

1.18

Ø1.25"


Ø

: Model KS6000- Two Inch Access Fittings Temperature Rating : 1500C (FL & AF Element Configuration Code) 2600C (FG & AG Element Configuration Code) Pressure Rating : 3600 psi Element’s Sealant : Epoxy (FL & AF Element Configuration Code) Glass (FG & AG Element Configuration Code) Filler Material : Alumina Probe Body Material : AISI 316 SS 0 0 0 Temperature Reading : -40 C to 260 C (1 C reading step)

Model F6112 and F6112T probes enable corrosion monitoring close to the actual surface of pipeline/vessel conditions and do not interrupt pigging operation. These probes are available in two options, adjustable and fixed configurations. The probe with adjustable configuration has two standard probe’s lengths, 1.25" and 2.00", for usage in conjunction with 5.25" height access fittings and to cover all possible pipe sizes and schedules. While the probe with fixed configuration is intended for longer probe’s length requirement than that with adjustable configuration. Alternative probe body and sacrificial element materials are available for ordering. All probes are factory tested for compatibility with wide range of instrumentation. Probe extension adapter is required to make cable connection to the probe, and it is ordered additionally. KS - CTG - MKT -03 REV .5

KOROSI SPECINDO

LENGTH CALCULATION PROCEDURE Ø Adjustable Flush Probe (Note: to be used with 5.25" height access fittings) Order Length 1.25” (Short) AF All Schedules Schedule 5s to 160 Schedule 5s to 120 Schedule 5s to 100 Schedule 5s to 80 Schedule 5s to 80 Schedule 5s to XS Schedule 5s to XS Schedule 5s to 40 + Sched. XS

Nominal Pipe Size 3'' & 4'' 6'' 8'' 10'' 12'' 14'' 16'' 18'' 20''

2” (Long) AF N/A Schedule XXS Schedule 140 up Schedule 120 up Schedule 100 up Schedule 100 up Schedule 80 up Schedule 80 up Schedule 60 & 80 up

Ø Fixed Flush Probe (Note: to be used with access fittings with height above 5.25")

FLANGE ACCESS FITTING (LA+FG+MF+WG+PW)-4.1"

NON-FLANGE ACCESS FITTING WG+PW+1.25"


ORDERING PROCEDURE MODEL DESCRIPTION F6112 Flush electrodes F6112T Flush electrodes with temperature detector CODE XXX

ORDER LENGTH Insert 3 digit length in inch ELEMENT CONFIGURATION CODE FL Flush electrodes with epoxy sealant and fixed configuration FG AF AG

Flush electrodes with glass sealant and fixed configuration Flush electrodes with epoxy sealant and adjustable configuration Flush electrodes with glass sealant and adjustable configuration ELECTRODE DIMENSIONS CODE 2 standard electrodes S2 S3

3 standard electrodes ELEMENT MATERIAL CODE CS02 Carbon steel 1018 For Other Materials Consult Material Code Data Sheet in The Appendix CODE 10 20

F6112

3.00

FL

S2

CS02


20

EXAMPLE OF CLIENT ORDERING PROCEDURE KS - CTG - MKT -03 REV .5

3-7

S ECTION 4 DATA COLLECTION INSTRUMENT (DCI) FOR ER AND LPR MEASUREMENTS

KOROSI SPECINDO

MODEL KSHHU-HANDHELD DATA LOGGER AND UP/DOWN-LOADER

Fig. 4-1. Handheld data logger and up/down-loader.

Specifications Ø Type of Measurement Ø Ø Ø Ø Ø

Ø Ø Ø Ø Ø

: ER, LPR and temperature 0 0 Temperature Reading : -40 C to 260 C Resolution : 16 bits Accuracy : 0.1% 0 0 Operating Temp. : -20 C to 60 C Power Supply : Battery pack with charger Weight / Dimension : 0.75 Kg / 106x187x50 mm Environment Safe : IP65 Intrinsic Safe : EX ia IIC T4 Data Communication : RS-232 serial ASCII Bus Memory : 5400 data readings

Featuring enhanced portable digital corrosion data collection instrument, lightweight, easy handling, rugged construction, intrinsically safe and high resolution, the KSHHU is a microprocessor based instrument which measures the signal of passive corrosion sensor input using embedded signal conditioning, then, amplifies and converts it into 16 bits analogue digital converter.


4-1

4-2

KOROSI SPECINDO The KSHHU collects measurements up to 4000 data readings directly from ER/LPR probe for uploading to PC and viewing with Korosi Specindo Corrosion Monitoring Software (KS-CMS), which will be furnished along with the KSHHU. It can also be used to program a field mounted data logger with many parameters and to download corrosion data from the field mounted data logger. The corrosion data collection, calculation and temperature correction are stored into an internal non-volatile memory, backed-up by lithium battery. Temperature data can also be obtained when using dual ER/temperature and LPR/temperature probes. It is to be noted that the battery is rechargeable, but not directly in the device.

Applications

CHARGER + COM

PROBE

PORTABLE LOGGER HANDHELD UPLOADER

KSHHU Pipe 1

2

3

ABC

DEF

4

5

6

GHI

JKL

MNO

7

8

PQRS

TUV

WXYZ

CLEAR

0

ENTER

9

Probe

Direct Measurement

Hazard Area

Non-Hazard Area

HHU to DCI

HHU to PC (RS-232)

DCI KOROSI SPECINDO Corrosion Monitoring Equipment, Chemical Injection and Sampling System www.korosospecindo.com

CHARGER + COM

CHARGER + COM

PROBE

PROBE

DCI

DATA COLLECTION INSTRUMENT



Pipe 2

3

ABC

DEF

4

5

6

GHI

JKL

MNO

1

1

PC

Download Data

2

3

ABC

DEF

4

5

6

GHI

JKL

MNO

7

8

7

8

PQRS

TUV

WXYZ

PQRS

TUV

WXYZ

CLEAR

0

ENTER

CLEAR

0

ENTER

9

Probe

Downloading data and setting parameter into DCI


Uploading Data

9

KOROSI SPECINDO

KSHHU ORDERING PROCEDURE MODEL KSHHU

Handheld Corrosion Data Logger and Up/Downloader CODE ER LPR

KSHHU

INSTRUMENTMEASUREMENT Electrical Resistance Linear Polarization Resistance

ER (Complete Set Accessories of KSHHU)

Note: Complete set accessories of KSHHU includes: 1. Communication cable and connector 2. Test probe 3. KS-CMS 4. Extension adapter

Example Client Order

5. Carrying case 6. Battery charger 7. Operating manual 8. USB to serial adapter

KSHHU ACCESSORIES ORDERING PROCEDURE MODEL KSHHUA

Handheld Corrosion Logger / Up-Downloader Accessories CODE 01

KSHHUA

ACCESSORIES Communication Cable and Connector

02

KS-Corrosion Monitoring Software (KS-CMS)

03 04

Spare battery

05

Dummy Test Probe

01

Battery Charger



4-3

4-4

KOROSI SPECINDO

MODEL DCI-FIELD MOUNTED DATA LOGGER AND TRANSMITTER

KOROSI SPECINDO Corrosion Monitoring Equipment,Chemical Injection & Sampling System www.korosispecindo.com

DCI DATA COLLECTION INSTRUMENT

(a)

(b)

Fig. 4-2. Field mounted data logger/transmitter with either weather proof (a) or explosive proof (b) enclosure.

Specifications Ø Type of Measurement Ø Ø Ø Ø Ø

Ø

Ø Ø Ø

: ER, LPR and temperature Temperature Reading : -400C to 2600C Resolution : 16 bits Accuracy : 0.1% Operating Temp. : -200C to 600C (model DCI-Dx/Tx) -400C to 850C (model DCI-Dx/Tx-d) Power Supply : Battery pack (model DCI-Dx/Dx-d) External power (model DCI-Tx/Tx-d) Weight / Dimension : 2.3 Kg / 152x152x102 mm (1 ch., model DCI-Dx/Tx) 3.2 Kg / 203x152x102 mm (4 ch., model DCI-Dx) 3.1 Kg / 110x110x188 mm (1 ch., model DCI-Dx/Tx-d) Environment Safe : IP66 (model DCI-Dx/Tx) IP68 (model DCI-Dx/Tx-d) Intrinsic Safe : EX ia IIC T4 (model DCI-Dx/Tx) EX d ia IIC T4 (model DCI-Dx/Tx-d) Data Communication : RS-232 serial ASCII Bus (model DCI-Dx/Dx-d) RS-485 serial ASCII Bus (model DCI-Tx/Tx-d) 4-20 mA current loop (model DCI-Tx/Tx-d) HART protocol (model DCI-Tx/Tx-d)


KOROSI SPECINDO Featuring enhanced resolution, intrinsically safe and the ability to obtain metal loss/corrosion rate reading on a conventional ER/LPR probe, the DCI data logger, model DCI-Dx,(with a weather-proof enclosure) or model DCI-Dx-d (with an explosive-proof enclosure) is a fixed instrument for field mounting to record corrosion activity detected by passive measuring probes with output of electrical resistance or linear polarization resistance. The DCI data logger is available with two options, single channel or four channels. Collected data is stored on board backed up by lithium battery for later retrieval by the handheld uploader, model KSHHU. Meanwhile, the DCI transmitter is a field mounted instrument capable of transmitting data to control room via options of serial protocol RS-488, analog 4-20 mA current loop or HART protocol. The DCI transmitter with 4-20 mA data communication, howerver, only transmits metal loss/corrosion rate data without time and temperature data. The DCI data logger/transmitter is certified intrinsically safe for hazardous area operation. The DCI transmitter is housed in a weather-proof enclosure, model DCI-Tx, or explosive-proof enclosure, model DCI-Tx-d. The probe cable is connected through a water-tight cable gland. Hence, the DCI data logger/transmitter is suitable for use in almost any indoor and outdoor environment. Setup of the DCI data logger/transmitter during preliminary installation for a new probe can be done using the KSHHU. Temperature measurement is feasible with dual ER/temperature and LPR/temperature probes.

Applications Hazard Area RS-232


CHARGER + COM

PROBE

DCI



Pipe 1 4 GHI

2

3

ABC

DEF

5

6

JKL

Download Data

MNO

7

8

9

PQRS

TUV

WXYZ

CLEAR

0

ENTER

Probe

Model DCI – Dx – XX – 01 Data Logger

Hazard Area

Non-Hazard Area


Control Room (PC) DCI


4-20mA Intisically Safe Isolator

Pipe

Probe

External Power

Model DCI – Tx – XX – A Transmitter (4-20 mA)


4-5

4-6

KOROSI SPECINDO

Hazard Area

Non-Hazard Area


Control Room (SCADA) DCI


4-20mA Intisically Safe Isolator

External Power

Probe

Model DCI – Tx – XX – H Transmitter (4-20 mA with HART protocol)

Hazard Area

Non-Hazard Area

KOROSI SPECINDO Corrosion Monitoring Equipment, Chemical Injection and Sampling System www.korosospecindo.com

DCI-l

Control Room (PC) DCI


RS-485 Junction Box

Intisically Safe Isolator

Probe-1 External Power KOROSI SPECINDO Corrosion Monitoring Equipment, Chemical Injection and Sampling System www.korosospecindo.com

DCI-n DCI


RS-485

Probe-n

Model DCI – Tx – XX – D4 Transmitter (RS-485)


KOROSI SPECINDO

DCI ORDERING PROCEDURE A. DATA LOGGER VERSION MODEL DCI – Dx

Data Collection Instrument – Data Logger Version CODE INSTRUMENT MEASUREMENT ER Electrical Resistance Linear Polarization Resistance LPR CODE DATA LOGGER TYPE 01 Single channel Four channel 04

DCI-Dx ER 01 (Complete Set Accessories of DCI – Data Logger Version)


Note: KSHHU is required for data logger Complete set accessories of DCI data logger includes: 1. Communication cable and connector 2. Test probe 3. KS-CMS 4. Ten feet probe cable 5. Operating manual

B. TRANSMITTER VERSION MODEL DCI – Tx

Data Collection Instrument – Transmitter Version CODE ER LPR

INSTRUMENTMEASUREMENT Electrical Resistance Linear Polarization Resistance CODE A H D4

COMMUNICATION CABLE 4-20mA current loop HART protocol RS-485 Serial ASCII Bus

ER A DCI-Tx (Complete Set Accessories of DCI – Transmitter Version)


Note: External 24 V DC is required for DCI transmitter Complete set accessories of DCI transmitter includes: 1. Test probe 2. KS-CMS 3. Ten feet probe cable 4. Operating manual


4-7

4-8

KOROSI SPECINDO

DCI ACCESSORIES ORDERING PROCEDURE MODEL DCIA

Data Collection Instrument Accessories CODE 01 02 03 04 05 06

DCIA

01


ACCESSORIES Communication cable and connector KS-Corrosion Monitoring Software (KS-CMS) Battery pack for data logger Intrinsically safe isolator unit (signal barrier and power barrier) Power supply 10-35 V DC Corrosion meter


KOROSI SPECINDO

EXTENSION ADAPTER, PROBE CABLE AND TEST PROBE EXTENSION ADAPTERS

Fig. 4-3. Extension adapters.

An extension adapter is required to make the connection between the DCI and probe in 2" access fitting. Extension adapters may be permanently installed using a ½" NPT compression fitting which mates with the carrier plug or protective cover. This configuration provides a weather proof permanent connection for on-line or data logging instrument. a short plain type is usually used with a portable instrument. Extension adapter bodies are made from 316 SS. The extension adapter with compression fitting have pressure retaining glass sealed connectors forming a secondary containment system in conjunction with a high pressure heavy duty cover. The connectors are available in standard large (C) size to fit all KOROSI SPECINDO and most other probes, or in a special small (S) size for some other makers.

