Metal Samples catalog

Corrosion Coupons 

Corrosion Monitoring 

Materials Evaluation 

Precision Machining 

Sales Staff 

About Us 

ISO 9001 Certified 

Contact Info 

New Products & Svcs. 

Catalog XI.6

Metal Samples Company is a division of Alabama Specialty Products, Inc. (ASPI) and works in association 

with other divisions of ASPI to provide you with a wide range of products and services. 

• Materials evaluation products 

• Corrosion monitoring products 

• Precision machining services 

• Laser cutting & welding services 

• Laser systems and equipment 

• Specialized laser R&D services 

• Maufacturing research 

• Medical equipment 

For more information on our company divisions, call for a product brochure or visit our corporate web site at: 

www.alspi.com

Business Philosophy 

Metal Samples, a division of Alabama Specialty Products, Inc., is committed to superior quality, 

quick delivery, fair pricing, and excellent service. With our rapidly-expanding physical plant, stateof-the-art 

equipment, ever-broadening product lines, dedicated research, and highly-skilled work 

force, we stand ready to meet your specific manufacturing needs. 

However, it takes more than buildings, equipment, and personnel to produce excellence; it takes 

espirit de corps. That is why our company works energetically as a whole, realizing the significance 

of our motto, “May the beauty of the LORD our GOD be upon us and may He establish the work 

of our hands.” Psalm 90:17.

About Metal Samples 

Metal Samples specializes in manufacturing 

products for corrosion monitoring & materials 

evaluation and in providing precision machining 

services. Since 1980 we have supplied products 

and services to nuclear, medical, aerospace, 

chemical processing, water treating, and 

petroleum industries around the world. 

From the beginning, founder Don Johnson's goal has been to operate this business based 

on Christian principles. With blessings from God, Metal Samples has grown to include 200 

employees and continues to develop new products and technologies to meet the growing 

needs of our customers.

Metal Samples Contact Info 

Home Office: 

P.O. Box 8, 152 Metal Samples Rd. 

Munford, AL 36268 

Phone: (256) 358-4202 

Fax: (256) 358-4515 

E-mail: msc@alspi.com 

Web site: www.metalsamples.com 

Houston Sales Office: 

6327 Teal Mist Lane 

Fulshear, TX 77441 

Phone: (832) 451-6825

Alabama Specialty Products, Inc. (ASPI) 

Executive Staff 

Don Johnson 

ASPI CEO 

James Gray 

Metal Samples President 

Brad Finley 

Vice President 

Metal Samples 

Sales & Support Staff 

Brenda Smith 

Sales Manager 

Cindy Maddox 

Int’l. Coordinator 

Bertha Benjamin 

Sales Rep. 

Rob Huntley 

Sales Rep. 

Andrew Abbott 

Sales Rep. 

Deborah Tinney 

Sales Rep. 

Ron Weishaar 

Sales Mgr. (Houston)

Terms & Delivery Services 

• Terms - Net 30 days (subject to credit approval) 

• Minimum order inside USA - $100.00 

• Minimum order outside USA - $300.00 

• Overnight delivery available for many stock items 

• Orders outside the USA subject to additional charges 

• VISA, MASTERCARD, and AMERICAN 

EXPRESS accepted. 

(Full terms & conditions at www.metalsamples.com.) 

Engineering / Design / CAD 

Our CAD department uses the latest in computer-aided drafting and design 

technology, including 3-D modeling software. 

Our engineering team has experience in corrosion, aerospace, electrical, 

mechnical, manufacturing, and materials engineering. These engineering 

capabilities, coupled with our machining expertise, allow us to help our 

customers find solutions to their specific application needs. 

Quality Assurance (ISO 9001) 

We emphasize high standards when it comes to the quality of your parts. To ensure the finished product will 

meet our customers approval, we maintain advanced training for personnel, procurement of state-of-the-art 

inspection equipment, and constant upgrading in our quality control area. 

Our quality assurance begins with the receipt of raw materials and is adhered to throughout the manufacturing 

process until the final product is shipped. Technicians use high-tech inspection equipment to check the accuracy 

of your parts. Our quality assurance program is ISO 9001 certified, guaranteeing the highest quality on all of 

your orders.


Introduction to Corrosion Monitoring 

Corrosion Coupons for Monitoring 

Electrical Resistance (ER) Monitoring 

Linear Polarization Resistance (LPR) Monitoring 

Specialized Monitoring 

High Pressure Access Systems 

Injection & Sampling Systems 

Accessories 

Return to Main menu

Introduction to Corrosion Monitoring 

What is Corrosion Monitoring 

The field of corrosion measurement, control, and prevention covers a very broad spectrum of technical 

activities. Within the sphere of corrosion control and prevention, there are technical options such as cathodic 

and anodic protection, materials selection, chemical dosing and the application of internal and external 

coatings. Corrosion measurement employs a variety of techniques to determine how corrosive the environment 

is and at what rate metal loss is being experienced. Corrosion measurement is the quantitative method 

by which the effectiveness of corrosion control and prevention techniques can be evaluated and provides the 

feedback to enable corrosion control and prevention methods to be optimized. 

A wide variety of corrosion measurement techniques exists, including: 

Non Destructive Testing 

Analytical Chemistry 

• Ultrasonic testing 

• pH measurement 

• Radiography • Dissolved gas (O 2 

, CO 2 

, H 2 

S) 

• Thermography • Metal ion count (Fe 2+ , Fe 3+ ) 

• Eddy current/magnetic flux 

• Microbiological analysis 

• Intelligent pigs 

Operational Data 

• pH 

• Flow rate (velocity) 

• Pressure 

• Temperature 

Fluid Electrochemistry 

• Potential measurement 

• Potentiostatic measurements 

• Potentiodynamic measurements 

• A.C. impedance 


• Weight loss coupons 

• Electrical resistance 

• Linear polarization 

• Hydrogen penetration 

• Galvanic current 

Some corrosion measurement techniques can be used on-line, constantly exposed to the process stream, 

while others provide off-line measurement, such as that determined in a laboratory analysis. Some techniques 

give a direct measure of metal loss or corrosion rate, while others are used to infer that a corrosive 

environment may exist. 

Corrosion monitoring is the practice of measuring the corrosivity of process stream conditions by the use of 

“probes” which are inserted into the process stream and which are continuously exposed to the process 

stream condition. 

Corrosion monitoring “probes” can be mechanical, electrical, or electrochemical devices.

Corrosion monitoring techniques alone provide direct and online measurement of metal loss/corrosion rate in 

industrial process systems. 

Typically, a corrosion measurement, inspection and maintenance program used in any industrial facility will 

incorporate the measurement elements provided by the four combinations of on-line/off-line, direct/indirect 

measurements. 

• Corrosion Monitoring 

• Non Destructive Testing 

• Analytical Chemistry 

• Operational Data 

Direct, On-line 

Direct, Off-line 

Indirect, Off-line 

Indirect, On-line 

In a well controlled and coordinated program, data from each source will be used to draw meaningful 

conclusions about the operational corrosion rates with the process system and how these are most effectively 

minimized. 

The Need for Corrosion Monitoring 

The rate of corrosion dictates how long any process equipment can be usefully and safely operated. The 

measurement of corrosion and the action to remedy high corrosion rates permits the most cost effective 

plant operation to be achieved while reducing the life-cycle costs associated with the operation. 

Corrosion monitoring techniques can help in several ways: 

(1) by providing an early warning that damaging process conditions exist which may result in a corrosioninduced 

failure. 

(2) by studying the correlation of changes in process parameters and their effect on system corrosivity. 

(3) by diagnosing a particular corrosion problem, identifying its cause and the rate controlling parameters, 

such as pressure, temperature, pH, flow rate, etc. 

(4) by evaluating the effectiveness of a corrosion control/prevention technique such as chemical inhibition 

and the determination of optimal applications. 

(5) by providing management information relating to the maintenance requirements and ongoing condition 

of plant. 

Corrosion - 2

Corrosion Monitoring Techniques 

A large number of corrosion monitoring techniques exist. The following list details the most common techniques 

which are used in industrial applications: 

• Corrosion Coupons (weight loss measurements) 

• Electrical Resistance (ER) 

• Linear Polarization Resistance (LPR) 

• Galvanic (ZRA) 

• Hydrogen Penetration 

• Microbial 

• Sand/Erosion 

Other techniques do exist, but almost all require some expert operation, or otherwise are not sufficiently 

rugged or adaptable to plant applications. 

Of the techniques listed above, corrosion coupons, ER, and LPR form the core of industrial corrosion 

monitoring systems. The four other techniques are normally found in specialized applications which are 

discussed later. 

These corrosion monitoring techniques have been successfully applied and are used in an increasing range of 

applications because: 

• The techniques are easy to understand and implement. 

• Equipment reliability has been demonstrated in the field environment over many years of 

operational application. 

• Results are easy to interpret. 

• Measuring equipment can be made intrinsically safe for hazardous area operation. 

• Users have experienced significant economic benefit through reduced plant down time and 

plant life extension. 

Corrosion Coupons (Weight Loss) 

The Weight Loss technique is the best known and simplest 

of all corrosion monitoring techniques. The method involves 

exposing a specimen of material (the coupon) to a 

process environment for a given duration, then removing 

the specimen for analysis. The basic measurement which is 

determined from corrosion coupons is weight loss; the 

weight loss taking place over the period of exposure being 

expressed as corrosion rate. 

The simplicity of the measurement offered by the corrosion coupon is such that the coupon technique forms 

the baseline method of measurement in many corrosion monitoring programs. 

Corrosion - 3

The technique is extremely versatile, since weight loss coupons can be fabricated from any commercially 

available alloy. Also, using appropriate geometric designs, a wide variety of corrosion phenomena may be 

studied which includes, but is not limited to: 

• Stress-assisted corrosion 

• Bimetallic (galvanic) attack 

• Differential aeration 

• Heat-affected zones 

Advantages of weight loss coupons are that: 

• The technique is applicable to all environments - gases, liquids, solids/particulate flow. 

• Visual inspection can be undertaken. 

• Corrosion deposits can be observed and analyzed. 

• Weight loss can be readily determined and corrosion rate easily calculated. 

• Localized corrosion can be identified and measured. 

• Inhibitor performance can be easily assessed. 

In a typical monitoring program, coupons are exposed for a 90-day duration before being removed for a 

laboratory analysis. This gives basic corrosion rate measurements at a frequency of four times per year. The 

weight loss resulting from any single coupon exposure yields the “average” value of corrosion occurring 

during that exposure. The disadvantage of the coupon technique is that, if a corrosion upset occurs during 

the period of exposure, the coupon alone will not be able to identify the time of occurrence of the upset, and 

depending upon the peak value of the upset and its duration, may not even register a statistically significant 

increased weight loss. 

Therefore, coupon monitoring is most useful in environments where corrosion rates do not significantly 

change over long time periods. However, they can provide a useful correlation with other techniques such as 

ER and LPR measurements. 


ER probes can be thought of as “electronic” corrosion coupons. Like coupons, ER probes provide a basic 

measurement of metal loss, but unlike coupons, the value of metal loss can be measured at any time, as 

frequently as required, while the probe is in-situ and permanently exposed to the process stream. 

In this diagram, a standard ER instrument is connected to a 40 

mil wire loop element which has a useful life of 10 mils. The 

instrument still reads close to zero because the element is new. 

Here the instrument reads around half-scale, indicating that the 

element has experienced about 5 mils of metal loss or about half 

of its useful life. The instrument’s reading is increasing proportionally 

with the resistance of the element, which increases as a 

result of metal loss. 

Here the instrument reads almost full scale, indicating that the 

element has experienced 10 mils of metal loss and requires 

replacement. 

Corrosion - 4

The ER technique measures the change in Ohmic resistance of a corroding metal element exposed to the 

process stream. The action of corrosion on the surface of the element produces a decrease in its crosssectional 

area with a corresponding increase in its electrical resistance. The increase in resistance can be 

related directly to metal loss and the metal loss as a function of time is by definition the corrosion rate. 

Although still a time averaged technique, the response time for ER monitoring is far shorter than that for 

weight loss coupons. The graph below shows typical response times. 

100 

75 

50 

25 

MPY 

5 

MPY 

12 

MPY 

25 

0 2 4 6 8 10 12 14 

Time (Days) 

ER probes have all the advantages of coupons, plus: 

• Direct corrosion rates can be obtained. 

• Probe remains installed in-line until operational life has been exhausted. 

• They respond quickly to corrosion upsets and can be used to trigger an alarm. 

ER probes are available in a variety of element geometries, metallurgies and sensitivities and can be 

configured for flush mounting such that pigging operations can take place without the necessity to remove 

probes. The range of sensitivities allows the operator to select the most dynamic response consistent with 

process requirements. 


The LPR technique is based on complex electro-chemical 

theory. For purposes of industrial measurement applications it 

is simplified to a very basic concept. In fundamental terms, a 

small voltage (or polarization potential) is applied to an 

electrode in solution. The current needed to maintain a 

specific voltage shift (typically 10 mV) is directly related to 

the corrosion on the surface of the electrode in the solution. 

By measuring the current, a corrosion rate can be derived. 

The advantage of the LPR technique is that the measurement 

of corrosion rate is made instantaneously. This is a more powerful tool than either coupons or ER where the 

fundamental measurement is metal loss and where some period of exposure is required to determine 

corrosion rate. The disadvantage to the LPR 

Corrosion - 5

technique is that it can only be successfully performed in relatively clean aqueous electrolytic environments. 

LPR will not work in gases or water/oil emulsions where fouling of the electrodes will prevent measurements 

being made. 

Galvanic Monitoring 

The galvanic monitoring technique, also known as Zero Resistance Ammetry (ZRA) is another electrochemical 

measuring technique. With ZRA probes, two electrodes of dissimilar metals are exposed to the 

process fluid. When immersed in solution, a natural voltage (potential) difference exits between the electrodes. 

The current generated due to this potential difference relates to the rate of corrosion which is occurring 

on the more active of the electrode couple. 

Galvanic monitoring is applicable to the following electrode couples: 

• Bimetallic corrosion 

• Crevice and pitting attack 

• Corrosion assisted cracking 

• Corrosion by highly oxidizing species 

• Weld decay 

Galvanic current measurement has found its widest applications in water injection systems where dissolved 

oxygen concentrations are a primary concern. Oxygen leaking into such systems greatly increases galvanic 

currents and thus the corrosion rate of steel process components. Galvanic monitoring systems are used to 

provide an indication that oxygen may be invading injection waters through leaking gaskets or deaeration 

systems. 


Biological Monitoring 

Biological monitoring and analysis generally seeks to identify the presence 

of Sulphate Reducing Bacteria - SRB’s. This is a class of anaerobic 

bacteria which consume sulphate from the process stream and generate 

sulphuric acid, a corrosive which attacks production plant materials. 

Sand / Erosion Monitoring 

These are devices which are designed to measure erosion in a flowing 

system. They find wide application in oil/gas production systems where particulate matter is present. 

Hydrogen Penetration Monitoring 

In acidic process environments, hydrogen is a by-product of the corrosion reaction. Hydrogen generated in 

such a reaction can be absorbed by steel particularly when traces of sulphide or cyanide are present. This 

may lead to hydrogen induced failure by one or more of several mechanisms. The concept of hydrogen 

probes is to detect the amount of hydrogen permeating through the steel by mechanical or electrochemical 

measurement and to use this as a qualitative indication of corrosion rate. 

Corrosion - 6

Instrumentation 

There exists a variety of instrument options associated with the various corrosion monitoring techniques. 

Three classifications are: 

• Portable Meters and Data Loggers 

• Field-Mounted Data Loggers 

• Field-Mounted Transmitters 

In some applications such as those experienced in oil/gas production and refining, instrumentation is required 

to be certified for use in “hazardous areas”. For portable instruments this is most often achieved by having 

the equipment certified as “intrinsically safe” by a recognized authority such as BASEEFA (U.K.), U.L. 

(U.S.A.), ITS (U.S.A.), or CENELEC (Europe). For hardwired continuous monitoring electronics, isolation 

barriers can be used to ensure that, in the event of a fault condition, insufficient energy is transmitted to 

the hazardous field area for an explosive spark to be produced. 

Probe Fitting Styles 

There are two fundamental fitting styles for corrosion probes: fixed and removable under pressure. 

Fixed styles of probes/sensors have typically a threaded or flanged attachment to the process plant. For 

fixed styles of sensors, removal can only be accomplished during system shut down or by isolation and 

depressurization of the sensor location. 

From time to time, corrosion coupons and probes require removal and replacement. It is sometimes more 

convenient to be able to remove and install sensors while the process system is operational. To facilitate this, 

there are two distinct systems which permit removal/installation under pressure. 

In refinery and process plant environments where pressures are normally less than 1500 psi, a Retractable 

System is used. This consists of a packing gland (stuffing box) and valve arrangement. For environments 

such as those experienced in oil/gas production where pressures of several thousand psi are experienced, a 

special High Pressure Access System is used. This permits the safe and easy installation/removal of corrosion 

monitoring devices at working pressures up to 3600 psi. 

Applications of Corrosion Monitoring Techniques 

Corrosion monitoring is typically used in the following situations: 

• Where risks are high - high pressure, high temperature, flammable, explosive, toxic processes. 

• Where process upsets can cause high corrosivity. 

• Where changes in operating conditions can cause significant changes in corrosion rate. 

Corrosion - 7

• Where corrosion inhibitors are in use. 

• In batch processes, where corrosive constituents are concentrated due to repeated cycling. 

• Where process feedstock is changed. 

• Where plant output or operating parameters are changed from design specifications. 

• In the evaluation of corrosion behavior of various alloys. 

• Where induced potential shifts are used to protect systems and/or structures. 

• Where product contamination due to corrosion is a vital concern. 

Corrosion monitoring may be used in virtually any industry where corrosion prevention is a primary 

requirement. Some examples of industries and specific areas of interest include, but are not limited to: 

Oil/Gas Production 

• Flowlines 

• Gathering Systems 

• Transport Pipelines 

• Water Injection Facilities 

• Vessels 

• Processing 

• Water Systems 

• Chemical Injection Systems 

• Drilling Mud Systems 

• Water Wash Systems 

• Desalters 

Utilities 

• Cooling Systems 

• Effluent Systems 

• Make-Up Water Systems 

• Boiler Water Systems 

Refining 

• Crude Overheads 

• Visbreakers 

• Vacuum Towers 

• Sour Water Strippers 

• Amine Systems 


Pulp and Paper 

• Digesters 

• White Liquor 

• Boiler Systems 

Petrochemicals/Chemicals/Processing 

• Process Systems 


In any corrosion monitoring system, it is common to find two or more of the techniques combined to provide 

a wide base for data gathering. The exact techniques which can be used depend on the actual process 

fluid, alloy system, and operating parameters. 

Corrosion monitoring offers an answer to the question of whether more corrosion is occurring today as 

compared to yesterday. Using this information it is possible to qualify the cause of corrosion and quantify its 

effect. Corrosion monitoring remains a valuable weapon in the fight against corrosion, thereby providing 

substantial economic benefit to the user. 

Metal Samples Corrosion Monitoring Systems 

A Division of Alabama Specialty Products, Inc. 

152 Metal Samples Rd., Munford, AL 36268 Phone: (256) 358-4202 Fax: (256) 358-4515 

E-mail: msc@alspi.com Internet: www.metalsamples.com 

Houston Office: 6327 Teal Mist Lane, Fulshear, TX 77441 Phone: (832) 451-6825


Introduction to Corrosion Coupons 

and Weight Loss Analysis 

Standard Coupons 

Coupon Ordering and Options Available 

Welded Coupons 

Stressed Coupons 

Elastomeric Coupons 

Test Racks 

Coupon Holders 

Easy Tool Retracting System 

Length Calculation & Accessories for 

Retractable Coupon Holders 

Corrosion Coupons for 


Coupon Holders for 


Bypass Piping Systems 

Post Exposure Coupon Analysis 

Coupon Storage (VCI Bags) 

Alloys List 

Alloys Listed by Trademark 

Articles on Coupon Testing 

Return to Main Menu

Corrosion Coupons and Weight Loss Analysis 

Introduction 

The simplest, and longest-established, method of estimating corrosion losses in plant 

and equipment is weight loss analysis. A weighed sample (coupon) of the metal or 

alloy under consideration is introduced into the process, and later removed after a 

reasonable time interval. The coupon is then cleaned of all corrosion product and is 

reweighed. The weight loss is converted to a corrosion rate (CR) or a metal loss 

(ML), as follows: 

Corrosion 

Rate (CR) 

= 

Weight loss (g) * K 

Alloy Density (g/cm 3 ) * Exposed Area (A) * Exposure Time (hr) 

The constant can be varied to calculate the corrosion rate in various units: 

Desired Corrosion Rate Unit (CR) Area Unit (A) K-Factor 

mils/year (mpy) in 2 5.34 x 10 5 

mils/year (mpy) cm 2 3.45 x 10 6 

millimeters/year (mmy) cm 2 8.75 x 10 4 

Metal 

Loss (ML) 

= 


Alloy Density (g/cm 3 ) * Exposed Area (A) 

Desired Metal Loss Unit (ML) Area Unit (A) K-Factor 

mils in 2 61.02 

mils cm 2 393.7 

millimeters cm 2 10.0 

The technique requires no complex equipment or procedures, merely an appropriately shaped coupon, a carrier 

for the coupon (coupon holder), and a reliable means of removing corrosion product without disruption of the 

metal substrate. Weight loss measurement is still the most widely used means of determining corrosion loss, 

despite being the oldest method currently in use. 

Weight loss determination has a number of attractive features that account for its sustained popularity: 

• Simple - No sophisticated instrumentation is required to obtain a result. 

• Direct - A direct measurement is obtained, with no theoretical assumptions or 

approximations. 

• Versatile - It is applicable to all corrosive environments, and gives information on 

all forms of corrosion. 

The method is commonly used as a calibration standard for other means of corrosion monitoring, such as Linear 

Polarization and Electrical Resistance. In instances where slow response and averaged data are acceptable, 

weight loss monitoring is the preferred technique.

Coupon Preparation and Cleaning 

The choice of technique for initial preparation of the coupon surface, and for cleaning the coupon after use, is 

critical in obtaining useful data. Both the relevance and reproducibility of weight loss data are highly sensitive to 

the inherent suitability of these techniques, and to the care with which they are executed. 

Surface finishing methods vary across a broad range for specific 

applications. Blasting with glass bead, sand, or other aggregate can 

provide an acceptable finish for some applications. Sanding with 

abrasive belts, or surface or double disc grinding with abrasive stones 

also provides an excellent surface for evaluation. 

Coupon after being exposed 

to corrosive environment. 

Cleaning of specimens before weighing and exposure is critical to remove any contaminants that could affect test 

results. 