PROBE CABLE Extension cable is required to connect the probe to the field mounted data logger/transmitter. The probe cable has 6 pin MIL-C-5015 connector and 6 wire cores with diameter of 18 AWG. Care should be exercised when adding cable extension as measurement quality may be degraded with increase of length.

TEST PROBE Test probe is useful for field diagnostic and testing of probe and instrument system. When attached to an instrument, it gives a stable constant response which can be used to check.


4-9

4-10

KOROSI SPECINDO

ORDERING PROCEDURE A. EXTENSION PROBE MODEL EPKS

Extension Probe CODE PL

EXTENSION PROBE TYPE Plain Body with large (C) Probe connector

PR SW SR

Plain Body with small (S) Probe connector ½” NPT threaded compression fitting & large (C) probe connector ½” NPT threaded compression fitting & small (S) probe connector CODE 92 206 XXX

EPKS

LENGTH 92 mm 206 mm Order length


092

SW

B. PROBE CABLE MODEL PCKS

Probe Cable CODE CB CS JB JS

PROBE CABLE TYPE Probe cable with standard al. connector Probe cable with st. steel connector (high temp.) Cable with protective box at instrument end, std al. connector Cable with protective box at instrument end, st. steel connector at probe end (high temp.)

CODE 003 XXX

PCKS

CABLE LENGTH 3 Meters Order length

010

CS


C. TEST PROBE MODEL TPKS

Test Probes CODE ER LPR

TPKS

ER

TEST PROBE TYPE Electrical Probe Linear Polarization Resistance


Note: Add “ HT ” at the end of ordering codes for extension probe and probe cable for high temperature application KS - CTG - MKT -03 REV .5

S ECTION 5 TWO INCH SYSTEM EROSION, SULFATE REDUCING BACTERIA (SRB), HYDROGEN MONITORING PROBE AND CHEMICAL INJECTION/SAMPLING EQUIPMENT

KOROSI SPECINDO

TWO INCH SYSTEM HIGH PRESSURE SAND-EROSION MONITORING PROBE PROTECTIVE COVER

PRESSURE GAUGE SOLID PLUG ASSY

SAND PROBE NUT ACCESS FITTING BODY

NIPPLE SHUT-OFF VALVE

PIPE LINE

SAND-EROSION SACRIFICIAL ELEMENT

Fig. 5-1. Sand-erosion monitoring system with sacrificial element.

Specifications Ø Mounting Ø Temperature Rating Ø Pressure Rating

Ø Probe Body Material

: Model KS6000- Two Inch Access Fittings 0 : 260 C : 3600 psi : AISI 316 SS / Duplex SS

Sand-erosion monitoring system is used to detect wall-thining of pipeline caused by sand-erosion. The sand-erosion monitoring system explained in Section 2 operates based on Electrical Resistance (ER) measurement. Meanwhile, the sand-erosion monitoring system in the present section simply consists of sacrificial element without the ER measurement involved. The sacrificial element is closed at one end and has thread at the other end to connect to the sand probe nut shown in Fig. 5-1. The sand probe nut enables the sacrificial element to be attached to the solid plug and used in KS6000-access fitting assembly with tee. The effect of sand eventually erodes through the sacrificial element, exposing the closed end to the operating pressure. The fluid flow is then directed through ports in the sand probe nut to the tee portion of the access fitting body. Through the nipple and shut-off valve, the fluid flow pressure is indicated by the pressure gauge. The sacrificial element is 5/8" in Outer Diameter (OD) and available in three wall thicknesses: 0.016", 0.028" and 0.035". The 0.016" thickness is standard wall thickness for 2" OD pipe, 0.028" thickness is standard wall thickness for 3" to 6" OD pipes and 0.035" thickness is standard wall thickness for 8" and larger OD pipes.


5-1

5-2

KOROSI SPECINDO The sacrificial element is constructed from AISI 316 SS or Duplex SS, and it complies to NACE MR0175/ISO15156 for practice in Sulfide Stress Cracking (SSC) induced environments. The placement of the sacrificial element is approximately inserted 60% into pipeline Inner Diameter (ID). This placement allows for maximum sand impingement at center of line where flow velocity is the greatest while still permitting heavier suspended particles, riding slightly lower in the flow stream, contact the sacrificial element.

LENGTH CALCULATION PROCEDURE NON FLANGE

FLANGE

LA

FG

LA

Remark LA : height of access fitting WG : weld gap=0.0625" (ANSI B31.1 2010) PW : pipe wall thickness FG : flange face-to-face gap MF : mating flange height POD : pipe outer diameter IN : Sacrificial element length

MF

NON-FLANGE ACCESS FITTING (LA+WG+(0.6POD))-(2"+IN)

WG

FLANGE ACCESS FITTING (LA+FG+MF+WG+(0.6POD))-(2"+IN) PW POD

ORDERING PROCEDURE A) The access fitting body assembly and tee size can be ordered following the procedure in Section 6. B) The sand probe nut length can be ordered following the table below.


KOROSI SPECINDO Part Number

Nut Length

KS300A

X.XX

Sand Probe Nut

1.75 2.75

NPT Thread Sizes X

Using for 5.25'' High Access Fitting

1

1/4'' NPT

Using for 6.25'' High Access Fitting

Material XXX SA03

AISI 316 SS

SA05

Duplex SS

For other materials option consult KS

Client Ordering: P/N KS300A-1.75-1-SA04 à 1.75" sand probe nut length, 1/4'' NPT thread size, material AISI 316 SS

C) The length of the sacrificial element is calculated using the previous formulas, and the ordering procedure is done following the next table. Part Number KS Sand Tube Probe

Thickness

Order length

Material

XXXXX

XXX

XXX

10016

0.016'' Element Thickness

10028


10035


Length in inch, see calculation method above

SA03

AISI 316 SS


Client Ordering: P/N KS10016-6.50-SA03 à 0.016" sacrificial element thickness, 6.5'' length, AISI 316 SS material.

D) The nipple and shut-off valve suitable to the tee size of the access fitting body can be selected from this table.

Access fitting tee size

Nipple 4" x sch 80

Shut-off valve

Nipple flange

Part number

Part number

Part number

¼''

4025

5025

6025

½''

4050

5050

6050

¾''

4075

5075

6075

1’'

4100

5100

6100

Client Ordering: P/N KS5025 à ¼" NPT shut-off valve P/N KS4025 à ¼" NPT nipple 4", schedule 80 P/N KS6025 à ¼" NPT nipple flange

E) Spare part: sand probe nut seal material Part number

Description

230573

Viton o-ring with teflon back-up ring

230574

Ethylene propylene o-ring with teflon back-up ring

230575

Kalrez o-ring with teflon back-up ring

230576

Hydrin o-ring with teflon back-up ring

230577

Nitrile o-ring with teflon back-up ring

230578

Viton B FR58 (explosion decompression resistance) with teflon back-up ring


5-3

5-4

KOROSI SPECINDO

TWO INCH SYSTEM SULPHATE REDUCING BACTERIA (SRB) MONITORING PROBE

Fig. 5-2. SRB probe.

Specifications Ø Mounting Ø Temperature Rating Ø Pressure Rating

Ø Probe Body Material

: Model KS6000- Two Inch Access Fittings 0 : 260 C : 3600 psi : AISI 316 SS

Monitoring Sulphate Reducing Bacteria (SRB) is recognized as an important task of understanding and controlling corrosion. Producing good quality biofilm samples from any closed system is an essential first step to successful SRB monitoring. SRB probe consists of Delrin/glass-filled PTFE holder housing six removable studs. The SRB probe is mounted on the standard solid plug in the access fitting assembly. The six studs can come in any material required. SRB probe is usually inserted in dead-leg locations where the biofilm formation is most likely to occur. Typically installation of the SRB probe is bottom of line and flush installation. In cases where the dead-leg locations are not available, flow over the studs needs to be reduced using the fixed shield option available for this product.


KOROSI SPECINDO

LENGTH CALCULATION PROCEDURE NON-FLANGE ACCESS FITTING Flush monitoring (LA+PW+WG)-2.5" Middle of line monitoring (LA+WG+0.5POD)-2.5" Bottom of line monitoring (LA+POD+WG)-(PW+3") FLANGE ACCESS FITTING Flush monitoring (LA+FG+MF+WG+PW)-2.5" Middle of line monitoring (LA+FG+MF+WG+0.5POD)-2.5" Bottom of line monitoring (LA+FG+MF+WG+POD)-(PW+3")

Remark LA : height of access fitting WG : weld gap=0.0625" (ANSI B31.1 2010) PW : pipe wall thickness

FG MF POD

: flange face-to-face gap : mating flange height : pipe outer diameter

ORDERING PROCEDURE Part number

Order length

Holder type

Stud material

PSM

XXX

XX

X

Probe SRB monitoring

Length Of SRB probe holder

S6 Delrin holder C 6 studs

P6

PTFE holder 6 studs

Body material XXXX

Carbon steel

B

Brass

S

316 SS

SA03

316 SS

For other materials o ption consult KS

Client Ordering: P/N PSM-3.25-S6-C-SA03 à SRB probe for two inch access fitting; Length: 3.25"; 316 SS material; holder type: Delrin holder 6 studs; carbon steel material stud without shield

Spare part Part Number

XXX

SPS SR B probe s pare

Stud material

Item type

SP6 RSS LS S

S et of 6 studs R etaining screw set of 6 Locking screw for b ody

X C B S

Carbon steel Brass 316 S S

Client Ordering : P/N SPS-SP6-C à SRB probe spare, 6 stud sets, carbon steel material.


5-5

5-6

KOROSI SPECINDO

TWO INCH SYSTEM HYDROGEN MONITORING PROBE 15

Vacuum gauge

Bleed cross assembly Capillary tube

Bleed cross assembly

Adhesive patch Non-intrusive hydrogen probe

Intrusive hydrogen probe

Fig. 5-3. Hydrogen monitoring systems.

Hydrogen atoms often produced in acidic environments can permeate through steels and, later, are released as hydrogen molecules which lead to hydrogen induced cracking and hydrogen blistering. Several techniques for hydrogen monitoring, i.e., intrusive and non-intrusive/patch types, make use of the fact that the released hydrogen gas will build up pressure. Intrusive hydrogen probe consists of a steel tube exposed to the process and connected to a bleed cross assembly which is equipped with a pressure gauge, thermometer and bleed valve. The thermometer is used to measure the temperature of the hydrogen gas so that volume calculation can be made using temperature and pressure, whereas, the bleed valve is for releasing the pressure build-up periodically. An exposure length of 3" is standard for the intrusive hydrogen probe and the wall thickness is usually thinner than the pipe wall allowing shorter response time. The intrusive hydrogen probe may be removed and replaced under operating pressure permitting online replacement or inspection of the tube. Non-intrusive hydrogen monitoring is established by mounting the bleed cross assembly directly into an NPT threadolet welded to the pipe wall with a blind installation (no penetration of the pipe wall). A sealed pocket existing in between the bleed cross assembly and threadolet allows for the pressure build-up. The non-intrusive hydrogen monitoring is slower to respond than the intrusive hydrogen probe due to the time taken for the hydrogen atoms to permeate the full pipe wall thickness, but the result is representative of the actual pipe wall.


KOROSI SPECINDO

5-7

Adhesive patch hydrogen monitoring requires no welding as the patch is secured with an adhesive. A thin capillary tube connects the patch to a manifold block on which a vacuum gauge and evacuation/test outlet are equipped. The adhesive patch entraps the hydrogen gas in a small pocket between the pipe wall and the adhesive patch that is fixed to the pipe wall at its edges. The pocket is vacuumed using a small hand pump, and the vacuum state must be re-established periodically. Successive time measurements of vacuum decay can be employed to calculate the hydrogen flux rate. Temperature correction is not necessary with the adhesive patch hydrogen monitoring making the recording and calculation simple. The test outlet is used with a gas tester to confirm that the hydrogen is the cause of the vacuum decay. The manifold assembly comes in a polycarbonate housing and additional length of capillary tube can be ordered to allow the manifold block to be located at some distance from the adhesive patch, enabling the device to be applied on burried pipeline.

ORDERING PROCEDURE Please contact KOROSI SPECINDO for order length of instrusive hydrogen probe. INTRUSSIVE HYDROGEN PROBE MODEL

DESCRIPTION

KS700

High-pressure Access Fitting System (KS6000)

KS720

Retractable System (KS500)

KS750

Fixed System (KS300)

CODE

BLEED CROSS ASSEMBLY

O

No bleed cross

B

Bleed cross

CODE XXX

ORDER LENGTH (only use for KS700) Length of probe (inch)

CODE

BLEED CROSS ASSEMBLY (only use for KS720)

18

18 Inches

24

24 Inches

29

29 Inches

CODE

SAFETY CLAMP (only use for KS720)

0

No Safety Clamp

1

Safety Clamp

CODE

SAFETY CLAMP LENGTH (only used for KS720)

0

Standard Length 4 inch

CODE

K S700 K S720 K S750

B B B

NPT SIZE (only used for KS750)

0

3/4'' NPT

1

1'' NPT

5.00 18

1

0 1

EXAMPLE : CLIENT ORDERING PROCEDURE KS - CTG - MKT -03 REV .5

5-8

KOROSI SPECINDO NON-INTRUSIVE HYDROGEN PROBE MODEL KS760

DESCRIPTION Threadolet system CODE

BLEED CROSS ASSEMBLY

O B

No bleed cross Bleed cross CODE

BODY MATERIAL

CS36 CS10

AISI 1022 CS ASTM A105 CS CODE P2 P3 P4 P6 P8 P12 P20 PF

KS760

B

CS10

LINE SIZE 2'' 3'' 4'' 6'' 8''-10'' 12''-18'' 20''-36'' Flat

P3


ADHESIVE PATCH HYDROGEN MONITORING DESCRIPTION

MODEL

Vacuum Patch (6'') c/w manifold block, capillary tube, adhesive kit, applicator and operating kit-pump

KS780

SPARES & ACCESSORIES PART NUMBER

DESCRIPTION Intrusive

Non-intrusive

Bleed Cross Assembly

700500

700500

Gauge 1- 100 psi

100120

100125

Thermometer

200300

200400

O-ring Seal

250320

250325

Valve

270200

270200

280700XX

280800XX

Probe Insert-Length Capillary Tube


Adhesive patch 100123

290092

KOROSI SPECINDO

TWO INCH SYSTEM CHEMICAL INJECTION/SAMPLING SYSTEM PROTECTIVE COVER

NPT NIPPLE

SOLID PLUG ASSY

INJECTION/SAMPLING NUT ASSY FLANGE ACCESS FITTING BODY

NIPOLED

PIPE LINE

PARALLEL NOZZLE HOLDER

PERPENDICULAR NOZZLE HOLDER

OPEN

SAMPLING QUIL

NOTCHED QUIL

Fig. 5-4. Chemical injection/sampling system.