Reference should be made to NACE Recommended Practice RP-0775 and ASTM G-1 & G-4 for further 

detail on surface finishing and cleaning of weight-loss coupons. 

Coupon Position and Orientation 

Irrespective of the degree of care exercised in the surface preparation of coupons, many uncontrollable factors 

(e.g. microstructural defects) can reduce the accuracy of weight loss determinations. Therefore, using duplicate 

(Figure 1) or multi-replicate (Figure 2) coupon samples is considered good practice. 

Coupon orientation must be consistent in order to make different data sets comparable. Generally, an orientation 

parallel to the process flow is preferable since this more nearly reflects the true condition experienced by the 

vessel wall (Figure 1). Metal Samples Corrosion Monitoring Systems MH coupon holders have an automatic 

flow alignment feature. All other holders are marked on the top side with flow direction for manual alignment. 

Positioning is another critical factor in obtaining relevant information. For example, a multi-phase product may 

produce layered flow, giving rise to corrosion rates that vary with depth in the process stream. Such situations 

can be monitored with a ladder-strip coupon holder (Figure 2). 

Flow 

Figure 1. Preferred Flow Direction 

Figure 2. Ladder Strip Coupon Holder

Possibly the most common issue in coupon positioning arises from the fact that a true representation of the 

corrosion experienced by the pipe/vessel can only be established when the weight loss coupon is in the plane of 

the vessel/pipe wall. Only in this position can the coupon experience the same flow regime as the pipe surface 

being monitored. In response to this situation, the use of flush-disc coupons has become widespread (Figure 3). 

The general issue of coupon orientation and positioning in relation to flow regime, plant geometry, and process 

fluid is complex and tends to be specific to each application. However, the most common coupon configurations 

have been discussed above. 

Figure 3. Flush Disc Coupon Holder in High Pressure Access Fitting 


Specific design of coupon holders incorporates two basic factors: 

• Number, style, and configuration of coupons 

• System entry method 

Fixed (Pipe Plug) Coupon Holders 

The simplest system entry design for coupon holders is the fixed or pipe plug coupon holder (Figure 4). This 

type of coupon holder is normally offered on a ¾", 1", or 2" NPT pipe-plug. The size of the plug to be used is 

the limiting factor as to the coupon configuration that can be used. These coupon holders are usually constructed 

in AISI 316L stainless steel, have a pressure rating of 3000 psi, and a temperature rating of 450°F/232°C. This 

design of coupon holder is recommended for use in a by-pass loop which can be isolated, or in systems having 

frequent and regular shut-down, since system depressurization is required during insertion and removal. 

Figure 4. Fixed (Pipe Plug) Coupon Holder


A design that is commonly used in the refining and petrochemical industry is the retractable type coupon holder 

as shown in Figure 5. This coupon holder design employs a packing gland that allows insertion and removal, 

through a ball-valve, without system depressurization. A safety cable and safety nut are also provided to prevent 

blowout. Retractable coupon holders can be used up to 1500 psi and 500°F (260°C), and are constructed of 

AISI 316L stainless steel. Normally, a 1" FNPT packing gland is used in conjunction with either a 1", or a 1½" 

full port ball valve, depending on the type of coupon configuration chosen. (See the RT4000 sheet for more 

information.) 

Figure 5. Retractable Coupon Holder 

Retrievable Coupon Holders 

The oil and gas production industry generally employs retrievable coupon holders that operate with high pressure 

access systems. This will allow insertion/removal under pressures up to 3600 psi. Metal Samples Corrosion 

Monitoring Systems supplies both generic (HP) and proprietary (MH) coupon holders. (See Coupon 

Holders for High Pressure Access Systems.) 

The retrievable coupon holder is installed on to the solid plug. The assembly can then be inserted or removed 

from the system using a special service valve and retrieval tool. 

Retrievable coupon holders are generally constructed in AISI 316L stainless steel to meet the requirements of 

NACE standard MR-0175 for sour service use. These are available for all standard coupon configurations. 

Retrievable, retractable, and pipe plug style coupon holders cover the needs of most industries and applications. 

However, the requirement for special coupon holder designs is significant, and Metal Samples Corrosion 

Monitoring Systems has the facility to design and build coupon holders to any customer-supplied specification. 







Accurate monitoring of corrosion rates in any environment is 

critical when viewed in terms of the maintenance and repair costs 

associated with corrosion and material failure. Test coupons provide 

an inexpensive means of on-line monitoring that will allow 

you to effectively measure the corrosivity within your system. By 

observing the mils-per-year corrosion rate of an exposed coupon, 

valuable information can be provided regarding the material’s life expectancy. 

Metal Samples can make coupons in any size, shape, or material you need. Coupons can be stenciled with alloy 

and sequence numbers for proper identification. Mill test reports, identifying element compositions of materials 

used, are provided on all orders. The following coupons are four of the most commonly used in corrosion 

testing. 

P/N CO100 

P/N CO131 

Shape 

Finish 

Identification 

Surface Area 

Rectangular 

Double disc or glass bead 

Stenciled (alloy, sequence) 

3.38 in 2 

Shape 

Finish 


Surface Area 

Rectangular 

120 grit, glass bead, or mill 

Stenciled (alloy, heat no., sequence) 

3.47 in 2 

P/N CO146 

P/N CO220 

Shape 

Finish 


Surface Area 

Rectangular 

Shape 

Glass bead or mill 

Finish 



4.26 in 2 Surface Area 

Circular 

120 grit, glass bead, or mill 


2.72 in 2 

Finishes 

• Mill - finished as produced from mill. 

• Glass Bead - blasted with fine glass beads to remove mill scale. 

• 120 Grit - fine finish using a 120 grit belt. Commonly used in corrosion tests, such as pitting studies, where 

smooth surface finish is desired. Finishes up to 600 grit (extremely fine) can be provided. 

• Double Disc Ground - extra fine finish using an abrasive disc that leaves minimal residue. Excellent for studies 

where surface finish is critical. Can produce 16-32 RMS finishes on common steels and 8 RMS on carbide steels.

Coupon Ordering and Services Available 

When placing your order for coupons, be ready to provide the sales person with information regarding the type of 

material you are testing, the size coupons required, surface finish desired, and if applicable, mounting hole size and 

location. The following options are available: 

• Manufacturing on time and material basis 

• Samples mounted on test racks and ready 

for installation 

• Preweighing - coupons are cleaned, preweighed 

on an electronic scale, and individually packaged 

• Weight log charts provided on computer disk 

• Non-standard coupons 

• Coupon measuring 

• Heat-treating, sensitizing, hot dip galvanizing 

• Manufacturing from your material if requested 

• Coupons made to specific requirements for 

mounting hole locations, coupon welding, 

stressing, and packaging 

• Plating - nickel, nickel cadmium, cadmium, 

chrome, silver, gold, and others upon request 

• Electro-polishing, hard facing 

• Non-metallic coatings 

• Anodizing and alonizing 

Standard Coupons 

Flat Coupons 

P/N Size Hole Hole Location 

Area 

Sq. In. 

CO100 1/2" x 3" x 1/16" 3/16" 1/4" fr. end 3.38 

CO101 1" x 2" x 1/16" 3/16" 1/4" fr. end 4.32 

CO102 1/2" x 3" x 1/16" 9/64" 1/8" fr. end 3.41 

CO103 1/2" x 3" x 1/16" 1/4" 1/4" fr. end 3.34 

CO104 1/2" x 3" x 1/16" (2) 1/4" 1/2" fr. ea. end 3.24 

CO105 1/2" x 3" x 1/16" 3/16" 1/2" fr. end 3.38 

CO106 1/2" x 3" x 1/16" 1/4" 1/2" fr. end 3.34 

CO115 1/2" x 3" x 1/16" 1/4" 1/4" fr. end 

CO117 3/8" x 3" x 1/16" 9/64" 1/8" fr. end 2.64 

CO118 1/2" x 3" x 1/16" (2) 1/4" 1/4" & 3/4" end 3.24 

CO120 3/8" x 3" x 1/16" (2) 1/4" 1/4" & 3/4" end 2.48 

The coupons listed above are made from a variety of materials 

(see Alloys list). 

Cylindrical Coupons 

Area 

P/N Size Thread Slot Sq. In. 

ES200 1/4" Ø x 2 1/2" 1/4"-20 x 3/8" 1/16" 1.96 

Scale coupons (or deposition coupons) provide a 

qualitative measure of relative deposition rates in 

industrial water and manufacturing process systems. 

P/N CO115 (flat) 

P/N ES209 

(cylindrical) 

Mesh bio film coupons are used for quantification 

or identification of microorganisms. 

P/N COJ36 

ES201 1/4" Ø x 2" 1/4"-20 x 3/8" 1/16" 1.57 

ES202 1/4" Ø x 3" 1/4"-20 x 3/8" 1/16" 2.45 

ES204 1/4" Ø x 1 1/2" 1/4"-20 x 3/8" 1/16" 1.18 

ES209* 1/4" Ø x 3" 1/4"-20 x 3/8" 1/16" 

* ES209 has five 1/8" diameter scale holes.


Fixed (Pipe Plug) Coupon Holders 

Metal Samples carries a variety of standard pipe plug coupon holders for flat and cylindrical specimens. We can 

design and make these assemblies to meet your specifications for size and material requirements. 

Pipe Plug Assemblies for Flat Coupons 

P/N 

Plug Size 

3" (Std.) 

Stem 

Used with 

Coupon P/N 

RC12E*100036 3/4" NPT Nylon CO102, CO117 

RC13E*100036 1" NPT Nylon CO102, CO117 

RC12Q*100036 3/4" NPT Teflon ® CO102, CO117 

RC13Q*100066 1" NPT Teflon ® CO102, CO117 

RC12E*010036 3/4" NPT Nylon CO100, CO103, CO115 

RC13E*010036 1" NPT Nylon CO100, CO103, CO115 

RC12Q*010030 3/4" NPT Teflon ® CO100, CO103, CO115 

RC13Q*010026 1" NPT Teflon ® CO100, CO103, CO115 









RC11E*010036 1/2" NPT Nylon CO100, CO103, CO115 

* Add "3" to part number for Carbon Steel or "C" for PVC plug. 

(Example: Carbon Steel 3/4" pipe plug Nylon stem = RC12E3100036.) 

Pipe Plug Assemblies for Cylindrical Coupons 

P/N Carbon Steel Plug Insert # of Stems 

PA2080413709 2" NPT Nylon 8 

PA2080413783 2" NPT Teflon ® 8 

RC11Q3040000 1/2" NPT Teflon ® 1 

RC12Q3040000 3/4" NPT Teflon ® 1 

RC13Q3040000 1" NPT Teflon ® 1 

All of these holders are used with ES2 series coupons. 

Bypass Piping Systems 

We provide conventional or custom-designed bypass systems 

for on-line corrosion monitoring. Commonly used in the industrial 

water treatment industry to determine the corrosive properties 

of potable or cooling water, these systems are available in 

PVC, carbon and stainless steels, and other materials. 

Bypass systems are easily installed to your existing piping. 

Normally, all you need is a 1" NPT male fitting on which to 

attach the bypass. Standard bypass systems come equipped with 

4 pipe plug assemblies, 4 pre-weighed mild steel coupons, and 

a 5-gpm flow control valve.

Adjustable Coupon Holders 

Low Pressure or Hand Insertable systems can be used for pressures 

up to 125 psi. This assembly is commonly used in the water treating 

industry for coupon insertion through a full port valve. An example 

of this is in a municipal water pumping station, where leakage during 

withdrawal of the test coupon would not be critical. See the SR3000 

for more detials. 