Chemical injection/sampling system is fundamental to corrosion control program and it is applicable to various processes in the petroleum, chemical and water treatment industries. The chemical injection system may be used for the injection of wide range of chemicals such as biocide, demulsifier, corrosion inhibitor, oxygen scavenger, glycol, dewaxer, methanol and odorizer. The sampling system is used to take samples of the process fluid. The samples are then analyzed in the laboratory for corrosion inhibitor concentration, presence of metal ions, oxygen concentration and scale forming compounds. The chemical injection system is a complex technology. Principle factors related to the chemical injection and process systems are as follows. 1. Pressure differential: It is the difference between the injection pressure and the process line/vessel pressure. 2.Viscosity: It is a measure of the fluid resistance to flow. The more viscous the fluid, the smaller the spray angle. 3.Temperature: It directly affects viscosity.


5-9

5-10

KOROSI SPECINDO 4. Spray angle: It is affected by viscosity, spray distance and pressure differential. 5.Spray coverage: It is calculated theoretical area covered. 6.Specific gravity: The specific gravity of a liquid is the density ratio of the liquid to water. The flow rate of a liquid is affected by its specific gravity. Injection rate is the amount of chemical to be injected within a specified time period and it is defined as liter per hour or Gallon Per Hour (GPH). Injections systems are available for injection rates varying from 0.38 liter per hour (0.1 GPH) to 250 liter per hour (65.7 GPH). The maximum fluid velocity is usually at the center of line, hence, the most effective position for injection is generally at the center of the pipe in the direction the product flow. If the pipeline is to be pigged, the injection position should be flushed with the pipe wall which eliminates the need to remove the injection probe before the pigging operation. A typical two inch system chemical injection/sampling system is shown in Fig. 5.4 which consists of as in the followings. 1.Access fitting body with a side tee through which the fluid transfer takes place. The tee may be connected to a nipple or flange by thread or weld. The tee size is rated according to the injection rate and pressure of injection. 2.Solid plug assembly fitted inside the access fitting body is used to hold an injection nut which has injection/sampling tube screwed/welded to its base. 3. Protective cover provides heavy duty protection on both the access fitting body and solid plug assembly. 4. Injection/sampling nut transfers the injected liquid into the process or sampled liquid out of the pipeline or vessel. 5.Injection/sampling tubes are available in various end forms, namely, open, quill, NPT and head ends. Open and quill end tubes rely on the natural turbulence within the pipeline to disperse the injected chemical. These tubes are clog proof and, particularly, the quill end tube give good dispersion provided that the product flow is greater than 4.6 m/s. NPT end tube is similar to the open end tube but it is threaded, thus, allowing attachment of a female nozzle. Head end tube is usually used for parallel injection at the center of the line, and it is designed to accept the standard nozzle assembly. 6.Atomization nozzle permits atomization of the fluid as it is injected into the pipe line or vessel. The atomization nozzle comes with either male or female NPT thread, and it contains cap, core and strainer. Chemical injection/sampling system components are manufactured from AISI 316 SS which complies to NACE MR0175/ISO15156 for practice in Sulfide Stress Cracking (SSC) induced environments.


KOROSI SPECINDO


FLANGE

LA

FG

MF

LA

WG

TOP OF LINE

PW POD MIDDLE OF LINE


NON-FLANGE ACCESS FITTING Top of line monitoring (LA+PW+WG)-(1.5"+IN) Middle of line monitoring (LA+WG+0.5POD)-(2"+IN) Bottom of line monitoring (LA+POD+WG)-(2.5"+PW+IN) FLANGE ACCESS FITTING Top of line monitoring (LA+FG+MF+WG+PW)-(1.75"+IN) Middle of line monitoring (LA+FG+MF+WG+0.5POD)-(2.25"+IN) Bottom of line monitoring (LA+FG+MF+WG+POD)-(2.75"+PW+IN)

FG MF POD



5-11

5-12

KOROSI SPECINDO

ORDERING PROCEDURE A) The access fitting body assembly and tee size can be ordered following the procedure in Section 6. B) The injection/sampling nut length can be ordered following the table below.

Model

Injection nut length

NPT thread size

X.XX

X

KS300A 1.75

2.75

Injection nut

3.75

5.50

Use for 5.25'' High Access Fitting Use for 6.25'' High Access Fitting Use for 7.25'' High Access Fitting

XXXX

1

1

2

¼'' NPT

3

½'' NPT

8

Material

'' NPT

SA04

AISI 316L SS

SA05

Duplex SS

For other materials consult KS

Use for 8.25'' High Access Fitting

Client Ordering: P/N KS300A-1.75-2-SA04 à Injection nut length: 1.75" for access fitting height 5.25, 1/4" NPT thread size, AISI 316L SS material.

C) The length of the injection/sampling tube is calculated using the previous formulas, and the ordering procedure is done following the next table. Injection/sampling tube type XXXX

Model KS Injection/ sampling tube

NPT thread size X

Material XXXX

301A

Notched Quill

SA04

316 LSS

302A

Open

SA05

Duplex SS

303A

NPT

304A

Head

305A

Sampling Quill

For other material option consult KS

1

1

2

¼'' NPT

3

½'' NPT

8

'' NPT

Injection/sampling tube length XXXX Open/Quill/NPT Available from 1.25'' to 30'' Head Available from 2.25'' to 30''

Client Ordering: P/N KS301A-SA04-2-4.00 à Injection tube quill type, 316L SS Material, ¼" NPT thread, length: 4.00”.

D) The nipple and shut-off valve suitable to the tee size of the access fitting body can be selected from this table. Access fitting tee size

Nipple 4'' x sch 80

Shut -off valve

Nipple flange

Part number

Part number

Part number

¼''

4025

5025

6025

½'

4050

5050

6050

¾''

4075

5075

6075

1''

4100

5100

6100

Client Ordering: P/N KS4025 à 1/4" NPT nipple 4", schedule 80 P/N KS5025 à 1/4" Shut-off valve P/N KS6025 à 1/4" NPT nipple flange 4"


KOROSI SPECINDO E) If applicable select a suitable Nozzle Assembly/Cap and core from this table below: Part Number

Orifice Diameter / Nozzle Type

GPH Capacity & Pressure Differential 40 PSI

60 PSI

80 PSI

100 PSI

700030

0.30 -1/4'' FNPT

0.30

0.30

0.40

0.40

700031

0.40 -1/4'' FNPT

0.40

0.40

0.50

0.50

700032

0.60 -1/4'' FNPT

0.60

0.70

0.80

0.80

700033

0.30 -1/4'' NPT Flush

0.30

0.30

0.40

0.40

700034

0.40 -1/4'' NPT Flush

0.40

0.40

0.50

0.60

700035

0.60 -1/4'' NPT Flush

0.60

0.70

0.80

0.90

700036

0.30 - Cap/Core 9/16''

0.30

0.30

0.40

0.40

700037

0.40 - Cap/Core 9/16''

0.40

0.40

0.50

0.60

700038

0.60 - Cap/Core 9/16''

0.60

0.72

0.84

0.96

Client Ordering: P/N KS70030 à Orifice diameter 0.30-1/4'' FNPT

SPARE PARTS Injection nut seal materials Part number

Description

230573

Viton o-ring with teflon back-up ring

230574

Ethylene propylene o-ring with teflon back-up ring

230575

Kalrez o-ring with teflon back-up ring

230576

Hydrin o-ring with teflon back-up ring

230577

Nitrile o-ring with teflon back-up ring

230578

Viton B FR58 (explosion decompression resistance) with teflon back-up ring


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5-14

KOROSI SPECINDO

TWO INCH SYSTEM TEE-LESS CHEMICAL INJECTION SYSTEM Injection hose connection Shut-off Valve

Swagelok Tube Protective cover

Standard non-Tee access fitting

Check plug assembly

Nozzle

Fig. 5-5. Tee-less chemical injection system.

Tee-less chemical injection system allows injection of treatment chemicals through a standard two inch access fitting and it does not require a side tee. The tee-less chemical injection system comprises of check plug and pressure cover assemblies. The check plug assembly consists of a check valve built into a hollow plug body with an injection tube mounted directly below. The injection tube can be flush or projected position and equipped with quill or nozzle. The pressure cover assembly is connected to the top of the check plug and it acts as a back up pressure barrier for the check valve. The pressure cover assembly comprises of heavy duty protective cover with optional bleed valve and pressure gauge, swagelok tube and shut-off valve.


KOROSI SPECINDO


FLANGE

NON-FLANGE ACCESS FITTING Top of line monitoring (LA+PW+WG)-5.3" Middle of line monitoring (LA+WG+0.5POD)-5.3" Bottom of line monitoring (LA+POD+WG)-(6"+PW)

LA

FG

FLANGE ACCESS FITTING Top of line monitoring (LA+FG+MF+WG+PW)-5.3" Middle of line monitoring (LA+FG+MF+WG+0.5POD)-5.3" Bottom of line monitoring (LA+FG+MF+WG+POD)-(6"+PW)

MF

LA

WG

TOP OF LINE

PW POD MIDDLE OF LINE


FG MF POD


ORDERING PROCEDURE A) The access fitting body assembly and tee size can be ordered following the procedure in Section 6. B) The check plug assembly may be determined from the table below. Model

NPT thread size

KS250A

X 1

¼'' NPT

2

½'' NPT

Check Plug Assy

Material XXXX SA03

AISI 316 SS

SA05

Duplex SS


Client ordering: P/N KS250A-1-SA03 à Check plug assy, 1/4’’ NPT thread size, AISI 316 SS Material.


5-15

5-16

KOROSI SPECINDO C) The length of the injection tube is calculated using the previous formulas, and the ordering procedure is done following the next table. Model KS Injection tube

Injection tube type XXXX

Material XXXX 316 SS

301A

Quill

SA03

302A

Open

303A

NPT

SA05 Duplex For other materials

Head

Option consult KS

304A

NPT thread size X

Injection tube length XXX Open/Quill/NPT

1

¼'' NPT

2

½'' NPT

Available from 1.25'' to 30'' X Head Available from 2.25'' to 30''

Client Ordering: P/N KS301A-SA03-1-4.00 à Injection tube quill type, 316 SS material, 1/4’’ NPT thread, length: 4.00"

D) Swage tube and shut-off valve to match the check plug assembly can be selected from the table below. Description

Part number

1/4'' NPT swage tube

KS2525

1/4'' NPT shut-off valve 1/2'' NPT swage tube

KS5025 KS2550

1/2'' NPT shut-off valve

KS5050

Client Ordering: P/N KS2525 à 1/4" NPT Swage Tube P/N KS5050 à 1/2'' NPT Shut off Valve

E) If applicable select a suitable Nozzle Assembly/Cap and core from this table below: Part Number

Orifice Diameter / Nozzle Type

GPH Capacity & Pressure Differential 40 PSI

60 PSI

80 PSI

100 PSI

700030

0.30 -1/4'' FNPT

0.30

0.30

0.40

0.40

700031

0.40 -1/4'' FNPT

0.40

0.40

0.50

0.50

700032

0.60 -1/4'' FNPT

0.60

0.70

0.80

0.80

700033

0.30 -1/4'' NPT Flush

0.30

0.30

0.40

0.40

700034

0.40 -1/4'' NPT Flush

0.40

0.40

0.50

0.60

700035

0.60 -1/4'' NPT Flush

0.60

0.70

0.80

0.90

700036

0.30 - Cap/Core 9/16''

0.30

0.30

0.40

0.40

700037

0.40 - Cap/Core 9/16''

0.40

0.40

0.50

0.60

700038

0.60 - Cap/Core 9/16''

0.60

0.72

0.84

0.96

Client Ordering: P/N KS70030 à Orifice diameter 0.30-1/4'' FNPT


S ECTION 6 TWO INCH SYSTEM ACCESS FITTING ASSEMBLIES

KOROSI SPECINDO

MODEL KS6000(KS6000H)-TWO INCH SYSTEM (HYDRAULIC) ACCESS FITTING ASSEMBLIES KS6000(KS6000H)-two inch system (hydraulic) access fitting assemblies provide access of corrosion monitoring, erosion monitoring, Sulfate Reducing Bacteria (SRB) monitoring, hydrogen monitoring, chemical injection and sampling equipments into a high pressure system, vessel or pipeline. Installation of the access fitting assembly and insertion/retrieval of the equipments mentioned above under operating condition are possible using special tools, namely, hot-tapping, retriever and service valve tools. KS6000(KS6000H)-two inch system (hydraulic) access fitting assemblies consists of access fitting body, solid/hollow plug and protective cover. The access fitting body comes with either non-flange or flange type connecting part. Standard materials of the access fitting body, solid/hollow plug and protective cover are commonly ASTM A105 carbon steel, AISI 316 stainless steel and mild steel, respectively. Nevertheless, different materials are available upon request. The design of KS6000(KS6000H)-two inch access fitting assembly satisfies the following standards: ASME B31.3

- Chemical plant and petroleum refinery piping

ASME/ANSI B16.5

- Pipe flanges and flange fittings

API RP 14E

- Offshore production platform piping system

NACE MR0175/ ISO15156

- Sulfide stress cracking resistant metallic materials for oilfield equipment.

The various types of access fitting body and ordering procedure are to be elaborated next in the remaining of this section.


6-1

6-2

KOROSI SPECINDO

KS6000-TWO INCH SYSTEM NON-FLANGE ACCESS FITTING ASSEMBLY FLARWELD

PROTECTIVE COVER

KS100A SOLID PLUG ASSEMBLY

KS120A HOLLOW PLUG ASSEMBLY

TEE

NON-TEE

FLARWELD ACCESS FITTING BODY

Access Fitting Body (NON TEE) ¼'' TEE ½'' TEE ¾'' TEE 1'' TEE

Height (inch)

Weight (lbs)

5.25 5.25 6.25 6.25 7.25

6.50 6.25 8.10 7.80 8.70

Korosi Specindo design meets the following condition: Maximum Working Pressure Temperature Service


: 6000 psig 0 0 : -29 C to 260 C : Sour Service (H2S)

KOROSI SPECINDO

KS6000-TWO INCH SYSTEM NON-FLANGE ACCESS FITTING ASSEMBLY BUTTWELD

PROTECTIVE COVER



TEE

NON-TEE

BUTTWELD ACCESS FITTING BODY


Height (inch)

Weight (lbs)

5.25 5.25 6.25 6.25 7.25

6.50 6.25 8.10 7.80 8.70




6-3

6-4

KOROSI SPECINDO

KS6000-TWO INCH SYSTEM NON-FLANGE ACCESS FITTING ASSEMBLY SOCKETWELD

PROTECTIVE COVER



TEE

NON-TEE

SOCKETWELD ACCESS FITTING BODY


Height (inch)

Weight (lbs)

6.25 6.25 6.25 6.25 7.25

8.70 8.40 8.10 7.80 8.70




KOROSI SPECINDO

KS6000-TWO INCH SYSTEM NON-FLANGE ACCESS FITTING ASSEMBLY NPT

PROTECTIVE COVER



TEE

NON-TEE

NPT ACCESS FITTING BODY

Access Fitting Body

Height (inch)

Weight (lbs)

(NON TEE) ¼'' TEE ½'' TEE ¾'' TEE 1'' TEE

6.25 6.25 6.25 6.25 7.25

8.70 8.40 8.10 7.80 8.70




6-5

6-6

KOROSI SPECINDO

ORDERING PROCEDURE NON-FLANGE ACCESS FITTING ASSEMBLY MODEL KS 6000 ACCESS FITTING

CODE

FLARWELD

FLW

BUTTWELD

BTW

SOCKETWELD

SKW

NPT

NPT PLUG ASSEMBLY CODE

XXX

1st digit-Type

2nd digit-Material

3nd digit-Packing Seal

O

Not required

O

Not required

O

Not required

S

Solid

A

AISI 316 SS

A

Viton o-ring, teflon primary packing

H

Hollow plug

B

AISI 316 LSS

B

EP o-ring, vespel primary packing

C

Hastelloy C276

C

Kalrez o-ring, vespel primary packing

D

Nitronic 60

D

No o-ring, nitronic 60 primary packing

E

Carbon steel

E

Nitrille o-ring, teflon primary packing

F

Other material

F

Vitton B FR58, teflon primary packing

G

Other packing seal

plug

CODE

ACCESS FITTING BODY

NT

Non-Tee

T25

¼'' Tee

T50

½'' Tee

T75

¾'' Tee

T100

1'' Tee CODE

BODY MATERIAL

CS36

AISI 1022 CS

CS10

ASTM A105 CS

CS05

ASTM A350 LF2 CS

SA03

AISI 316 SS

SA05

Duplex SS

For other materials option consult KS CODE

LINE SIZE (for flarweld access fitting only)

P2

2''

P3

3''

P4

4''

P6

6''

P8

8''-10''

P12

12''-18''

P20

20''-36''

PF

Flat CODE

C0 C1 C2 C3 C4 C5 C6


PROTECTIVE COVER

Not required Without hole (P/N KS 221) With hole (P/N KS 220) Without hole c/w bleed valve (P/N KS 222) Without hole c/w bleed valve & pressure gauge (P/N KS 223) With hole c/w bleed valve & pressure gauge (P/N KS 224) With large hole (P/N KS 225)

KOROSI SPECINDO

KS6000-TWO INCH SYSTEM FLANGE ACCESS FITTING ASSEMBLY ANSI RF FLANGE

PROTECTIVE COVER



TEE

NON-TEE ANSI RF FLANGE ACCESS FITTING BODY

ACCESS BODY NON TEE

150#

300#

400/600#

900/1500#

Height (Inch)

Weight (Lbs)

Height (Inch)

Weight (Lbs)

Height (Inch)

Weight (Lbs)

Height (Inch)

5.25

11.00

5.25

11.50

6.25

15.25

6.25

15.00

2500#

Weight (Lbs)

Height (Inch)

Weight (Lbs)

6.25

30.75

6.25

40.20

6.25

30.25

6.25

40.00

¼'' TEE

5.25

10.75

5.25

11.25

½'' TEE

7.25

10.50

7.25

12.75

7.25

14.50

8.25

31.75

8.25

40.75

¾'' TEE

7.25

10.25

7.25

12.50

7.25

14.25

8.25

31.50

8.25

40.50

1'' TEE

7.25

10.00

7.25

12.25

7.25

14.00

8.25

31.25

8.25

40.25




6-7

6-8

KOROSI SPECINDO

KS6000-TWO INCH SYSTEM FLANGE ACCESS FITTING ASSEMBLY ANSI RJ FLANGE

PROTECTIVE COVER



TEE

NON-TEE ANSI RJ FLANGE ACCESS FITTING BODY

ACCESS BODY

150# Height (Inch)

300#

400/600#

Weight (Lbs)

Height (Inch)

Weight (Lbs)

Height (Inch)

900/1500#

Weight (Lbs)

Height (Inch)

2500#

Weight (Lbs)

Height (Inch)

Weight (Lbs)

NON TEE

5.25

9.75

5.25

11.50

6.25

12.75

6.25

25.75

6.25

40.20

¼'' TEE

5.25

9.50

5.25

11.25

6.25

12.50

6.25

25.50

6.25

40.00

½'' TEE

7.25

13.50

7.25

17.00

7.25

18.00

8.25

38.50

8.25

40.75

¾'' TEE

7.25

13.25

7.25

16.75

7.25

17.75

8.25

38.25

8.25

40.50

1'' TEE

7.25

13.00

7.25

16.50

7.25

17.50

8.25

38.00

8.25

40.25




KOROSI SPECINDO

KS6000-TWO INCH SYSTEM FLANGE ACCESS FITTING ASSEMBLY 2-1/16" API RJ FLANGE

PROTECTIVE COVER



TEE

NON-TEE 2-1/16" API RJ FLANGE ACCESS FITTING BODY

ACCESS BODY

2000# Height (Inch)

3000/5000#

Weight (Lbs)

Height (Inch)

10000#

Weight (Lbs)

Height (Inch)

Weight (Lbs)

NON TEE

6.25

15.75

6.25

30.75

6.75

46.00

¼'' TEE

6.25

18.00

6.25

38.00

6.25

45.50

½'' TEE

7.25

17.75

8.25

37.75

8.25

45.25

8.25

45.00

8.25

44.75

¾'' TEE

7.25

17.50

8.25

37.50

1'' TEE

7.25

17.25

8.25

37.25




6-9

6-10

KOROSI SPECINDO

ORDERING PROCEDURE FLANGE ACCESS FITTING ASSEMBLY MODEL KS 6000 ACCESS FITTING CODE RF

ANSI RF ANSI RJ

RJ

API RJ

API PLUG ASSEMBLY CODE

XXX

1st digit-Type

2nd digit-Material


O

Not Required

X

Not Required

X

Not Required

S

Solid

A

AISI 316 SS

A

Viton O-Ring, Teflon Primary Packing

H

Hollow Plug

B

AISI 316 LSS

B

EP O-Ring, Vespel Primary Packing

C

Hastelloy C-276

C

Kalrez O-Ring, Vespel Primary Packing

D

Nitronic 60

D

No O-Ring, Nitronic 60 Primary Packing

E

Carbon Steel

E

Nitrille O-Ring, Teflon Primary Packing

F

Other Material

F

Vitton B FR58, Teflon Primary Packing

G

Other Packing Seal

Plug

CODE

ACCESS BODY

NT

Non Tee

T25

¼'' Tee

T50

½'' Tee

T75

¾'' Tee

T100

1'' Tee

FLANGE SIZE ANSI RF

ANSI RJ

2-1/16'' API RJ

Code

Class

Code

Class

Code

Class

F12

150#

J12

150#

A22

2000#

F22

300#

J22

300#

A32

3000#

F32

400#

J32

400#

A52

5000#

F42

600#

J42

600#

A102

1000#

F52

900#

J52

900#

F62

1500#

J62

1500#

F72

2500#

J72

2500#

CODE

BODY MATERIAL

CS36

AISI 1022 CS

CS10

ASTM A105

CS05

ASTM A350 LF2 CS

SA03

AISI 316 SS

SA05 Duplex SS For other materials option consult KS

CODE C0 C1 C2 C3 C4 C5 C6

KS6000 KS6000 KS6000


SAA HAA SAA

NT NT T50

F12 J42 A22

CS10 SA03 SA05

C1 C5 C4

PROTECTIVE COVER Not required Without hole (P/N KS 221) With hole (P/N KS 220) Without hole c/w bleed valve (P/N KS 222) Without hole c/w bleed valve & pressure gauge (P/N KS 223) With hole c/w bleed valve & pressure gauge (P/N KS 224) With large hole (P/N KS 225)

RF RJ API

KOROSI SPECINDO

KS6000-TWO INCH SYSTEM ACCESS FITTING ASSEMBLY SPARE PARTS KS100A SOLID PLUG ASSEMBLY ½'' NPT plug

Height Weight Diameter

Solid plug body

O-ring Primary packing Solid plug nut w/ set screw

½'' NPT plug

: 4.00 inch : 1.77 lbs (0.8 kg) : 1.75 inch

Part No.

Description

KS100A 50316 KS105-B 35300 26395 36116 31260

Solid plug assembly ½'' NPT plug Solid plug body O-ring Primary packing Solid plug nut Set screw

Material 316L SS 316L SS 316L SS Viton PTFE (25% glass)

316L SS 18-18 SS

KS120A HOLLOW PLUG ASSEMBLY Height Weight Diameter

: 4.00 inch : 1.99 lbs (0.9 kg) : 1.75 inch

Hollow plug body

Part No.

Description

Material

Hollow plug assembly ½'' NPT plug Hollow plug body Probe packing Primary packing Hollow plug nut Hollow plug bore sealing nut Set screw

316 LSS Plastic 316 LSS

Primary packing

KS120A 50317 KS106-B 16223 26395 36234 3229

Hollow plug nut w/ set screw Probe insert packing Hollow plug bore sealing nut

Weight (lbs) 1.77 0.13 1.50 0.01 0.01 0.11 0.01

31620

PTFE (25% glass) PTFE (25% glass)

316 LSS 316 LSS 18-18 SS

Weight (lbs) 1.99 0.03 1.40 0.01 0.01 0.17 0.25 0.02

Plug body is coated by solid film lubricant for anti galling


6-11

6-12

KOROSI SPECINDO

KS6000-TWO INCH SYSTEM ACCESS FITTING ASSEMBLY SPARE PARTS

HEAVY DUTY PROTECTIVE COVER (4000 PSI) Part Number

Description

Material

Diameter (inch)

Body Height (inch)

Diameter (inch)

KS220

Protective Cover with Hole

Carbon Steel

3.5

4

5.5

KS221

Protective Cover without Hole

Carbon Steel

3.5

4

5.7

Carbon Steel

3.5

4

5.5

Carbon Steel

3.5

4

5.2

Carbon Steel

3.5

4

5.2

Carbon Steel

3.5

2

2.2

KS224

Protective Cover without Hole, c/w Bleed Valve Protective Cover without Hole, c/w Bleed Valve & Pressure Gauge Protective Cover with Hole, c/w Bleed Valve & Pressure Gauge

KS225

Protective Cover with Large Hole

KS222 KS223

NOTE : FOR OTHER MATERIALS OPTION CONSULT KS Part Number

Description

Material

35220

O-Ring

Viton

35221

Bleed Valve

316 SS

35223

Pressure Gauge

316 SS

SERVICES OF SEALS AND “O” RINGS FOR PLUG ASSEMBLY No

Part Number

1 2 3 4 5 6 7 8

35300 35305 35310 35315 35320 26395 26397 26398

9

26399


Material O-Ring, Viton O-Ring, Ethylene Prophylene O-Ring, Kalrez O-Ring, Nitrille O-Ring Viton B FR58 Expl. Decompression Primary Packing, Teflon Primary Packing, Vespel Primary Packing, Duplex Primary Packing, Nitronic 60 Don't use ''O'' Ring at these temperature