Packing Gland systems are used in more demanding environments, 

where ratings up to 1,500 psi are required and leakage is prohibited. 

These systems do not require line (process) shutdown to insert or 

withdraw coupons. The assembly is used for coupon insertion through at 

least a 1" full port valve. A safety chain is provided to prevent accidental 

ejection. See the RT4000 for more details. Also see Length Calculation 

and Accessories. 

Retrievable Coupon Holders 

These coupon holders are used with High Pressure Access Systems where 

pressure ratings up to 3,600 psi are required. See HC Series Coupon Holders 

for more information. 

Post Exposure Coupon Analysis 

Metal Samples offers post exposure coupon analysis. Our trained technicians 

will perform weight loss analysis and determine mils per year 

(MPY) corrosion rates of your exposed test samples. We are in adherence 

to ASTM-G1 specifications for cleaning and analyzing coupons. 

When using this service, ensure that initial coupon weights, exposure 

dates, and locations are recorded for each 

sample. This information can be recorded 

on the front of a VCI coupon storage bag. 

Optional services include pit depth measurement and photos of the coupons before 

and after analysis. For additional information on post exposure coupon analysis 

see "Coupon Evaluation after Exposure".

Coupon Storage Bags 

Vapor corrosion inhibitor (VCI) bags are excellent for storage of ferrous 

and non-ferrous coupons. With VCI bags, coupons can be protected from 

corrosion for up to one year when stored under the proper environmental 

conditions. Pertinent data regarding coupon exposure can be recorded in 

the appropriate spaces on the front of the bag. Ask for P/N BG5001 when 

ordering these bags. 

Welded Coupons 

Corrosion rates can vary between welded and non-welded metals, therefore it is advisable to study the behavior 

of both conditions. Studies involve examination of the parent material, the heat-affected zone, the weld metal, 

and the interfaces between all metals involved. The surface effects produced by welding, heat-tint formation or 

oxidation, fluxing action of slag, and the deliquescence of slag can be important factors in the corrosion behavior 

of metals. 

Ideally, the coupon used should be the same thickness and welded with the same 

welding process as the material used in the production equipment. Usually this is not 

practical so a representative sample must be studied. 

Typical welding techniques used are Shielded Metal Arc (SMAW), Gas Tungsten 

Arc (GTAW), and Gas Metal Arc (GMAW). Specimens are ground smooth after 

welding, unless otherwise specified, so as to provide a uniform surface for microscopic 

investigation. 

Welded coupons can be prepared with or without the use of filler metal. 

The autogenous weld is prepared without the use of filler metal. This 

type of weld is the most economical method. Autogenous welds are 

commonly used to evaluate corrosion rates of welded materials and the 

usage of these materials in corrosive environments. An autogenous weld 

is produced by GTAW and can be used to test material weldability and 

gas shield usage, and to set welding parameters. 

Autogenous Weld Coupon 


1/8" 

1" 

2" 

.375 thru 

Autogenous weld 

3/4" 

.375" 

3/8" 

Notes: 

1. 120 grit standard finish unless otherwise specified. 

2. 1/8" nominal thickness. 

3. Standard weld is autogenous weld across end (A.W.A.E.). 

Sanded after weld.

Stressed Coupons 

Stress corrosion cracking occurs when tensile stress combines with a corrosive environment to attack a material. 

Testing for this type of corrosion is critical in storage tanks, pressure piping, and vessels commonly used 

in chemical processing plants and petrochemical refineries. Metal Samples can make your stressed samples in 

accordance with all ASTM standards including G30, G38, G39, and G58 or to your custom specifications. 

P/N CS502 

ASTM G30 

P/N CS502W (Welded) 

ASTM G58 

1/2" 

Approximate 

stenciling 

location 

(if required) 

1/2" 

R (Radius) 

3/8" D (Hole Diameter) 

Centrally Located 

X 

W 

3/4" 

M 

L 5" 

T 1/16" 

P/N TF2445 

ASTM G39 

P/N TF2404 Stressing Frame 

For use with P/N TF2445 

P/N CO303 

Twist Specimen 

P/N CS500 

Tear Drop 

P/N CS513 

"C" Ring - ASTM G38

Elastomeric Coupons 

Metal Samples in conjunction with International Seal Co., 

Inc., and DuPont Dow Elastomers offers a selection of 

elastomeric coupons. These coupons are used for assistance 

in effectively selecting materials for elastomeric testing and 

applications. 

Fluoro and Perfluoro elastomer based materials 

Compound 

V75 

V75BR 

V121 

V176 

V115 

V141 

CV75 

PF75 

Kalrez 

4079 

Descriptio n 

® 

75 

Durometer General Purpose black Vito n "A" based compoun d 

® 

75 

Durometer General Purpose brown Vito n "A" based compoun d 

® 

75 

Durometer improved chemical resistant Vito n "B" based compoun d 

® 

75 

Durometer lead free acid resistant Vito n "B" 

® 

75 

Durometer improved low temperature Vito n "GLT" based compoun d 

® 

75 

Durometer excellent chemical resistant Vito n "F" based compoun d 

® 

75 

Durometer "Super Chemical" resistant Vito n 

75 Durometer "Ultimate Chemical" 

temperatures up to 500°F 

75 Durometer "Ultimate Chemical" 

temperatures up to 600°F 

resistant Perfluoro material for 

resistant Perfluoro material for 

Ethylene Propylene elastomeric based materials 

E425 

70 Durometer high performance peroxide cured EPDM compoun d 

Meets ASTM D2000 4CA 715, A25, E35, C32, F19 

E429 

70 Durometer EPDM compound that meets ANSI/NSF 61 

Nitrile elastomer based material 

N470 

70 Durometer low compression set nitrile compoun d 

Meets ASTM D2000 3CH 720, A25, B14, EO16, EO36 

N442 

70 Durometer NBR compound that meets ANSI/NSF 61 

Viton® is a registered trademark of DuPont Dow Elastomers.

Test Racks 

Metal Samples offers test racks used to mount 

coupons and secure them directly to operating 

equipment or within a process system. Test racks 

make it easy to evaluate how corrosion would 

effect differing alloys and material finishes under 

identical conditions. Rack usage helps eliminate 

coupon loss which might occur if samples were 

individually placed in a process flow. 

Racks can be fabricated to meet your requirements for material and size. Typical racks are flat bar racks, spool 

racks, and pipeline insertion racks. Other racks include angle bar racks and outdoor exposure racks. A variety of 

insulators, washers, and spacers used to isolate coupons can also be ordered separately. 

Guidelines for Supporting Specimens 

Corrosive behavior of materials subjected to immersion, partial 

immersion, or vapor phase can have great variance. For this 

reason, specimens to be tested should be properly positioned. 

There are several important points to be considered when 

supporting specimens for exposure: 

Pipeline 

Insertion Rack 

• Each specimen location should be identified by sketch 

and recorded. 

• The corrosive media should have access to the coupons. 

• The test rack should have adequate corrosion resistance 

to endure the test. 

• Specimens should be electrically isolated from other 

metals unless galvanic effects are being studied. 

• Specimens should be located in easily accessible areas. 

Spool Rack 

Flat Bar Rack

Insulators, Washers, & Spacers 

Metal Samples makes a variety of insulators, washers, and spacers used to isolate test specimens. We also make 

insulator kits (P/N KR5102) that contain an assortment of washers, screws, nuts, and stems. These kits are designed 

for field use when a variety of insulators are needed. The chart shown here is a general guide to material 

applications. Call for recommendations on use in hazardous or severe environments. 

Material vs. Environment 

Material 

Acids Alkalies Organic 

Water 

Absorption 

Oxygen 

and High Ionizing 

Temperature 

Resistance 

Weak Strong Weak Strong Solvents % 24 hrs. Ozone Vacuum Radiation High Low 

R = Resistance A = Attacked SA = Slight Attack A-O = Attacked by Oxidizing Acids G = Good F = Fair P = Poor L = Little Change 

Tensile 

Strength 

lb/in 

Fluorocarbons 

TFE Inert Inert Inert Inert Inert 0.0 Inert - P 550 G-275 2,500 

Nylon G A R R R 1.5 SA - F 300 G-70 10,000 

Polyethylene 

(low density) R A-O R R G 0.15 A F F 140 G-80 2,000 

Polyethylene 

(high density) R A-O R R G 0.1 A F G 160 G-100 4,000 

Polypropylene R A-O R R R 0.01 A F G 300 P 5,000 

Rigid polyvinyl 

chloride R R R R A 0.10 R - P 150 P 6,000 

Phenolics SA A SA A SA 0.6 - - G 400 L 7,500 

Zirconia 

ceramics R R R R R 0.0 R - - - - - 

Alumina 

ceramics R R R R R 0.0 R - - 3180 - - 

Rod Insulators 

Crevice Washers 

Material P/N OD (inches) ID (inches) 

Teflon ® 04783004370093 .437 .250 

04783004370031 .437 .375 

04783002180015 .218 .188 

04783002960025 .296 .250 

04783003750062 .375 .250 

04783004060078 .406 .250 

04783005000062 .500 .375 

04783006250125 .625 .375 

04783006250078 .625 .470 

04783008750162 .875 .550 

Contact our sales department for the availability of insulators, washers, and spacers not listed. 

Dimensions (inches) 

Material P/N ID OD Thickness 

# of 

Slots 

Teflon ® CW1902783 .265 .625 .250 12 

CW1900783 .391 .625 .250 12 

CW1904783 .265 .625 .100 12 

Ceramic CW1902473 .265 .625 .250 12

Shoulder Washers 

Spacers & Flat Washers 

Material 

Ceramic 

Dimensions (inches) 

P/N L A B G F 

SW1402473 .050 .375 .090 .193 .250 

SW1425473 .050 .625 .125 .250 .375 

TFE Glass SW1439785 .109 .625 .094 .250 .313 

Teflon ® SW1419783 .109 .625 .188 .250 .375 

SW1400783 .109 .625 .109 .250 .313 

SW1402783 .063 .375 .063 .188 .250 

SW1403783 .125 .625 .438 .250 .406 

SW1406783 .234 .625 .109 .250 .375 

SW1407783 .109 .625 .109 .250 .375 

SW1413783 .063 .656 .500 .250 .406 

SW1418783 .125 .641 .500 .359 .453 

Nylon 

SW1420783 .188 .625 .109 .250 .375 

SW1421783 .125 .438 .063 .188 .297 

SW1423783 .055 .625 .500 .250 .531 

SW1424783 .063 .750 .250 .250 .500 

SW1425783 .050 .625 .109 .250 .375 

SW1426783 .050 .625 .313 .250 .375 

SW1427783 .313 .500 .063 .203 .313 

SW1443709 .125 .375 .031 .188 .250 

SW1427709 .313 .500 .063 .203 .313 

SW1444709 .047 .375 .094 .188 .250 

Teflon ® Dimensions (inches) 

Material P/N L A B 

ST1214783 .375 .625 .375 

ST1219783 .750 .750 .490 

ST1200783 .500 .375 .250 

ST1202783 .250 .375 .250 

ST1203783 .188 .375 .250 

ST1204783 .250 .625 .250 

ST1205783 .750 .500 .359 

ST1206783 .500 .500 .344 

ST1207783 .500 .625 .375 

ST1208783 .250 .625 .406 

ST1209783 .625 .625 .375 

ST1221783 .375 .500 .375 

ST1225783 .375 .625 .500 

ST1226783 1.00 .625 .265 

ST1231783 .125 .422 .363 

ST1232783 .375 .375 .250 

ST1253783 .062 .500 .250 

ST1254783 .062 .625 .250 

ST1255783 .125 .500 .125 

ST1256783 .188 .445 .250 

09709E1000- 

FW0000 

.047 .438 .203 

ST1240709 .062 .375 .203 

Nylon ST1239709 .062 .375 .250 

ST1230709 .125 .500 .313 

09709E2500- 

FW0000 

.094 .500 .250 

ST1220473 .250 .500 .375 

ST1240473 .062 .375 .188 

Ceramic ST1247473 .500 1.00 .560 

ST1248473 .125 .600 .394 

ST1249473 .125 .625 .250 

Fasteners 

We make a variety of fasteners in almost any material required, including: 

• Brass • HASTELLOY ® C-276 

• 304 

• Carpenter® 20Cb3 

• 316 • HASTELLOY ® B-2 

• Teflon® 

• Titanium 

• Nylon • INCONEL® alloy 600 

• Tantalum 

Teflon® is a registered trademark of DuPont. HASTELLOY® is a registered trademark of Haynes International, Inc. INCONEL® alloy 600 is a registered 

trademark of Special Metals. Carpenter® 20Cb3 is a registered trademark of Carpenter Technologies.