Temperature Range 0

0

-4 F to 450 F -600F to 2750F -200F to 5540F 600F to 2210F 0 0 -4 F to 450 F -200F to 5000F 0 0 350 F to 500 F 0 350 F to 5000F 0

In Excess of 500 F

KOROSI SPECINDO

KS6000H-TWO INCH SYSTEM HYDRAULIC NON-FLANGE ACCESS FITTING ASSEMBLY FLARWELD KS221H

KS220H

KS222H

KS223H

KS224H

PROTECTIVE COVER

KS100HA SOLID PLUG ASSEMBLY

KS120HA HOLLOW PLUG ASSEMBLY

TEE

NON-TEE

HYDRAULIC FLARWELD ACCESS FITTING BODY


Height (inch)

Weight (lbs)

6.50 6.50 7.50 7.50 8.50

15 15 17 17 17




6-13

6-14

KOROSI SPECINDO

KS6000H-TWO INCH SYSTEM HYDRAULIC NON-FLANGE ACCESS FITTING ASSEMBLY BUTTWELD KS221H

KS220H

KS222H

KS223H

KS224H

PROTECTIVE COVER



TEE

NON-TEE

HYDRAULIC BUTTWELD ACCESS FITTING BODY


Height (inch)

Weight (lbs)

6.50 6.50 7.50 7.50 8.50

15 15 17 17 17




KOROSI SPECINDO

KS6000H-TWO INCH SYSTEM HYDRAULIC NON-FLANGE ACCESS FITTING ASSEMBLY SOCKETWELD KS221H

KS220H

KS222H

KS223H

KS224H

PROTECTIVE COVER



TEE

NON-TEE

HYDRAULIC SOCKETWELD ACCESS FITTING BODY


Height (inch)

Weight (lbs)

6.50 6.50 7.50 7.50 8.50

14 16 16 16 16




6-15

6-16

KOROSI SPECINDO

KS6000H-TWO INCH SYSTEM HYDRAULIC NON-FLANGE ACCESS FITTING ASSEMBLY NPT KS221H

KS220H

KS222H

KS223H

KS224H

PROTECTIVE COVER



TEE

NON-TEE

HYDRAULIC NPT ACCESS FITTING BODY


Height (inch)

Weight (lbs)

6.50 6.50 7.50 7.50 8.50

15 16 17 15 17




KOROSI SPECINDO

ORDERING PROCEDURE NON-FLANGE HYDRAULIC ACCESS FITTING ASSEMBLY MODEL KS 6000H ACCESS FITTING

CODE

FLARWELD

FLWH

BUTTWELD

BTWH

SOCKETWELD

SKWH

NPT

NPTH PLUG ASSEMBLY CODE

XXX

1st digit-Type

2nd digit-Material


O

Not required

O

Not required

O

Not required

S

Solid

A

AISI 316 SS

A

Viton o-ring, teflon primary packing

H

Hollow plug

B

AISI 316 LSS

B

EP o-ring, vespel primary packing

C

Hastelloy C276

C

Kalrez o-ring, vespel primary packing

D

Nitronic 60

D

No o-ring, nitronic 60 primary packing

E

Carbon steel

E

Nitrille o-ring, teflon primary packing

F

Other material

F

Vitton B FR58, teflon primary packing

G

Other packing seal

plug

CODE

ACCESS FITTING BODY

NT

Non-Tee

T25

¼'' Tee

T50

½'' Tee

T75

¾'' Tee

T100

1'' Tee CODE

BODY MATERIAL

CS36

AISI 1022 CS

CS10

ASTM A105 CS

CS05

ASTM A350 LF2 CS

SA03

AISI 316 SS

SA05

Duplex SS

For other materials option consult KS CODE

LINE SIZE (for flarweld access fitting only)

P2

2''

P3

3''

P4

4''

P6

6''

P8

8''-10''

P12

12''-18''

P20

20''-36''

PF

Flat CODE

C0 C1 C2 C3 C4 C5 C6

PROTECTIVE COVER

Not required Without hole (P/N KS 221) With hole (P/N KS 220) Without hole c/w bleed valve (P/N KS 222) Without hole c/w bleed valve & pressure gauge (P/N KS 223) With hole c/w bleed valve & pressure gauge (P/N KS 224) With large hole (P/N KS 225)


6-17

6-18

KOROSI SPECINDO

KS6000H-TWO INCH SYSTEM HYDRAULIC ACCESS FITTING ASSEMBLY SPARE PARTS KS100HA HYDRAULIC SOLID PLUG ASSEMBLY ½'' NPT plug Wear ring

Solid plug body Wear ring

Primary packing Solid plug nut w/ set screw

½'' NPT plug Wear ring

Height Weight Diameter

: 4.35 inch : 2.63 lbs (1.19 kg) : 1.77 inch

Part No.

Description

KS100HA 50316 KS131 132 26395 KS133 31620

Solid plug assembly ½'' NPT plug Solid plug body Wear ring Primary packing Solid plug nut Set screw

Material 316L SS 304 SS 316L SS PTFE PTFE (25% glass)

316L SS 18-18 SS

KS120HA HYDRAULIC HOLLOW PLUG ASSEMBLY Height Weight Diameter

: 4.35 inch : 2.37 lbs (1.08 kg) : 1.77 inch

Hollow plug body

Part No.

Description

Material

Wear ring

KS120HA 50316 KS141 16223 26395 36234 3229

Hollow plug assembly ½'' NPT plug Hollow plug body Probe packing Primary packing Hollow plug nut Hollow plug bore sealing nut Set screw Wear ring

316L SS 304 ss 316L SS

Primary packing Hollow plug nut w/ set screw Probe insert packing Hollow plug bore sealing nut

31620 132

PTFE (25% glass) PTFE (25% glass)

316L SS 316L SS 18-18 SS PTFE

Plug body is coated by solid film lubricant for anti galling


Weight (lbs) 2.63 0.11 2.36 0.04 0.01 0.11 0.01

Weight (lbs) 2.37 0.11 1.79 0.01 0.01 0.17 0.25 0.02 0.04

KOROSI SPECINDO

KS6000H-TWO INCH SYSTEM HYDRAULIC ACCESS FITTING ASSEMBLY SPARE PARTS KS220H

KS221H

KS224H

KS223H

KS222H

HEAVY DUTY PROTECTIVE COVER (6000 PSI) Part Number

Description

Material

Diameter (inch)

Body Height (inch)

Weight (Kg)

KS220H

Protective Cover with Hole

Carbon Steel

3.5

1.88

2.50

KS221H

Protective Cover without Hole

Carbon Steel

3.5

1.88

2.50

Carbon Steel

3.5

2.80

4.00

Carbon Steel

3.5

2.80

4.00

Carbon Steel

3.5

2.80

4.00

KS222H KS223H KS224H

Protective Cover without Hole, c/w Bleed Valve Protective Cover without Hole, c/w Bleed Valve & Pressure Gauge Protective Cover with Hole, c/w Bleed Valve & Pressure Gauge

NOTE : FOR OTHER MATERIALS OPTION CONSULT KS Part Number

Description

Material

35220

O-Ring

Viton

35221

Bleed Valve

316 SS

35223

Pressure Gauge

316 SS

SERVICES OF SEALS AND “O” RINGS FOR PLUG ASSEMBLY No

Part Number

1 2 3 4 5 6 7 8

35300 35305 35310 35315 35320 26395 26397 26398

9

26399

Material O-Ring, Viton O-Ring, Ethylene Prophylene O-Ring, Kalrez O-Ring, Nitrille O-Ring Viton B FR58 Expl. Decompression Primary Packing, Teflon Primary Packing, Vespel Primary Packing, Duplex Primary Packing, Nitronic 60 Don't use ''O'' Ring at these temperature

Temperature Range 0

0

-4 F to 450 F -600F to 2750F -200F to 5540F 600F to 2210F 0 0 -4 F to 450 F -200F to 5000F 0 0 350 F to 500 F 0 350 F to 5000F 0

In Excess of 500 F


6-19

6-20

KOROSI SPECINDO

KS6000H-TWO INCH SYSTEM HYDRAULIC FLANGE ACCESS FITTING ASSEMBLY ANSI RJ FLANGE KS221H

KS220H

KS222H

KS223H

KS224H

PROTECTIVE COVER



TEE

NON-TEE ANSI RJ FLANGE HYDRAULIC ACCESS FITTING BODY

ACCESS BODY

150#

300#

400/600#

900/1500#

2500#

Height (Inch)

Weight (Lbs)

Height (Inch)

Weight (Lbs)

Height (Inch)

Weight (Lbs)

Height (Inch)

Weight (Lbs)

Height (Inch)

Weight (Lbs)

NON TEE

6.50

20

6.50

21

7.50

25

7.50

40

7.50

50

¼'' TEE

8.50

23

8.50

27

8.50

28

9.50

49

9.50

55

½'' TEE

8.50

23

8.50

27

8.50

28

9.50

49

9.50

55

¾'' TEE

8.50

23

8.50

27

8.50

28

9.50

49

9.50

55

1'' TEE

8.50

23

8.50

27

8.50

28

9.50

49

9.50

55




KOROSI SPECINDO

KS6000H-TWO INCH SYSTEM HYDRAULIC FLANGE ACCESS FITTING ASSEMBLY ANSI RF FLANGE KS221H

KS220H

KS222H

KS223H

KS224H

PROTECTIVE COVER



TEE

NON-TEE ANSI RF FLANGE HYDRAULIC ACCESS FITTING BODY

ACCESS BODY

150#

300#

400/600#

900/1500#

2500#

Height (Inch)

Weight (Lbs)

Height (Inch)

Weight (Lbs)

Height (Inch)

Weight (Lbs)

Height (Inch)

Weight (Lbs)

Height (Inch)

Weight (Lbs)

NON TEE

6.50

20

6.50

21

7.50

25

7.50

40

7.50

50

¼'' TEE

8.50

23

8.50

27

8.50

28

9.50

49

9.50

55

½'' TEE

8.50

23

8.50

27

8.50

28

9.50

49

9.50

55

¾'' TEE

8.50

23

8.50

27

8.50

28

9.50

49

9.50

55

1'' TEE

8.50

23

8.50

27

8.50

28

9.50

49

9.50

55




6-21

6-22

KOROSI SPECINDO

KS6000H-TWO INCH SYSTEM HYDRAULIC FLANGE ACCESS FITTING ASSEMBLY API RJ FLANGE KS220H

KS221H

KS222H

KS223H

KS224H

PROTECTIVE COVER



TEE

NON-TEE API RJ FLANGE HYDRAULIC ACCESS FITTING BODY

ACCESS BODY

2000#

3000/5000#

Height (Inch)

Weight (Lbs)

Height (Inch)

Weight (Lbs)

NON TEE

7.50

25

7.50

¼'' TEE

8.50

27

9.50

½'' TEE

8.50

27

10000# Weight (Lbs)

40

Height (Inch) 7.50

49

9.50

55

9.50

49

9.50

55

49

9.50

55

49

9.50

55

¾'' TEE

8.50

27

9.50

1'' TEE

8.50

27

9.50

50




KOROSI SPECINDO

ORDERING PROCEDURE FLANGE HYDRAULIC ACCESS FITTING ASSEMBLY MODEL KS 6000H ACCESS FITTING CODE RF

ANSI RF ANSI RJ

RJ

API RJ

API PLUG ASSEMBLY CODE

1st digit-Type O SH

XXX HH

2nd digit-Material


Not Required

X

Not Required

X

Not Required

Solid plug

A

AISI 316 SS

A

Glass filled PTFE wearing ring,

hydraulic Hollow plug

B

AISI 316L SS

C

Hastelloy C-276

hydraulic

D

Nitronic 60

E

Carbon Steel

F

Other Material

CODE

ACCESS BODY

NTH

Non Tee

T25H

¼'' Tee

T50H

½'' Tee

T75H

¾'' Tee

T100H

1'' Tee

Glass filled PTFE primary packing B

Glass filled PTFE wearing ring, Vespel primary Packing

C

Glass filled PTFE wearing ring, Nitronic 60 primary Packing

D

Other Packing Seal

FLANGE SIZE ANSI RF

ANSI RJ

2-1/16'' API RJ

Code

Class

Code

Class

Code

Class

F12H

150#

J12H

150#

A22H

2000#

F22H

300#

J22H

300#

A32H

3000#

F32H

400#

J32H

400#

A52H

5000#

F42H

600#

J42H

600#

A102H

1000#

F52H

900#

J52H

900#

F62H

1500#

J62H

1500#

F72H

2500#

J72H

2500#

CODE

BODY MATERIAL

CS36

AISI 1022 CS

CS10

ASTM A105

CS05

ASTM A350 LF2 CS

SA03

AISI 316 SS

SA05 Duplex SS For other materials option consult KS

CODE C0 C1 C2 C3 C4 C5

KS6000H KS6000H KS6000H

SHAA NTH HHAA NTH SHAA T50H

F12 J42 A22

CS10 SA03 SA05

C1 C5 C4

PROTECTIVE COVER Not required Without hole (P/N KS 221H) With hole (P/N KS 220H) Without hole c/w bleed valve (P/N KS 222H) Without hole c/w bleed valve & pressure gauge (P/N KS 223H) With hole c/w bleed valve & pressure gauge (P/N KS 224H)

RF RJ API


6-23

S ECTION 7 TWO INCH SYSTEM RETRIEVAL TOOLS

KOROSI SPECINDO

TKS R RETRIEVER AND ACCESSORIES On line retrieval of corrosion coupon and replacement of corrosion probes is essential for effective corrosion monitoring of continuous process. Retriever and service valve tools are designed to provide this capability when used with the two inch system access fittings. The retrieval tool is available with 3600 psi pressure rating and a variety of lengths to suit the corrosion coupon holder and probe lengths to be retrieved. Model TKS R retriever and TKS K service valve tools can be used for any KOROSI SPECINDO two inch system access fittings. The major components of the retriever are a stationary inner barrel, thread adapter, moveable stainless steel outer barrel, mandrel rod and socket adapter assembly which are in accordance to NACE MR0175/ISO15156-1. Sealing within the unit is achieved with viton oring, teflon back up rings and graphite impregnated teflon seals. A bleed valve assembly incorporated in the retriever allows product bleed-off away from the operator for safety and cleanliness. It can be also used for back pressuring and product sampling. The TKS R-retriever operates using pressure balance principle ensuring that it extends and collapses in a safe and easily controlled way. Balance is achieved by equalizing valve and ports. Careful maintenance is essential to obtain maximum life from the equipment. Tools and valves should be dismantled and cleaned after each use and seals should be replaced regularly. Seals and spare parts are available to provide the necessary minor and major overhauls. The TKS R-retriever assembly is equipped with service tools and supply of spare parts. These tool kits are contained in a sturdy box to provide easy storage and portability. The retriever with standard stroke lengths are indicated below and longer stroke length is available on special order basis. Please contact KOROSI SPECINDO for detail.

Fig. 7-1. Model TKS R Retriever


7-1

7-2

KOROSI SPECINDO TKS R-RETRIEVER DIMENSIONS & WEIGHT DESCRIPTION Retriever Collapsed (A), inch Retriever Extended (B), inch Removal Clearance (C), inch Retriever Kit Weight (Lbs) Retriever Assembly Weight (Lbs) Maximum Holder Length (D), inch Maximum Probe Length (D), inch

14" 21.70 35.80 46.43 71.5 35 5 4

STROKE LENGTH * 18" 25" 37" 49" 61" 25.50 32.50 44.50 56.50 68.50 50.62 57.62 69.62 81.62 93.62 61.25 68.25 80.25 92.25 104.25 89.5 108.5 130.5 151.5 173 97 82 66 53 113 40 28 16 9 52 39 27 15 8 51

C B

R E M OVA L CLE ARAN CE

R E TR IE V E R EXTEND ED

A

R E TR IE V E R C O L LA P S E D

R E T R IE V E R S E R V IC E V A L V E H O O K -U P

* Stroke length custom order is available, contact KS sales ORDERING PROCEDURE The length of stroke required governs sizing of Retrievers. The stroke defined as the distance the Solid or Hollow Plug Assembly and its longest tool or attachment must travel from its seated position within the Access Fitting Body through the Service Valve allowing the ball valve to be closed. Determine stroke length required for longest retrievable attachment to be used. Select the next longer stroke length Retriever Kit available.

D M A X IM U M D E V IC E

Figure 7-2

Part Number

Description

Stroke Length

Pressure Rating

TKS

X

XX

XX

Tool KS6000

R

Retriever Tool

14

14'' Stroke

18

18'' Stroke

25

25'' Stroke

37

37'' Stroke

49

49'' Stroke

36

3600 psi

60

6000 psi

61 61'' Stroke Client ordering TKS-R-14-36 à Retriever tool with 14" stroke length and 3600 psi pressure rating Description TKS

X A Accessories

Accessories & spare part K Spare part

XX BP DH ST RS RR RW RH RB TL SA TT TB BH WS OA

Client ordering TKS-A-BP à Back pressure pump


Back Pressure Pump Diverter Hose Assembly Surge Tube Assembly Retriever Seal Kit Retriever Repair Kit Retriever Wood Clamp Retriever Head Bar Retriever Box Tools Kits Socket Adapter Assy Thread Tap Thread Brush Brass Hammer Wrench Set Over Shoot Adapter

Fig. 7-3. TKS R retriever seal & repair kits.

KOROSI SPECINDO

TKS K SERVICE VALVE AND ACCESSORIES The complete service valve kit includes TKS service valve assembly with extension lever, brass hammer and a heavy duty field service box for safe storage and easy portability. The TKS service valve assembly is especially designed for use with two inch system access fittings and TKS R-retriever. Attached to the access fitting body, the valve is the control which allows the pressurized product to enter the retriever during insertion and removal of KS100A solid or KS120A hollow plug assemblies. The service valve complies to API 6FA and API 607 as a fire safe unit. The service valve assembly also contains the pressurized product when the retriever is disconnected. Retriever and service valve hook-up is indicated in Figure 1. The service valve assembly is basically a ball type valve with full-opening port with a special pressure equalizing port which allows the operator to slowly release line pressure to the retriever. With pressure balanced on both sides of the ball, the valve can be operated without difficulty or torque problems, even on high pressure systems. The valve also incorporates a secondary special built-in vent to atmosphere valve allowing product bleed-off away from the operator for safety and cleanliness. With the aid of the optional accessory, diverter hose assembly, the bleed valve can also be used for product sampling, back-pressuring for product or pressure relief. Should the solid or hollow plug thread, packing, or o-ring become damaged, preventing service valve removal, a service valve blanking plug can be used to seal the open end of the valve.

Fig. 7-4. TKS service valve assembly.

The service valve blanking plug, available as an optional accessory, is mated to the ACME thread of the service valve after removing the retriever. This provides a secondary seal for the valve. The service valve can then be left in place, completely sealing the access fitting until corrective repairs can be made at a later time. Flanged valves, alternative materials and high temperature valves are available on special order.

TKS K SERVICE VALVE DIMENSIONS & WEIGHT DESCRIPTION Service valve face to face dimension Service valve end to end dimension Dimension assembly weight (kg) Dimension valve cubage

DIMENSION 179.5 cm (7.07'') 232 cm (9.12'') 16.2 Kg 1.00 ft cubic


7-3

7-4

KOROSI SPECINDO ORDERING PROCEDURE Pressure rating

Description X

TKS Tool KS6000

XX

Service Valve

K

36

3600 psi

60

6000 psi

Client ordering: TKS-K-36 à Service valve with 3600 psi pressure rating

Part number

Description

TKS

XX

X

P

Spare part

Accessories T

Tool

VS

Service valve seal kit

VR

Service valve repair kit

TC

Thread chaser

SR

Seat reamer

BP

Blanking plug

Client ordering: TKS-P-VS à Service valve seal kit

SERVICE VALVE REPAIR AND SEAL KITS Description

P/N

Repair kit

Bonnet

CS

TKS6000-102

Yes

Stem

316L SS

TKS6000-103

Yes

Ring back-up

SS

TKS6000-108

Seal stem

Viton

TKS6000-109

Ring thrust

SS

O-Ring

Viton

TKS6000-110

Yes Yes Yes Yes

TKS6000-111,114,117,118

Ball

316L SS

TKS6000-112

Yes

Carrier seat

316L SS

TKS6000-113

Yes

Ring seat seal

PEEK

TKS6000-115

Bleed valve 1/4'' NPT

TKS6000-122

Fig. 7-5. TKS service valve seal & repair kits.


Seal kit

Yes Yes

KOROSI SPECINDO

TKS THT HOT TAP TOOL AND ACCESSORIES Two inch system access fittings can be installed on the line or vessel while on line condition without shutdown or drain procedure. After the proper welding and hydrostatic procedure were done, using this hot tap assembly tool will provide the safe way to make hole on pipe wall under pressure, without worry of any spile or chips falling down to the stream. A variety of cutting tools can be used to cut the hole including step drills, cutters and end mills. The tool may also be used to cold tap fittings after welding during normal fabrication as it provides excellent control of hole size and alignment. The hot tap procedure may be summarized as follows: l Measure wall thickness of pipe or vessel at selected location l Weld two inch access fitting in place and hydrotest the weld using hydrostatic test plug l Install TKS K service valve into two inch access fitting l Install the hot tap machine and cutter, attach the tool body l Rotate the tool handles clockwise to cut the aperture l Disconnect the tool body from the hot tap plug after hot tapping process completed Hot tapping may be performed with line pressures up to 1440 psi (248 bar) and temperatures up to 240°F (115°C). Hot tap kit comprises all necessary items for the tapping procedure (except for the retriever and service valve kits) in a field carrying case.

Fig. 7-6. Model TKS THT hot tap tool.

NOTE: Hot tap operations must be performed by properly trained and qualified personnel working to approved procedures agreed by the user's safety authority. Service and training engineers are available from KOROSI SPECINDO technical service.


7-5

7-6

KOROSI SPECINDO HOT TAP KIT P/N

Description

Seal kit

Repair kit

Seal Packing

TKS6000-009

Bearing

TKS6000-013

Viton O-Ring

TKS6000-018

Retainer

TKS6000-017

Yes

Packing Retainer Brass

TKS6000-008

Yes

Yes Yes Yes

ORDERING PROCEDURE Part number

Access system

T

XXXXXX

&

X

XX

T

Tool

A

Accessory

S

Spare Part

Two inch

Tool

KS6000

accessories

system access fitting

Fig. 7-7. Types of cutter.


Description

Type HT HD EM SD C4 C6 HT MS TK HS HP HG HB

Hot Tap Kit Hollow Drill End Mill Step Drill 4 Tooth Cutter 6 Tooth Cutter Hydrostatic Test Plug Assy Magnetic Swap Assy Tool Kits Hot Tap Spare Part Kit Hot Tap Plug Assy Hot Tap Gland Hot Tap Box

KOROSI SPECINDO

TKS RP MECHANICAL RETRIEVER TKS RP retriever manufactured by KOROSI SPECINDO provides safety and ease of operation for retrieval of any two inch system corrosion monitoring devices. TKS RP retriever tool has unique features: Extension of rod moves with mechanical system to allow a safe operation l Compact design, easy to use and light weight l All main parts are made from 316L SS which complies to NACE MR0175/ISO15156-1 l Sealing within the unit is achieved with viton o-ring and graphite impregnated teflon seals l A bleed valve assembly incorporated in the TKS RP retriever allows product bleed off away from operator for safety and cleanliness. It can also be used for fluid sampling. l

This retriever operates on a mechanical system by means of a rotating hand wheel. Careful maintenance is essential to obtain maximum lifetime of the equipment. It should be dismantled and cleaned after each use and seals are replaced regularly, especially, after hot tapping process (first time installation) as metal chips can cause damage on gear rack. Seals and repair kits are available which provide the necessary items for major or minor overhauls. TKS RP retriever assembly is furnished with service tools. Parts subject to wear with normal use are available in seal and repair kits. The retriever assembly, service tools and spare parts are contained in a sturdy box to provide easy storage and portability. Fig. 7-8. Model TKS RP retriever tool.


7-7

7-8

KOROSI SPECINDO TKS RP retriever assembly with various standard stroke lengths are indicated in the table below. Special stroke length is available on special order basis. please contact KS Sales.

Item

Description

A B

PARKER 08YK 4 M4F-SN

Stroke length* 14"

18"

25"

37"

49"

61"

Retrieval tool overall length - inches

35

39

57

81

105

129

Max. holder / probe length - inches

4

8

15

27

39

51

Retriever and service valve overall C

length to access fitting upper end - inches

44

52

66

90

114

138

D

Recomended clearance - inches

56

64

78

102

126

150

Weight - lbs

45

47

50

54

59

63

3

* Stroke length custom order is available, contact KS Sales Figure 7-9

Ordering Procedure The length of stroke required governs sizing of retrievers. The stroke length is defined as the distance of the solid/hollow plug assembly and the corrosion coupon holder/ corrosion probe must travel from the plug’s seated position within the access fitting body through the service valve allowing the ball valve to be closed.

Part number TKS

Tools KS

Client Ordering: TKS RP - 18 - 36


Description XXXXX

RP

Retriever Tool

Stroke length XX 14

14” Stroke

18

18” Stroke

25

25” Stroke

37

37” Stroke

49

49” Stroke

61

61” Stroke

Pressure rating XX

36

3600 Psi

60

6000 Psi

Retriever TKS RP with 18” stroke and 3600 psi pressure rating.

KOROSI SPECINDO

Part Number

Description X

CRP

A

Accessories

S

Spare Part

Component retriever RP6000

XX DH ST TT TB OA BP DH RK SK WS BH SA RB-XX

Diverter hose assembly Surge tube assembly Thread tap Thread brush Overshot adapter Back pressure pump Diverter hose assembly Retriever repair kit Retriever seal kit Wrench set Brass hammer Socket adapter assembly Retriever box (xx= stroke length available are 18” , 25”, 37”, 49” and 61”)

Client ordering: CRP-A-BP

Component retriever RP6000 accessories, back pressure pump.

Fig. 7-10. Components and spare parts of TKS RP retriever assembly.


7-9

7-10

KOROSI SPECINDO

TKS6000 KHT HOT TAP TOOL AND ACCESSORIES Model TKS6000 hot tap tool provides hot tapping of two inch system access fittings onto pipeline while under operation pressure (up to 3600 psi) safely without product loss. Three different types of cutter are provided: 6 teeth cutter for small pipe diameter, 4 teeth cutter for thick pipe wall and ball end mill cutter for correcting access fitting bore and pipe hole misalignment. Operation of hot tap tool can be manually driven or motor driven in a range of 80 to 100 rpm. After finishing hot tapping, service valve and retriever tools must be in place to retrieve the cutter assembly from the access fitting in case of under operating condition. Hot tap tool comes complete with accessories inside a heavy duty carrying box.