Model SR3000 

Low Pressure Adjustable Coupon Insertion System 

I.L.* 

Insertion Rod 

3/4" or 1" Adjustable 

Mounting Plug 

Knob for Hand 

Insertion of System 

3" 

Coupon Adapter 

2" < Std. Length 

Safety Cable 

Model SR3000 coupon insertion system is an adjustable unit commonly used in the water treating 

industry. The system is designed to mount onto a 1” piping system, but can easily be adapted to 

fit your specific requirements. The system consists of an insertion rod with a coupon adapter. The 

standard assembly is available with 3/4” or 1” NPT threads on the mounting plug. A safety cable and 

safety nut are also provided to prevent blowout. Several coupon holders and lengths are available. 

Note: Since the adjustable mounting plug on the SR3000 is not a packing gland, some system leakage 

may occur if retracted or inserted into a pressurized system. Therefore, this model is suggested 

for use only in non-hazardous systems. 

*The insertion length (I.L.) shown here is based on a standard Metal Samples Corrosion Monitoring 

Systems part #CO118 coupon and may vary for other coupons depending on the coupon length and 

hole location. 

Specifications: 

Body - 316 Stainless Steel 

Temperature Rating - 100°F 

Pressure Rating - 125 PSI / 8.5 Bar (TFE Ferrule) 

- 1,500 PSI / 102 Bar (Metal Ferrule) 

Mounting - 1" Full Port Valve (Min.) 

Std. Length I.L. (max) 

18" 16.5" 

24" 22.5" 

30" 28.5" 

36" 34.5" 

42" 40.5" 






SR3000 Ordering Information 

Model 

SR32 

SR33 

Low Pressure Adjustable Coupon Insertion System with 3/4" NPT 

Low Pressure Adjustable Coupon Insertion System with 1" NPT 

Insertion Rod & Mounting Material 

22 

44 

316 

C276 

Coupon Options 

010 

030 

Fits P/N CO100 

Fits P/N CO118 

Length 

18 

24 

30 

36 

42 

16.5 inches max. insertion length 





Coupon Adapter and Insulators 

1 

2 

4 

5 

SR32 22 030 18 4 Example of Probe Ordering # 

Coupon adapter same material as rod, Teflon ® insulators 

Teflon ® coupon adapter, Teflon ® insulators 

Coupon adapter same material as rod, nylon insulators (standard) 

Nylon coupon adapter, nylon insulators 

For alloys, sizes, or other special requirements not listed, contact our sales department.

Model RT4000 

Coupon Insertion System 

Retractable with Packing Gland 

I.L.* 

Knob for Hand 

Insertion of Probe 

3" 

1" NPT 

Coupon 

Coupon Adapter 

Safety Chain 

2" < Std. Length 

Adapter for Easytool 

Insertion of Probe 

Model RT4000 coupon insertion system is a retractable unit commonly used in field and plant 

applications. A specially designed packing gland is used to insert or retract a coupon from a pressurized 

system without a process shutdown. The insertion system is designed to mount onto a 1" piping 

system, but can easily be adapted to fit your specific requirements. The system consists of an insertion 

rod with a coupon adapter, and a packing gland. A safety chain and safety nut are also provided 

to prevent blowout. Standard packing material in the packing gland is Teflon ® , however, grafoil 

packing can be provided for high temperature applications. (Special consideration must be given to 

the insulator material selection for high temperature applications. Contact our sales department for 

assistance.) Several coupon holders and lengths are available. *The insertion length (I.L.) shown 

here is based on a standard Metal Samples Corrosion Monitoring Systems part #CO118 coupon and 

may vary for other coupons depending on the coupon length and hole location. 



Temperature Rating - 500°F / 260°C - Teflon ® 

850°F / 454°C - Grafoil 

Pressure Rating - 1500 PSI / 102 Bar 


S td. Length I.L. (Max.) 

24" 

18.54" 

30" 

24.54" 

36" 

30.54" 

42" 

36.54" 

The Easy Tool is required for probe insertion or 

retraction in systems with pressure over 150 pounds. 






Model 

RT45 

RT75 

RT00 

RT4000 Ordering Information 

® 

R etractable Coupon Insertion System 1" Female NPT, Packing Gland with Teflon 

Retractable Coupon Insertion System 1" Female NPT, Packing Gland with Grafoil 

Retractable Coupon Insertion System Replacement Insertion Rod 

Insertion Rod & Mounting Material 

20 316 (when ordering only Insertion Rod - RT00) 

22 316 

40 C276 (when ordering only Insertion Rod - RT00) 

44 C276 

Coupon Options 

010 Fits P/N CO100 


040 Fits P/N ES200 (Cylindrical Coupons) 



Length 

24 18.54 inches max. insertion length 




Coupon Adapter and Insulators 

® 

1 C oupon adapter same material as rod, Teflon insulator s 

® ® 

2 T eflon c oupon adapter, Teflo n insulator s 

3 Coupon adapter same material as rod, ceramic insulators 

4 Coupon adapter same material as rod, nylon insulators 

5 Nylon coupon adapter, nylon insulators 

6 Coupon adapter same material as rod, no insulators 

RT45 

22 

030 

24 

1 Example of Probe Ordering # 



for High Pressure Access Systems 

Corrosion coupons are generally used in weight loss tests. Properly 

selected, such coupons will provide quantitative estimates of 

corrosion rates as well as physical evidence of the type of corrosion 

occurring in the process environment. In order to provide 

reproducible data, selected coupons must have a uniform shape, 

size, surface area, and surface finish. Coupons should be fabricated 

of an alloy that is similar in composition to the process equipment of 

interest. 

NACE has published a Recommended Practice RP-0775 entitled Preparation and Installation of Corrosion 

Coupons and Interpretation of Test Data in Oil Production Practice. 

Strip Coupons 

Strip coupons are available in two standard sizes: 3" x 7/8" x 1/8" (76 mm x 22 mm x 3 mm) and 6" x 7/8" 

x 1/8" (152 mm x 22 mm x 3 mm). Both sizes have two mounting holes for attachment to the Strip Coupon 

Holder. Strip coupons are supplied complete with nylon insulation for mounting purposes. Strip coupons are 

typically mounted in pairs and need to be oriented such that they are parallel to the direction of flow. 

3" Strip 

(PN CO111) 

6" Strip 

(PN CO169) 

Flush Disc Coupons 

These circular coupons are most commonly used with holders that mount the coupon flush with the interior 

of the pipe or vessel. They have a chamfered hole which permits recessed mounting with a stainless steel 

flathead screw. Flush disc coupons are most frequently used where pigging would otherwise require the 

removal of intrusive-type coupon assemblies prior to the pigging operation; or alternatively where waterdrop 

out in the bottom of horizontal pipe runs gives rise to corrosion problems. The disc coupon diameter 

is 1¼" (32 mm) with a thickness of 1/8" (3 mm). The insulation and mounting screw is provided with the 

coupon holder. 

Flush Disc 

(PN CO142)

Ladder Strip Coupons 

These coupons are rectangular with the following dimensions: 2" x 7/8" x 1/8" (51 mm x 22 mm x 3 mm). 

They are designed to be mounted in pairs with three pairs of ladder strip coupons attached to a single ladder 

coupon holder. Ladder strip coupons are supplied with nylon insulation for mounting. 

2" Ladder 

(PN CO197) 

Scale Coupons 

Scale coupons are rectangular with a series of holes of varying sizes, and are used to determine scaling 

tendency. The strength of this tendency can be determined by the largest size hole that has accumulated 

scale. Scale coupons are typically used with strip coupon holders. 

3" & 6" Scale 

(PN CO185/196) 

• C1018 coupons are stamped with a sequence number. All alloy coupons are stamped with the 

alloy and the sequence number. 

• Coupons are pre-weighed and individually packaged in a vapor corrosion inhibitor (VCI) bag. 

• Coupons are supplied with a mill test report and a weight log chart. 

• Coupons are cleaned of all contaminants and have a 120 grit-blasted finish. 

• Nylon insulators are mounted into coupons. 

Coupon Holder Accessories: 

Part No. 

Description 

Strip Coupon Holder KR5119158 Mounting Kit - Coupon 

Disc Coupon Holder KR5120 Mounting Kit - Coupon 

Ladder Strip Coupon Holder KR5119158 Mounting Kit - Coupon 






HC Series Coupon Holders 

for High Pressure (HP TM and MH TM ) Access Systems 

Flush Disc 3" Strip 6" Strip Ladder 

Figure 1. Various coupon holder styles on HP access fittings. 

HC Series Coupon Holders are designed to be specifically compatible with either the HP or MH 

High Pressure Access Systems. The HP coupon holder can not be used with the MH system and vice 

versa. The HP coupon holder is attached to the solid plug assembly by means of a left-handed thread 

connection to ensure that it does not become loose during the retrieval procedure. The MH coupon 

holder is attached by means of a set screw arrangement and incorporates an orientation keyway feature 

to automatically align installed strip coupons parallel to the fluid flow. 

Coupon holders are manufactured from 316L stainless steel to meet NACE MR-0175 requirements 

for sour service. Mounting hardware is also manufactured from stainless steel and is supplied with 

coupon holders. Insulators are fabricated from Nylon and are supplied with the coupons. Coupons 

are ordered separately. Calculated lengths are rounded down to the nearest 1/8". 

Strip Coupon Holders 

Strip coupon holders are designed to suspend a pair of 3" or 6" coupons in a vessel or pipe. 

Calculating Strip Coupon Holder Length 

After selecting the access fitting body style to be used, 

determine the pipe or pressure vessel size and select the 

coupon length and line position where the coupon will 

be located. Coupon holders can be sized to monitor the 

top, middle, or bottom of the line. Use the following 

formulas to calculate the required holder length. 

With a non-flanged access fitting: 

Top-of-the-line Monitoring: L = (H + PW) - 2.5" 

Ordering Length 

Figure 2. Strip coupon holder

One half of the coupon extends into the pipe and the process environment. The other half is positioned 

in the access fitting body cavity and may be used to monitor the formation of gas pockets. 

Middle-of-the-line Monitoring: L = (H + ½OD) - (2.5" + ½CL) 

The coupon is centered so that ½ of the coupon is positioned on either side of the pipe’s centerline. 