Fig. 7-11. TKS6000 KHT hot tap tool. DESCRIPTION

Magnetic Accessories

Hot tap tool box weight = 56 lbs (26 kg) Hot tap tool box volume = 1.73 Cu.ft


Various Cutter

PART NUMBER

Hot tap kit

KS842621

Feed screw assembly

KS173602

Hydrostatic tester assembly

KS823121

Magnetic swap assembly

KS078121

Chip remover assembly

KS294321

Cutter, 6 tooth

KS129321

Cutter, 4 tooth

KS015302

Cutter, square end mill

KS755802

Repair kit

KS511121

S ECTION 8 ONE INCH RETRACTABLE COUPON HOLDER, ELECTRICAL RESISTANCE (ER) PROBE, LINEAR POLARIZATION RESISTANCE (LPR) PROBE, SAMPLING, CHEMICAL INJECTION AND RETRACTOR TOOL

KOROSI SPECINDO

ONE INCH RETRACTABLE ACCESS SYSTEM GENERAL OVERVIEW An extremely reliable access system widely used by the petrochemical and oil production industries. A simple and versatile method of access to a process stream for on-line insertion and removal of coupons, probes, injection and sampling systems. Suitable for service at 1000 psi or 1500 psi with options for additional back up seals in gas applications. The operating temperature of 260 oC may be extended to 450 oC by the use of graphite packing provided the insert component is also compatible. One inch retractable access system comprises of a packing gland assembly, coupon holder/probe, safety clamp and branch assembly with valve. The coupon holder, probe or inserted device has a diameter of 5/18" and stainless steel body, which can slide through the packing seal while retaining pressure integrity. The packing assembly is mated to the ambient side of the valve so when it is open the inserted device can be inserted into the process stream. The reverse process allows the inserted device to be retracted, then, the valve can be closed and the packing gland assembly can be removed for servicing. The inserted device is secured in place with an additional plate and rod of the safety clamp. For operating pressure above 250 psi, it is adviseable to use a retractor tool which provides mechanical advantage and safety during the insertion and retraction cycles. The packing gland assembly is available with 1" FNPT or flanged connection and AISI 316 SS body. Seals are reinforced PTFE. It is important that the internal diameter of any existing branch assembly is clearly identified before ordering equipment. A minimum 7/8" hole diameter on the valve must be provided since the safety stopper inserted devices has 3/4" diameter.

The following pages provide detailed information on length calculation and ordering procedure for the one inch retractable access system.

Safety clamp

Packing gland assembly

1" NPT Nipple

1" Full bore ball valve

1" NPT threadolet

Safety stopper Coupon holder, probe, sampling or injection tube

Remark I : depth of insertion W : wall thickness H : height of valve with branch assembly (282 mm for NPT packing gland and 260 mm for flanged packing gland) T : distance below the packing gland assembly P : height of the NPT packing gland assembly plus the travel distance (170 mm for NPT packing gland and 280 mm for flanged packing gland) Fig. 8-1. General arrangement drawing of one inch retractable access system.


8-1

8-2

KOROSI SPECINDO

MODEL KS500 SERIES RETRACTABLE CORROSION COUPON HOLDER

Fig. 8-1. Model KS510 retractable coupon holder.

Specifications Ø Maximum operating pressure : 1500 psi Ø Temperature Rating Ø Method of operation Ø Insertion rod diameter Ø Size of packing gland Ø Packing gland seals

Ø Material of construction Ø Coupon type

: 260 oC (reinforced PTFE packing) 450 oC (graphite packing) : insertion and removal using a retractor tool : 5/8" OD (standard) : 1" NPT 1", 1.5" or 2" Flange : reinforced PTFE or graphite packing : AISI 316 SS : single/double flat coupon, flush disc coupon, rod coupon or multiple disc coupon Note: maximum coupon size is determined by the valve size and the insertion rod must be marked to allow flat coupons to be properly installed.

Model KS500 series retractable corrosion coupon holder is compact, sturdy and lightweight. When operated with a retractor tool, it is the easiest operated low pressure coupon holder available on today’s market. The retractor remains in place only during insertion and removal of coupons, therefore, one retractor can service many KS500 series coupon holder.


KOROSI SPECINDO

To calculate length of retractable strip coupon holder wth 1" bore size NPT packing gland:

To calculate length of retractable strip coupon holder wth 1" bore size 300# flanged packing gland:

Example: 8" pipe, schedule 80, wall thickness 12.7 mm. 1" bore size retractable coupon holder at middle of line installation and depth of insertion 101.6mm

Example: 8" pipe, schedule 80, wall thickness 12.7 mm. 1" bore size retractable coupon holder at middle of line installation and depth of insertion 101.6mm

1. Determine distance below the packing gland (T) T=I+W+282=101.6+12.7+282=397 mm


2. When value of T has been calculated look into table 6.1 under column “DIM B” for closest value. Under the same line check the value of code (nominal insert). This nominal insert value is your order length. DIM B value > T value 502 mm > 397 mm Order length: 18"

2. When value of T has been calculated look into table 6.1 under column “DIM C” for closest value. Under the same line check the value of code (nominal insert). This nominal insert value is your order length. DIM B value > T value 392 mm > 374 mm Order length: 18"

3. Calculate clearance above pipe wall clearance=H+DIM B+P+100 = 282+502+170+100 = 1054 mm = 41.5"

3. Calculate clearance above pipe wall clearance=H+DIM C+P+100 = 260+392+280+100 = 1032 mm = 40.5"

ORDERING PROCEDURE MODEL Ks510 Ks520 Ks530

RETRACTABLE COUPON HOLDER Coupon holder with 1" NPT packing gland Coupon holder with flanged packing gland Coupon holder only

Reinforced PTFE packing Graphite packing (high temp.)


8-3

8-4

KOROSI SPECINDO

MODEL KS500 SERIES RETRACTABLE SAMPLING AND INJECTION SYSTEMS

Fig. 8-2. Model KS550 retractable sampling/injection system.


Ø Material of construction Ø Injection/sampling type

: 260 oC (reinforced PTFE packing) 450 oC (graphite packing) : insertion and removal using a retractor tool : 5/8" OD (standard) : 1" NPT 1", 1.5" or 2" Flange : reinforced PTFE or graphite packing : AISI 316 SS : open, plain, notched and nozzle Note: maximum inserted device size is determined by the valve size and the insertion rod must be marked to allow properly alligned orientation.

A comprehensive range of 5/8" diameter retractable insert for injection of chemicals and process sampling up to 260 oC and 1500 psi operating pressure, with optional 450 oC temperature. Standard insert tubes allow a range of quills and nozzle holder attachments to be used.


KOROSI SPECINDO

To calculate length of retractable injection/sampling with 1" bore size NPT packing gland:

To calculate length of retractable injection/sampling with 1" bore size 300# flanged packing gland:

Example: 8" pipe, schedule 80, wall thickness 12.7 mm. 1" bore size retractable injection quill at middle of line installation and depth of insertion 101.6mm

Example: 8" pipe, schedule 80, wall thickness 12.7 mm. 1" bore size retractable injection quill at middle of line installation and depth of insertion 101.6mm



2. When value of T has been calculated look into table 6.1 under column “DIM B” for closest value. Under the same line check the value of code (nominal insert). This nominal insert value is your order length. DIM B value > T value 502 mm > 397 mm Order length: 18"

2. When value of T has been calculated look into table 6.1 under column “DIM C” for closest value. Under the same line check the value of code (nominal insert). This nominal insert value is your order length. DIM B value > T value 392 mm > 374 mm Order length: 18"

3. Calculate clearance above pipe wall clearance=H+DIM B+P+100 = 282+502+170+100 = 1054 mm = 41.5"

3. Calculate clearance above pipe wall clearance=H+DIM C+P+100 = 260+392+280+100 = 1032 mm = 40.5"

ORDERING PROCEDURE Ks550 Ks560 Ks570

Injection/sampling with 1" NPT packing gland Injection/sampling with flanged packing gland Injection/sampling quill only

Open/flush Plain sampling quill Notched quill Nozzle vertical narrow cone, 20 mm Nozzle vertical wide cone, 20 mm Reinforced PTFE packing Graphite packing (high temp.)


8-5


Table 8.2

Table 8.1

672 822 972 7722 1272 649 799 949 1099 1249 670 820 970 1120 1270 649 799 949 1099 1249

8-6 KOROSI SPECINDO

KOROSI SPECINDO

MODEL R1500 SERIES RETRACTABLE ER PROBE (FLUSH, TUBULAR, WIRE LOOP AND TUBE LOOP)

Bore

Fig. 8-3. Model KS1502 retractable ER probe and general arrangement drawing of retractable ER probe installation.


Ø Material of construction Ø Element seal

: 150 oC (epoxy sealant) 260 oC (glass and weld sealants) : insertion and removal using a retractor tool : 5/8" OD (standard) : 1" NPT 1", 1.5" or 2" Flange : reinforced PTFE or graphite packing : AISI 316 SS : Epoxy or glass

A comprehensive range of ER probes for making metal loss measurements in process up to 1500 psi and 260 oC. Probes have bodies made from AISI 316 SS and 6 pin plated connector. Retractable probes are typically used for continuous on-line monitoring and well knowned for being easy to install and maintain.


8-7

8-8

KOROSI SPECINDO

CALCULATION: Length of retractable ER probe for NPT packing gland 1. Determine distance below the NPT packing gland (T): T = I+W+282 For 1" bore size NPT packing gland T = I+W+314 For 1.5" bore size NPT packing gland T = I+W+327 For 2" bore size NPT packing gland where, I : Depth of insertion ER probe (mm) W : Wall thickness (mm) 2. When value of T has been calculated look table 8-3 under “DIM B” column for closest value. Under the same line, check the norminal insert code. This norminal insert code is your order length. Dim B value > T value Order length XX” 3. Calculation clearance above pipe wall (C): C = 282+DIM B+P+100 For 1" bore size NPT packing gland C = 314+DIM B+P+100 For 1.5" bore size NPT packing gland C = 327+DIM B+P+100 For 2" bore size NPT packing gland where, DIM B : distance available below the NPT packing gland (mm) P : height of the NPT packing assembly plus the travel distance (170 mm)

Length of retractable ER probe for flanged packing gland 1. Determine distance below the flanged packing gland (T): T = I+W+K1 For 1" bore size flanged packing gland T = I+W+K2 For 1.5" bore size flanged packing gland T = I+W+K3 For 2" bore size flanged packing gland where, I : Depth of insertion ER probe (mm) W : Wall thickness (mm) K1, K2, K3 : constant, see Table 8.4 2. When value of T has been calculated look table 8-3 under “DIM C” column for closest value. Under the same line, check the norminal insert code. This norminal insert code is your order length. Dim C value > T value Order length XX” 3. Calculation clearance above pipe wall (C): C = K1+DIM C+P+100 For 1" bore size NPT packing gland C = K2+DIM C+P+100 For 1.5" bore size NPT packing gland C = K3+DIM C+P+100 For 2" bore size NPT packing gland where, DIM B : distance available below the NPT packing gland (mm) P : height of the NPT packing assembly plus the travel distance (280 mm)


KOROSI SPECINDO

Table 8.3

100 100

For any given length, Dim B is the distance below the NPT packing gland and Dim C is the distance below flanged packing gland. These are equivalent to (T) in the above method

Table 8.4


8-9

8-10

KOROSI SPECINDO

ORDERING PROCEDURE Retractable Retractable Retractable Retractable

flush probe loop probe tubular probe sand probe

Probe insert packing Probe, standard packing and probe Probe, high temperature packing and clamp Flush epoxy seal, 16 mm Flush epoxy seal, 19 mm Flush glass seal, 16 mm Flush glass seal, 19 mm Wire loop glass seal Tube loop galss seal Tubular long glass Tubular short glass Tubular long welded Tubular short welded Tubular long high temperature Tubular short high temperature Sand detection, thin gold film Sand detection, CRA element

0


KOROSI SPECINDO

MODEL L1500 SERIES RETRACTABLE LPR PROBE (PROJECTING AND FLUSH) Specifications Ø Maximum operating pressure : Ø

Ø Ø Ø

Ø

Ø Ø

1500 psi Temperature Rating : o 150 C (epoxy sealant) 260 oC (glass sealant) Method of operation : insertion and removal using a retractor tool Insertion rod diameter : 5/8" OD (standard) Size of packing gland : 1" NPT 1", 1.5" or 2" Flange Packing gland seals : reinforced PTFE or graphite packing Material of construction : AISI 316 SS Element seal : Epoxy or glass

A comprehensive range of LPR probes for making corrosion rate measurements in processes up to 1500 psi and 260 oC. Probes have body made of AISI 316 SS and 6 pin plated connectors. Probes with sensor heads over 16 mm diameter have a removable connector flange. For a full range of packing and accessories, see data sheet that recommends the use of a safety clamp assembly. Retractable probes are typically used in refineries; petrochemical plants and low pressure oil production operations. They are used for continuous on-line monitoring situations. Please contact KOROSI SPECINDO for information, advice and design support.

Bore)

Fig. 8-4. Model KS1500 series retractable LPR probe.