Bottom-of-the-line Monitoring: L = (H + OD) - (2.75" + PW + CL) 

The coupon is positioned approximately ¼" off the bottom of the line. 

With a flanged access fitting: 

Top-of-the-line Monitoring: L = (H + FG + MH + PW) - (2.5" + ½CL) 

Middle-of-the-line Monitoring: L = (H + FG + MH + ½OD) - (2.5" + ½CL) 

Bottom-of-the-line Monitoring: L = (H + FG + MH + OD) - (2.75" + PW + CL) 

Where: 

L = Coupon holder length 

H = Height of the access fitting body without a thread protector 

(MH = 5.5"/14 cm, HP = 5.25"/13.3 cm) 

PW = Pipe wall thickness 

OD = Outside diameter of the pipe 

CL = Effective length of the coupon (the portion of the coupon that is actually exposed to the process environment) 

For a 3" coupon, CL = 1.625" (4.13 cm) 

For a 6" coupon, CL = 4.750" (12.07 cm) 

FG = Gap between mating flange faces 

MH = Mating flange height from face to top of pipe 

Disc Coupon Holders 

Disc coupon holders are used with flush disc type coupons for measurement in either flush or nonintrusive 

configurations. They are available as fixed length or adjustable assemblies. These coupon 

holders offer the following advantages over strip coupon holders: 

1) They can be mounted flush with the pipe wall so that process effects occurring at the pipe 

wall are closely simulated. 

2) Holders properly sized to the flush position prevent coupon interference with pigging operations. 

3) Orientation of coupons to process flow is not required. 

Fixed Length Flush Disc Holder 

The fixed length flush disc coupon holder may be sized so that 

the coupon is positioned flush with the pipe wall, or is extended 

into the line at the top, center, or bottom position. 

The customer must specify holder length when ordering. For 

MH systems, minimum fixed length disc holder length is 2.875 

inches (7.3 cm). For HP systems, minimum fixed length disc 

holder length is 2.0 inches (5.08 cm). Fixed length holders are 

available in increment lengths of 0.125 inches (3.2 mm). 

Ordering Length 

Figure 3. Fixed Length 

Flush Disc Coupon Holder 

Holders - 2

Adjustable Length Flush Disc Holder 

Disc holder lengths start at 2.75" and are available in 1/8" increments. 

The holder’s adjustable rod allows for a total travel 

length of 1.5". Example: A 3.25" holder would be adjustable 

from 3.25 to 4.75 inches. 

Figure 4. Adjustable Length 

Flush Disc Coupon Holder 

Calculating Disc Coupon Holder Length 

Select the access fitting body style and determine the pipe or vessel size and line position where the 

coupon will be located. Then use the appropriate formula below to calculate the required fixed length 

disc coupon holder. 


Flush Monitoring: L = (H + PW) - (2.5") 

Middle-of-the-Line Monitoring: L = (H + ½OD) - (2.375") 

Bottom-of-the-Line Monitoring: L = (H + OD) - (PW + 2.75") 


Flush Monitoring: L = (H + PW + FG + MH) - (2.5") 

Middle-of-the-Line Monitoring: L = (H + FG + MH + ½OD) - (2.375") 

Bottom-of-the-Line Monitoring: L = (H + FG + MH + OD) - (PW + 2.75") 

Where: 



(MH = 5.5"/14 cm, HP = 5.25"/13.3 cm) 





Ladder Strip Coupon Holders 

Ladder strip coupon holders are designed to simultaneously monitor 

corrosion at various levels in a process line. This is a technique 

employed in large diameter pipelines (8" O.D. and greater) where 

corrosion may not be uniform across the diameter of the pipe, or in 

systems where flow is stratified. 

The holder body is a single blade containing holes spaced along its 

length for mounting the coupons. Special strip coupons are used with 

ladder holders. These coupons have a mounting hole at each end for 

secure mounting. Coupons are arranged so that three pairs may be 

mounted on the holder; one pair at the top, one pair at the center, and 

one pair at the bottom. A minimum holder length of 26 cm (10.25") 

is required to mount three pairs of coupons. Mounting procedures for 

ladder strip coupons are the same as for standard 2-hole strip coupons. 

Figure 5. Ladder Strip 

Coupon Holder 

Holders - 3

Calculating Ladder Strip Coupon Holder Length 

The following formulas are used to calculate the required, overall length of ladder strip coupon holders. 

These formulas automatically provide for coupon placement. 


L = (H + OD) - (PW + 2.75") 


L = (H + FG + MH + OD) - (PW + 2.75") 

Where: 







Multiple Disc Coupon Holders 

Multiple Disc Coupon Holders are suitable for pipes with O.D. greater than 6.00". Multiple Disc 

Holders allow coupons to be placed at a specific level in multi-phase or stratified flow. The coupons 

are insulated from the holder rod by Delrin Shoulder Washers. Delrin Spacers are used to provide 

insulation between coupons. Materials of construction satisfy the requirements of NACE MR-0175. 

Calculating Multiple Disc Coupon Holder Length 


L = (H + OD) - (PW + 2.75") 


L = (H + FG + MH + OD) - (PW + 2.75") 

Round down to the nearest 1/8" 

Where: 

L 

H 

= Coupon holder length 

= Height of the access fitting body without a thread protector 

(MH = 5.5", HP = 5.25") 





Holder 

Length 

Figure 6. Multiple Disc 

Coupon Holder 

Holders - 4

High Pressure Coupon Holder Ordering Information 

Model 

HC 

High Pressure Coupon Holder 

Coupon Type 

1 

2 

3 

4 

5 

6 

7 

8 

C 

D 

Strip (HP) 

Strip (MH) 

Flush disc - fixed length (HP) 

Flush disc - adjustable (HP) 

Flush disc - fixed length (MH) 

Flush Disc - adjustable (MH) 

Ladder (HP) 

Ladder (MH) 

Multiple disc (HP) 

Multiple disc (MH) 

Type 

1 

2 

Welded 

Non-welded 

Alloy 

XXX 

Coupon holders less than 4" will 

automatically be non-welded. 

Use Code in Alloy Chart 

Length (Round calculated length down to the nearest 1/8") 

XXXX Length in inches, stated in 2 decimal place format. 

Length must be greater than 2" and is given in increments of 1/8" 

(Ex: 3 1/8" = 0312) 

HC 1 1 158 0312 Example of Probe Ordering # 

Alloy Chart 

Code Description UNS # 

158 316 SS S31600 

A12 C276 N10276 

For alloys, sizes, or other special requirements not listed, contact our sales department. 






Alloys 

UNS Material Density 

(g/cm 3 ) 

Aluminum & Aluminum Alloys 

A03190 Al 319 2.79 

A03191 Al 319.1 

A03192 Al 319.2 

A03330 Al 333 

A03331 Al 333.1 2.70 

A03550 Al 355 2.71 

A03552 Al 355.2 2.68 

A03561 Al 356.1 

A03562 Al 356.2 2.68 

A03600 Al 360 

A03800 Al 380 

A03900 Al 390 

A04432 Al 443.2 

A05142 Al 514.2 

A05352 Al 535.2 

A07720 Al 772.0 

A91100 Al 1100 2.71 

A91145 Al 1145 

A92011 Al 2011 2.82 

A92014 Al 2014 2.80 

A92017 Al 2017 

A92024 Al 2024 2.77 

Al 2024 ALCLAD 

A92036 Al 2036 

A92090 Al 2090 

A92219 Al 2219 

A93003 Al 3003 2.73 

A93004 Al 3004 

A94043 Al 4043 

A95005 Al 5005 2.70 

A95050 Al 5050 2.69 

A95052 Al 5052 2.68 

A95083 Al 5083 2.66 

A95086 Al 5086 2.65 

A95154 Al 5154 2.66 

A95182 Al 5182 

A95254 Al 5254 

A95257 Al 5257 

A95454 Al 5454 2.68 

A95456 Al 5456 2.66 

A95652 Al 5652 

A96061 Al 6061 2.70 

A96063 Al 6063 2.70 

A97039 Al 7039 

A97050 Al 7050 

A97075 Al 7075 2.80 

Al 7075 ALCLAD 

A97178 Al 7178 2.82 


(g/cm 3 ) 

Copper & Copper Alloys 

C10100 CDA 101 OFE 8.89 

C10200 CDA 102 OFE 8.89 

C10300 CDA 103 8.89 

C11000 CDA 110 ETP 8.89 

C11400 CDA 114 STP 8.91 

C12200 CDA 122 DHP 8.94 

C15100 CDA 151 

C17200 CDA 172 8.23 

C17300 CDA 173 

C18200 CDA 182 

C19400 CDA 194 HSM 8.78 

C19500 CDA 195 

C22000 CDA 220 Com. Bronze 8.80 

C23000 CDA 230 Red Brass 8.75 

C26000 CDA 260 Cartridge Br. 8.53 

C26800 CDA 268 Yellow Brass 8.47 

C27200 CDA 272 

C27400 CDA 274 

C28000 CDA 280 Muntz Metal 8.39 

C31600 CDA 316 Leaded Bronze 8.83 

C33000 CDA 330 

C34500 CDA 345 

C35300 CDA 353 

C36000 CDA 360 FC Brass 8.49 

C36500 CDA 365 

C44300 CDA 443 Admiralty Br. 8.52 

C46400 CDA 464 Naval Brass 8.41 

C48500 CDA 485 Leaded Naval 8.44 

C51000 CDA 510 Phos. Bronze 8.86 

C51900 CDA 519 

C52100 CDA 521 

C61000 CDA 610 

C61300 CDA 613 8.50 

C61400 CDA 614 Al Bronze D 8.45 

C62300 CDA 623 

C62400 CDA 624 

C62500 CDA 625 

C63000 CDA 630 Ni Al Bronze 7.58 

C63200 CDA 632 

C64200 CDA 642 Al Bronze 7.69 

C65100 CDA 651 

C65500 CDA 655 High Silicon 8.52 

C67300 CDA 673 

C67400 CDA 674 

C67500 CDA 675 Mn Bronze A 8.63 

C68700 CDA 687 Al Brass 8.33 

C70600 CDA 706 (90/10) 8.94 

C71000 CDA 710 (80/20) 8.94 

C71500 CDA 715 (70/30) 8.94 

C72200 CDA 722 

C75200 CDA 752 

C83600 CDA 836 8.80 

C83800 CDA 838 

C84400 CDA 844 

C84500 CDA 845 


(g/cm 3 ) 

Copper & Copper Alloys (cont’d) 

C85200 CDA 852 

C85400 CDA 854 Leaded Yellow 8.45 

C85700 CDA 857 

C86200 CDA 862 

C86300 CDA 863 Mn Bronze 7.70 

C86400 CDA 864 

C87500 CDA 875 

C90300 CDA 903 Tin Bronze 8.80 

C90500 CDA 905 8.73 

C90700 CDA 907 8.80 

C91600 CDA 916 

C92200 CDA 922 8.64 

C92700 CDA 927 8.80 

C93200 CDA 932 8.91 

C93700 CDA 937 8.95 

C94400 CDA 944 

C95300 CDA 953 

C95400 CDA 954 Al Bronze 9L 7.45 

C95500 CDA 955 8.20 

C95800 CDA 958 8.80 

C96200 CDA 962 8.94 

C96400 CDA 964 8.94 

C97800 CDA 978 8.86 

Carbon & Alloy Steels 

G10050 C1005 

G10080 C1008 7.85 

G10090 C1009 

G10100 C1010 Mild Steel 7.87 

G10150 C1015 Mild Steel 7.87 

G10180 C1018 Mild Steel 7.87 

G10200 C1020 Mild Steel 7.87 

G10260 C1026 Mild Steel 7.87 

G10350 C1035 

G10400 C1040 

G10420 C1042 

G10450 C1045 7.84 

G10500 C1050 7.84 

G10600 C1060 

G10740 C1074 

G10750 C1075 

C1076 

G10800 C1080 

G10950 C1095 

G11170 C1117 

C11L17 

G11370 C1137 

G11410 C1141 

G11440 C1144 

G12144 C12L14 

G12150 C1215 

C15830 

G41300 C4130 7.85 

C4130X 7.85 

All alloys are subject to availability. For alloys not listed here, please contact our sales department. Densities listed are for general reference only.


(g/cm 3 ) 

Carbon & Alloy Steels (cont’d) 

C4130MOD 

G41400 C4140 Alloy Steel 7.85 

C4140C 

C4140D 

C41L40 

C41L50 

G41420 

G41500 

C4142 

C4150 

C4330V 

G43400 C4340 Alloy Steel 7.84 

C4340A 

C4340B 

G52986 C52100 

G86200 C8620 

G86300 C8630 

G87400 C8740 

G93106 C9310 

K01200 A179 7.85 

K01201 A192 

K01800 A516 Gr 55 

A213 

K01807 A214 7.86 

K02100 A516 Gr 60 7.83 

K02303 A572 Gr 50 

K02400 A537 CL1 

K02401 A515 Gr 60 / A283 Gr C 7.83 

K02504 A53 Gr A 7.84 

K02600 A36 7.85 

K02700 A516 Gr 70 7.83 

K02801 A285 Gr C 7.84 

K03000 A500 Gr B 

K03005 A53 Gr B 7.87 

K03006 A333 Gr 6 / A106 Gr B 7.84 

K03009 A350 Lf 1 

K03101 A515 G 70 7.83 

K03300 A455 

K02707 A210 Gr A1 

K03501 A210 Gr C 

K03502 A181 Gr 2 

K03506 A266 CL 2 

K11430 A588 Gr A/Cor-Ten B 7.83 

K11510 A242 Type1/Cor-Ten A 7.89 

K11547 A213 T2 

K11572 A182 F11(1¼Cr, ½Mo) 7.86 

K11597 A213 T11 

A513 

K11662 A514 Gr D 

K11757 A387 F12 7.87 

K11789 A387 F11 

K11804 A656 Gr 80 

A694 Gr 52 

K11820 A204 Gr A 

K11856 A514 Gr A 

K12020 A204 Gr B 

K12022 A302 Gr B 

K12023 A209 T1a 

K12045 A541 

K12521 A533 Gr A 


(g/cm 3 ) 

Carbon & Alloy Steels (cont’d) 

K12542 A202 Gr B 

K12766 A508 Class 2 

K13050 A350 Lf 5 

K13502 A508 CL1 

K20747 A710 Gr A 

K21590 A182 F22 (2¼ Cr, 1 Mo) 7.86 

K24728 A355 Gr A 

K31820 HY80 

K32018 A203 Gr E 

K32045 HY100 

HY130 

K41545 A387 F5 

K42544 A182 F5a (5 Cr, 1/2 Mo) 7.78 

K81340 A553 

A569 

A606 

A610 

A611 7.87 

K90941 A182 F9 (9 Cr, 1 Mo) 7.67 

N08705 HP 

HP50 

K91283 HP 9-4-30 

K92890 Nimark 250 

A120 

A366 

S50300 A182 F7 7.78 

S50200 A387 Gr 5 

Manganese Steel 

K44220 300M 

Coated, Plated or 

Special Conditioned Steels 

Aluminized Steel 

Chrome Plated Steel 

Galvanized Steel 

Terne Steel 

Tin Plated Carbon Steel 

Tin Plated Steel 

Heat & Corrosion Resistant Steels 

Including Stainless Steel 

S13800 13-8 PH Mo 

S15500 15-5 PH 7.80 

S15700 15-7 PH Mo 7.80 

15B30 

S17400 17-4 PH 7.80 

S17700 17-7 PH 7.80 

K14675 17-22A 

K23015 17-22AS 

18SR 

S16100 CROLOY 16-1 

S20100 201L 7.94 

S20300 203 

S30100 301 7.90 

S30200 302 7.94 


(g/cm 3 ) 


Including Stainless Steels (cont’d) 

302 HQ 

S30300 303 7.90 

303 (P-70) 

S30323 303Se 

S30400 304 7.94 

S30403 304L 7.94 

S30409 304H 

304 .25%B 

304 1%B 

S30451 304N 

S30453 304LN 

S30800 308 8.00 

S30883 308L 

S30900 309 7.98 

S30908 309S 8.00 

S31000 310 7.98 

S31008 310S 7.98 

S31009 310H 

S31600 316 7.85 

S31603 316L 7.98 

316LM 7.98 

S31653 316LN 

S31635 316Ti 7.98 

S31700 317 7.98 

S31703 317L 7.98 

S31725 317LM 7.98 

S31753 317LN 7.90 

317LNMo 7.98 

S32100 321 7.90 

S32900 329 7.98 

N08330 330 8.03 

N06333 333 8.24 

S34700 347 8.03 

S34800 348 

S40300 403 7.70 

S40500 405 7.80 

406A1 

406A2 

406A4 

S40900 409 7.64 

S41000 410 7.70 

S41008 410S 

S41600 416 7.70 

S41800 418 

S42000 420 7.70 

S42020 420F 

S42200 422 

S43000 430 7.72 

S43036 430Ti 

S43100 431 7.73 

S43700 437 

S43035 439 7.64 

S44002 440A 7.70 

S44004 440C 7.70 

S44100 441 

S44400 444 7.80 

S44600 446 7.65 



(g/cm 3 ) 


Including Stainless Steels (cont’d) 

N08904 904L 8.00 

904LN 

S21460 XM-14 (Tenelon) 

S38100 XM-15 

S66286 A-286 7.90 

S35000 AM 350 7.81 

S35500 AM 355 7.91 

AM 363 

Maraging 250; 300; 350 

Nickel Alloys 

N99645 Colmonoy 45 

N99646 Colmonoy 46 

N13100 IN 100 7.75 

N06003 Nichrome 5 

N06004 Nichrome 60 8.31 

N06008 Nichrome 70 

Nimonic 105 

Nichrome 3228 

Pure Metals 

M02XXX Barium B10 

L01XXX Cadmium 8.65 

R2XXXX Chromium 7.19 

R30XXX Cobalt 8.85 

W6XXXX Copper 8.89 

P00020 Gold (99.95) 18.88 

R02XXX Hafnium 13.10 

L04XXX Indium 

FXXXXX Iron 7.87 

L50050 Lead 11.35 

MIXXXX Magnesium 1.74 

M2XXXX Manganese 7.21/ 7.44 

R03XXX Molybdenum 10.22 

N02290 Nickel 8.57 

R04210 Niobium 8.57 

P03980 Palladium 12.02 

P04995 Platinum 21.45 

M3XXXX Silicon 2.33 

P07010 Silver 10.50 

R05XXX Tantalum 16.65 

L13008 Tin 7.30 

R07005 Tungsten 19.30 

R08XXX Vanadium 

Z15001 Zinc 7.13 

Magnesium Alloys 

M10410 Magnesium AS41A 

M11311 Magnesium AZ31B 1.83 

Magnesium WE43 

Magnesium ZC71 

M11910 Magnesium AZ91A 

M12330 Magnesium EZ33A 

M16400 Magnesium ZK40A 

M16410 Magnesium ZE41A 


(g/cm 3 ) 

Reactive & Refractory Metals 

Colubium 85 

Tantaloy “60” 

Tantaloy “63” 

60/Ta-40/Co 12.10 

R03640 Molybdenum (TZM) 10.22 

R30003 Elgiloy 8.30 

R30035 MP35N 8.91 

Ti Beta 21S 

Ti Di-Boride 

R50250 Ti Gr 1 4.52 

R50400 Ti Gr 2 (cp) 4.52 

R58010 Ti 3-11-13 

R50700 Ti Gr 4 

R54521 Ti 5-2.5 

R56210 Ti 6-2-1-1 

R54620 Ti 6-2-2-4 

R56401 Ti 6-4ELI 

R56260 Ti 6-2-4-6 

R56400 Ti Gr 5 (6 Al, 4 V) 4.43 

R52400 Ti Gr 7 4.52 

R54810 Ti 8-1-1 

Ti Gr 9 4.52 

R52250 Ti Gr 11 4.52 

R53400 Ti Gr 12 4.43 

Ti 15-3-3-3 

R52402 Ti Gr 16 4.52 

Ti 25MO 

Ti Gr 444 

Ti Gr 450 

Ti Gr 479 

R58640 Beta C-Ti 4.82 

HD17 Tungsten 

KBI 40 

KBI 41 

Tribocor 532 

R60702 Zirconium 702 6.10 

R60704 Zirconium 704 6.52 

R60705 Zirconium 705 6.51 

R60802 Zircalloy II 6.56 

R60804 Zircalloy IV 6.56 

Solders 

L50113 2.5 Sn/97 Pb/.5 Ag 

L50750 Calcium Sn Pb 

L51120 Lead (Chemical) 

L52605 Lead with 1% Sb 



L54320 5 Sn/95 Pb 11.00 

3 Sn/97 Pb (Modine Solder) 

L54520 10 Sn/90 Pb 10.90 

L54710 20 Sn/80 Pb 10.20 

L54822 30 Sn/70 Pb Alloy C 

L54915 40 Sn/60 Pb 9.31 

L55030 50 Sn/50 Pb 8.89 

60 Sn/40 Pb 8.42 

70 Sn/30 Pb 

92.5 Sn/7 Pb/.5 Ag 


(g/cm 3 ) 

P07500 

P07501 

P07720 

Solders (cont’d) 

Silver Solder B AG1A 

Silver Solder B AG3 

Silver Solder B AG8 

Anti-Friction Babbit 

DZL Tin Babbit 

Modine 

Lead Babbit 

Tin Babbit 

ZAMAK 3 

ZAMAK 5 

Tool Steels 

T11302 M2 8.16 

T11304 M4 

M35-1 

T11342 M42 

T11350 M50 

M509 

T12001 T1 8.67 

T20811 H11 7.75 

T20812 H12 

T20813 H13 7.79 

T20821 H21 

T30102 A2 7.86 

T30106 A6 

T30110 A10 

T30402 D2 7.76 

T30404 D4 

T30407 D7 

T31501 O1 

T31502 O2 

T31506 O6 

T41901 S1 

T41905 S5 

T41906 S6 

T41907 S7 

T51620 P20 

T61206 L6 7.86 

T72301 W1 

CPM10V 

AZ 

CRB-7 

T20813 H13 7.79 

M73 

Silicon Corbide 

KZ-84 Carbide 

KZ-94 Carbide 

Titanium Carbide 

Tungsten-Carbide C-2 14.85 

Tungsten-Carbide 6% NI 

Tungsten-Carbide 8% CO 

Tungsten 2% TH 



(g/cm 3 ) 