8-11

8-12

KOROSI SPECINDO

CALCULATION: Length of retractable LPR probe for NPT packing gland 1. Determine distance below the NPT packing gland (T): T = I+W+282 For 1" bore size NPT packing gland T = I+W+314 For 1.5" bore size NPT packing gland T = I+W+327 For 2" bore size NPT packing gland where, I : Depth of insertion LPR probe (mm) W : Wall thickness (mm) 2. When value of T has been calculated look table 8-3 under “DIM B” column for closest value. Under the same line, check the norminal insert code. This norminal insert code is your order length. Dim B value > T value Order length XX” 3. Calculation clearance above pipe wall (C): C = 282+DIM B+P+100 For 1" bore size NPT packing gland C = 314+DIM B+P+100 For 1.5" bore size NPT packing gland C = 327+DIM B+P+100 For 2" bore size NPT packing gland where, DIM B : distance available below the NPT packing gland (mm) P : height of the NPT packing assembly plus the travel distance (170 mm)

Length of retractable ER probe for flanged packing gland 1. Determine distance below the flanged packing gland (T): T = I+W+K1 For 1" bore size flanged packing gland T = I+W+K2 For 1.5" bore size flanged packing gland T = I+W+K3 For 2" bore size flanged packing gland where, I : Depth of insertion ER probe (mm) W : Wall thickness (mm) K1, K2, K3 : constant, see Table 8.4 2. When value of T has been calculated look table 8-3 under “DIM C” column for closest value. Under the same line, check the norminal insert code. This norminal insert code is your order length. Dim C value > T value Order length XX” 3. Calculation clearance above pipe wall (C): C = K1+DIM C+P+100 For 1" bore size NPT packing gland C = K2+DIM C+P+100 For 1.5" bore size NPT packing gland C = K3+DIM C+P+100 For 2" bore size NPT packing gland where,

DIM B : P

distance available below the NPT packing gland (mm) : height of the NPT packing assembly plus the travel distance (280 mm)

Example : 6” pipe, schedule 80 I = 3” depth of insertion W = 0,3” wall thickness T = I + W + 282 = 3” + 0.3” + 282 mm = 365.8 mm


38** 38** 38** 38** 38** 38** 38** 38** 38** 38**

KOROSI SPECINDO

Retractable projecting type Retractable flush type Probe insert only Probe + standard packing and clamp Probe + high temp. packing and clamp

2 3 2 3

Standard electrodes Standard electrodes Reduced area electrodes (only for L1500 model) Reduced area electrodes (4-40 UNC, only for L1500 model)

2 Standard electrodes 3 Standard electrodes 2 Reduced area electrodes (only for L1500 model) 3 Reduced area electrodes (4-40 UNC, only for L1500 model) 2 Standard electrodes pair (only for G code electrode)


8-13

8-14

KOROSI SPECINDO

MODEL KS500 SERIES RETRACTOR TOOL AND ACCESSORIES KS 500 retractor tool is a simple mechanical device that allows the KS500 series coupon holder, sampling/injection tubes and probes to be inserted and retracted through the packing gland assembly at working pressure where manual operation is not advisable. The tool gives complete control of the position of the inserted devices while the packing gland lock nut is release to allow insertion or retraction. Clamp arrangements grip the insert head and the packing gland. When the distance between the two clamps is altered by rotating the handle at the base of the unit, the insert devices is pulled or pushed through the packing gland to the desired position. Retractor tools are available in 24" or 36" lengths. The length refers to the longest nominal insert device length which the tool will accomodate, extra long model can be specially ordered. The tool is a lightweight construction and uses quality materials to provide a reliable and robust product. It can be mounted and operated in any orientation, allowing retraction of probes in the 6 o’clock position for example. A carrying case and manual are supplied with each tool. Gross weight of 20 Kg and operating radius 0.24 m (9.50").

ORDERING PROCEDURE

Fig. 8-5. General arrangement drawing of retractor tool.

SPARE PART


KOROSI SPECINDO

RETRACTABLE COMPLETE ASSEMBLY SERIES Offering a standard assembly of retractable access system for complete installation and also as a spare for equipment replacement.

Entry Valve,


8-15

8-16

KOROSI SPECINDO


KOROSI SPECINDO

KS500 ADAPTER KS500 adapter accomodates conversion of using two inch access system to using one inch retractable access system.

ACME access fitting adapter (external) This adapter screws on the outside of the two inch access fitting. A valve is then placed on the 1/2" - 2" NPT male threads. The adapter can be welded if required. It is to be noted that 2" NPT size adapter can be installed under pressure, while others must be installed under pressure free condition. Fig. 8-6. ACME access fitting adapter (external).

ACME access fitting adapter (flange) This adapter converts any ACME thread access fitting to a flanged installation. The adapter screw onto the ACME thread access fitting, weld if required, then a flanged valve can be attached. Fig. 8-7. ACME access fitting adapter (flange)

ORDERING PROCEDURE


8-17

8-18

KOROSI SPECINDO

MODEL L300 SERIES LABORATORY AND NPT PROBE (FLUSH, TUBULAR, WIRE LOOP AND TUBE LOOP)

Fig. 8-8. Model L300 NPT fixed ER probe.

Specifications Ø Maximum operating pressure : 100 psi (laboratory probe) Ø Temperature Rating

1500 psi (NPT probe) : 150 oC (epoxy sealant) 260 oC (glass and weld sealants)

Ø Material of construction Ø Element seal Ø Probe body material

: AISI 316 SS : Epoxy, glass or weld : AISI 316 SS

This selection of corrosion monitoring probes cover a complete range of ER and LPR probes in low and medium pressure configurations. These probes are for fixed installation and they can not be installed or changed in pressurized systems without shutdown. Laboratory probe is used for a variety of low pressure tasks. It has no threaded mounting but it is suitable for use with laboratory glass compression fittings and rubber bung insertion. The standard probe is epoxy sealed with stainless steel body. NPT fixed probe has a fixed insertion length below the NPT mounting thread. It is used for a variety of industrial corrosion monitoring tasks, such as, a pressurized test rigs or side stream test. It is suitable for interruptible and batch processes or locations where temporary isolation is available for installation and retrieval. The NPT thread configuration requires only a simple threadolet type fitting on the target pipework or vessel. NPT adjustable probe is similar in most respects to a NPT fixed probe with the added benefit of a variable insertion length through an addition of a swagelock tube fitting, ideal for applications where the equipment may be moved between locations with different insertion requirements due to variation in pipe diameter and wall thickness.


KOROSI SPECINDO

INSTRUMENT CONNECTIONS All probes are fitted with a 6 pin Mil-C-5015 connector which is compatible with all KOROSI SPECINDO instrumentation and any other instruments. All probes connectors are stainless steel with silver plated pin and threaded shells.

Fig. 8-9. General arrangement drawing of NPT ER probe.

CALCULATING PROBE LENGTHS FOR NPT PROBES In order to calculate the length of NPT probes, please refer to Fig. 8-9 and ensure the following informations are available: 1. The height (H) of the threaded fitting (threadolet) above the pipe wall in milimeters 2. The wall thickness (W) of the pipe in milimeters 3. The distance of the probe’s element that extends beyond the pipe wall in milimeters Look up the thread make-up distance (T), in Table 8-5, for the probe model you have selected. Order length = (H+W+D)-T Once you have calculated the order length, please refer to the Table 8-5 to find either: 1. A standard fixed probe length that is close enough in length to meet the requirement 2. A standard adjustable probe length with an insertion length that exceeds the order length required In either case, if you find that the standard probe length will meet the requirement, insert the letter STD into the product code section for length. If the standard probe length does not meet your requirement, insert the calculated length in millimeter into the probe code, remembering to use a three digits whole number e.g.: 098. Please note: it is not possible to order probes shorter than the minimum length for each type given in the table. In the case of adjustable probe, the minimum length and the order length define the lower and upper limits of the possible insertion. For example: a standard 1" NPT tubular probe with adjustable length has a possible insertion range between 125 mm and 325 mm below the probe thread. Accessories: we can supply mounting threadolet in all sizes and most materials, as well as extension cables.


8-19

All length is in mm and it is for standard KS electrode, for reduced type substract by 006 Order length shown in bold is standard, write “STD” in product or calculate other length in mm Codes: F=fixed length; ADJ=adjustable swagelock; F+A=available in fixed and adjustable style Adjustalbe 1-1/2" and 2" only available to special order Minimum insertion=shortest order length for fixed probes or least insertion for adjustable

8-20 KOROSI SPECINDO


KOROSI SPECINDO

NPT No - Thread

Wire loop Tube loop Tubular 4" Tubular 2" Flush epoxy Flush glass


8-21

8-22

KOROSI SPECINDO

NPT No - Thread

Projecting Flush 2 3 2 3


Standard electrode Standard electrode Reduced area electrode (only for PE type) Reduced area electrode (only for PE type)

S ECTION 9 KS DOUBLE BLOCK AND BLEED VALVE

KOROSI SPECINDO

MODEL KSDBB 6000 SERIES DOUBLE BLOCK AND BLEED VALVE KSDBB 6000 series feature independent quarterly open and close double ball valves for isolation service equipped with a heavy duty globe style needle valve for venting service.

Fig. 9-1. Model KSDBB 6001 (bolted connection).

KSDBB 6000 series are available in modular and one-piece-body designs. Flanged or NPT threaded connection, are possible for direct mounting to pipeline and vessel. KSDBB 6000 series comply to NACE MR 0175/ISO 15156. In addition, they are fire tested proof and fugitive emission tested proof in accordance to API 607/API 6A and ISO 15848, respectively. Application of KSDBB: 1. Sampling / chemical injection 2. Instrumentation valve 3. Isolation valve

Fig. 9-2. Model KSDBB 6003 (one piece body).

Upper

Upper

Bottom

Bottom

Vent

SAMPLING

CHEMICAL INJECTION

Upper connection Bleed/vent valve Bottom connection

Fig. 9-3. Typical application of KSDBB.


9-1

9-2

KOROSI SPECINDO

FEATURES AND STANDARD REFERENCE: Ø NPT threaded female outlet/inlet, process and vent connections are in compliance to Ø Ø

Ø

Ø Ø Ø Ø Ø

ANSI B1.20.1 Material thickness of pressure containing body conforms to ANSI B16.34 Flanged outlet/inlet and process connections, ½ to 2" size with 150 to 2500 lb and beyond 2500 lb class ratings, are in accordance to ANSI B16.5 and API SPEC 6A, respectively Valve inspection and testing comply to API STD 598 and API SPEC 6D Evaluation of valve construction and quality assurance program follows API RP 591 Material traceability according to ISO 9001:2000, item 7.5.3 Sour service suitability, NACE MR 0175 / ISO 15156 Fire tested proof, API 607 / API 6FA Fugitive emission tested proof, ISO 15848

Remark C : FG : PW : MF : WG : POD :

LENGTH CALCULATION PROCEDURE Center of line C+FG+MF+WG+PW+0.5POD


0.375" (constant) flange face to face gap pipe wall thickness mating flange height welding gap pipe outer diameter

KOROSI SPECINDO

ORDERING PROCEDURE

Modular design with bolt connection One piece body design (not available with 1/2" - 1" flange size) One piece body design with integral check valve (not available with 1/2" - 1" flange size) Modular design with integral check valve One piece body design with ball bleed valve (not available with 1/2" - 1" flange size)

6001 6003 6004 6005 6006 6007

One piece body design with ball bleed valve with integral check valve (not available with 1/2" - 1" flange size)

BOTTOM CONNECTION

BC

1 2 3 4 5

A B C D E

1/2" 3/4" 1" 1-1/2" 2"

F G

2-1/16" 1-13/16"

H I

3" 3/8"

Flange RF Flange RJ Flange API RJ NPT FF

L

15000

UPPER CONNECTION

UC

A B C D E

1/2" 3/4" 1" 1-1/2" 2"

F G

2-1/16" 1-13/16"

H I

3" 3/8"

CS10 CS05 XXXX

1 2 3 4 5

Flange RF Flange RJ Flange API RJ NPT FF

L

ASTM A105 CS ASTM A350 LF2

15000

FOR OTHER MATERIALS OPTION CONSULT KS

FP

GRPHITE FILLED PTFE

PP

PURE PEEK

PK

REINFORCED PEEK

XX

FOR OTHER MATERIALS OPTION CONSULT KS

SIZE OF NPT END CONNECTION 1

1/4"

2

1/2"

3

3/4" (not available with modular design)

4

1" (not available with modular design)

SIZE OF NPT VENT CONNECTION 1

1/4"

2

1/2"

FIRE SAFE DESIGN F

FIRE SAFE

N

NON FIRE SAFE

BORE SIZE (MM)

KSDBB

-

BCA1D-UCA10-SA03 - PK -

1

- 1

-

N

1

10

2

15 (not available with 1/2"-1" flange design)

- 1

-

6001


9-3

9-4

KOROSI SPECINDO

KSDBB ACCESSORIES FOR SAMPLING AND CHEMICAL INJECTION ORDERING PROCEDURE A) The double block and bleed valve design and connection size/type can be selected from the previous page. B) The sampling and injection probe size and length can be selected from the below table. 1/4" NPT 1/2" NPT 3/4" NPT 4

1" NPT

C) Determine a nipple connection, check valve and shut off valve from the below table.

1/4" NPT 1/2" NPT

D) If applicable select a suitable nozzle assembly cap and core from the below table.

E) Determine blanking plug using the below table.


KOROSI SPECINDO

KSDBB SPARE PARTS ORDERING PROCEDURE

SERIES DESCRIPTION 6001

MODULAR DESIGN WITH BOLT CONNECTION

6003

ONE PIECE BODY DESIGN (not available with 1/2"-1" flange size)

6004

ONE PIECE BODY DESIGN WITH INTEGRAL CHECK VALVE (not available with 1/2"-1" flange size)

6005

MODULAR DESIGN WITH INTEGRAL CHECK VALVE

6006

ONE PIECE BODY DESIGN WITH BALL BLEED VALVE (not available with 1/2" - 1" flange size)

6007

ONE PIECE BODY DESIGN WITH BALL BLEED VALVE WITH INTEGRAL CHECK VALVE (not available with 1/2" - 1" flange size)

Fig. 9-4. KSDBB seal and repair kit.


9-5

APPENDIX GUIDE TO MATERIAL CODES FOR USE WITH ER/LPR PROBE

Corossion Coupon FullCatalog

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