Non-Metals 

ABS 

Acetal 

Acrylic 

AD85 Ceramic 

Buna-N 

Butyl Rubber 

Ceramic 

Chlorobutyl 

Clear Vinyl 

CPVC 

Cured Rubber 

Delrin 

Delrin Black 

EPDM-42 

EPDM-60 

EPDM-70 .86 

EPDM-80 

Ethylene Propylene Teropolymer 

FRP 

Graphitar 14 

Graphite 1.91 

Halar 

Hypalon ® 

Kalrez ® 

Kanthal A1 

Kanthal D 

Kel-F 

Kynar 1.75 

Lexan 1.20 

Neoprene 1.40 

NORYL EN-265 

Nylatron GS 

Nylon 

Nylon 66 

Nylon 101 

Penlon 

Phenolic 

Plexiglass 

Polstyrene 

Polyamide-Nylon 

Polycarbonate 

Polyetheretherkeytone (PEEK) 

Polyethylene-Crosslink 

Polyethylene-High density .952 

Polyethylene-Low density .923 

Polyethylene-UHMW 

Polyprophylene .905 

Polyurethane 

Polyvinylchoride (PVC) 1.39 

Porcelain CTD 

PVCCL 

Pyrex 

Quartz 

Roulon 

Rubber 

Ryton 

Si C Ceramic 


(g/cm 3 ) 

Non-Metals (cont’d) 

Si C Hexaloy 

Silicon Lump 

Silicon Rubber 

Teflon ® 2.16 

Teflon ® FEP 

Teflon ® GL/F 

Teflon ® PFA 

Teflon ® PTFE 

Tefzel 

Ultra High Molecular Polyethlene 

Viton ® 1.81 

Viton ® A 

Viton ® B 

Miscellaneous Cast Alloys 

128 Gr C 

422 

ABEX-SPA 

ABEX-HC-250 

Alloyco N-3 

F10005 Grey Cast Iron G-2 C50 

F11401 Grey Cast Iron CL20 

F12101 Grey Cast Iron G-1 CL30 

F12401 Grey Cast Iron CL35 6.97 

F12801 Grey Cast Iron G-2 CL40 

F13502 Grey Cast Iron CL50 

F32800 Ductile Cast Iron 60-40-18 



Ductile Cast Iron 70-50-05 


F45000 A532 CLI Type A 

F45003 A532 CLI Type D 

F45009 A532 CL3 

F43010 A571 

J91309 A128 GRC 

J02502 A218 WCA Cast Steel 

J03002 A216 WCB Cast Steel 

J42045 A217-C5 

J22000 A217-WC5 

J03000 A27 GR60-30 

J03001 A27 GR65-35 

J02501 A27 GR70-40 

J03008 B STEEL 

J91150 CA-15 7.61 

J91540 CA-6NM 

J92110 CB-7Cu2 

J92200 CB-7Cu1 

J92600 CF-8 7.75 

J92602 CF-20 7.75 

J92700 CF-3 

J92701 CF-16F 7.75 

J92710 CF-8C 7.75 

J92800 CF-3M 7.75 

J92900 CF-8M 7.75 

J93000 CG-8M 7.75 


(g/cm 3 ) 

Miscellaneous Cast Alloys (cont’d) 

J93370 CD-4MCu 7.81 

J95150 CN-7M 8.00 

N06040 

N02100 

CY40 

CZ100 

CW2M 

N30002 CW12M 8.94 

CW6MC 

CW7M 

S45100 

J93005 

J93403 

J92603 

J93503 

J94204 

J94224 

J94605 

F6NM 

HD 

HE 

HF 

HH 

HK40 

HK50 

HT 

N7M 

N12M 

NI HARD I 

NI HARD IV 

NIRESIST Type 1 7.32 

NIRESIST Type 2 

NIRESIST Type 2B 

Miscellaneous Pipe Alloys 

K03006 A333 Gr 6 / A106 GrB 7.84 

A178 

API5LX-42 

API5LX-52 

API5LX-60 

API5LX-65 

API5LX-70 

API Gr5L (ASTM A53) 7.87 

C56 

C75 

C90 

C95 

J55 7.86 

K55 7.86 

L80 7.86 

N80 7.86 

P105 

P110 

Q125 

Zeron 100 7.80 

Teflon ® is a registered trademark of DuPont. Hypalon ® , Kalrez ® , and Viton ® are registered trademarks of DuPont Dow Elastomers. 


Alloys Listed by Trademark 


(g/cm 3 ) 

Allegheny Ludlum Corporation 

316LXN 8.03 

S31725 317LX 8.03 

S31726 317LXN 8.03 

N08367 AL-6XN ® 8.06 

AL-6XN Plus 

N08904 AL-904L 7.95 

S15500 AL 15-5 

S15700 AL 15-7 

S17400 AL 17-4 

S17700 AL 17-7 

N08020 AL 20 8.08 

S32003 AL 2003 7.78 

AL 22-3 

S44735 AL 29-4C ® 7.65 

S20400 AL 30 

S24000 AL 33 7.84 

K93600 AL 36 

AL 42 

AL 45 

S20910 AL 50 7.95 

N14052 AL 52 

N02200 AL 200 8.90 

N02201 AL 201 8.90 

S20153 AL 201LN 7.86 

AL 216 

S21904 AL 219 7.85 

S31803 AL 2205 7.88 

S32550 AL 255 7.72 

N10276 AL 276 8.90 

AL 304DA 7.86 

AL 310L 

N08800 AL 332 8.03 

AL 344 

N04400 AL 400 8.83 

AL 403 

AL 409Cb 7.76 

S40930 AL 409HP 7.76 

AL 410 7.65 

AL 410HC 

AL 418 Special 7.86 

AL 420 7.73 

AL 425 Mod 7.72 

AL 433 7.75 

AL 436S 7.75 

S43035 AL 439HP 

AL 440A 7.74 

AL 440C 

AL 441 7.71 

AL 441HP 

AL 467 

AL 468 

K94800 AL 4750 

N06600 AL 600 8.42 

N06601 AL 601 8.05 

AL 610 

AL 611 


(g/cm 3 ) 

Allegheny Ludlum Corp. (cont’d) 

N06625 AL 625 8.44 

N08800 AL 800 8.03 

N08810 AL 800H 8.03 

N08811 AL 800AT 8.03 

N08825 AL 825 8.13 

K91470 ALFA I 7.38 

K91470 ALFA II 7.34 

N06625 ALTEMP ® 625 8.44 

N07718 ALTEMP ® 718 8.19 

S66286 ALTEMP ® A-286 7.92 

N06002 ALTEMP ® HX 8.22 

S35000 AM 350 7.81 

S35500 AM 355 7.91 

AM 362 

AM 363 

S44627 E-BRITE 26-1 ® 7.67 

N08700 JS 700 7.95 

K91470 Ohmaloy ® 30 

K91470 Ohmaloy ® 40 

K94760 Sealmet ® 4 

Sealmet ® 485 

Silectron ® 

Carpenter Technology Corp. 

N08020 20Cb3 ® 8.08 

N08024 20Mo4 ® 8.11 

N08026 20Mo6 ® 8.13 

N20910 22 Cr-13 NI-5 Mn 7.88 

S28200 18-18 PLUS ® 7.88 

S45000 Custom 450 ® 7.75 

S45500 Custom 455 ® 7.76 

N07716 Custom 625 PLUS ® 8.40 

S32950 7 Mo PLUS ® 7.75 

N07031 PYROMET ® 31 7.99 

S30430 Custom Flo 302 HQ 7.92 

S30300 Project 70 ® Type 303 7.83 

N06600 PYROMET ® 600 8.43 

R30605 L605 9.20 

S66286 CONSUMET ® A286 7.92 

HyMu “77” 

HyMu “80” ® 8.74 

High Permability “45” 

High Permability “49” ® 8.18 

NI MARK ® 250 8.02 

Temp. Compensator “30” 8.70 

Temp. Compensator “32” 8.12 

K93601 Carpenter Invar “36” ® 8.05 

K94610 KOVAR ® 8.36 

K94100 Glass Sealing “42” 8.12 

N14052 Glass Sealing “52” 


(g/cm 3 ) 

Deloro Stellite Inc. 

Deloro ® alloy #30 

Deloro alloy #40 8.20 

Deloro alloy #50 

Delchrome ® alloy W 

Delchrome alloy #90 

Delchrome alloy #93 

Nistelle ® alloy B-2C 

Nistelle alloy C-4C 

Nistelle alloy X 

NoCo TM 02 

Stellite ® alloy #3 8.69 

R30404 Stellite alloy #4 8.73 

R30006 Stellite alloy #6 8.46 

R30016 

STELLITE 6B (Wrought Alloy) 

STELLITE 6K (Wrought Alloy) 

R30012 Stellite alloy #12 

Stellite alloy #19 







R31001 

Stellite alloy Star J 





Tribaloy ® T-400 8.99 

Tribaloy ® T-700 8.72 

Tribaloy T-745 

Tribaloy T-800 8.64 

Tribaloy T-900 

Delta Centrifugal Corp. (Cast Steels) 

A436 Type 1; Type 2; Type 3 

A439 D2; A439 D3 

B407 

J91150 CA 15 

CA 40; CA40F 

J91540 CA6NM 

CB7Cu-1; CB7Cu-2 

J93370 CD4MCu 

CF3; CF3M; CG3M 

CF8; CF8M; CG8M; CF8C 

CF10SMnN 

CF16Fa 

J93790 

J95150 

N02100 

CG6MMN 

CN7M 

CW6MC 

CW12MW 

CY40 

CZ100 

HD; HE; HF; HH; HK; HT 

All alloys are subject to availability. For alloys not listed here, please contact our sales department. Densities listed are for general reference only. 

All TM and ® listed under company headings are trademarks or registered trademarks of that company.


(g/cm 3 ) 

Delta Centrifugal Corp. (cont’d) 

M25S 

M30C; M30H 

M35-1 

N12M 

C96400 70-30 CuNi 

C96200 90-10 CuNi 

C83600 85-5-5-5 

C85700 Naval Brass 

C86500 65K Mn Brz 

C86300 100K Mn Brz 

C90300 Navy G 

C92200 Navy M 

C92300 Leaded Tin Brz 

C93200 660 Brz 

C95400 9C AL Brz 

C95500 9D AL Brz 

Flowserve 

N30107 Durco CW6M (Chlorimet 3)9.00 

J92600 Durco CF8 7.76 

J92900 Durco CF8M 7.76 

N30007 Durco N-7M (Chlorimet 2) 9.22 

J93370 Durco CD-4MCu 

J93900 Durcomet 5 7.85 

N24135 Durco M35 8.65 

Durichlor 51 7.06 

N08007 Durimet 20 (CN-7M) 7.96 

Duriod 7101 

Duriod 7107 

Duriod 7201 

Duriod 7301 

Haynes International 

N10001 HASTELLOY ® B alloy 

N10665 HASTELLOY B-2 alloy 9.20 

N10675 HASTELLOY B-3 ® alloy 9.20 

N10002 HASTELLOY C alloy 

N06455 HASTELLOY C-4 alloy 8.60 

N06022 HASTELLOY C-22 ® alloy 8.60 

N10276 HASTELLOY C-276 alloy8.80 

N06200 HASTELLOY C-2000 ® 8.50 

N06007 HASTELLOY G 8.27 

N06985 HASTELLOY G-3 alloy 8.27 

N06030 HASTELLOY G-30 ® alloy 8.22 

N10004 HASTELLOY W alloy 9.00 

N06002 HASTELLOY X alloy 8.23 

N08320 HASTELLOY 20MOD 

HAYNES 6B alloy 

R30605 HAYNES 25 alloy 9.13 

HAYNES 75 alloy 


N07214 HAYNES 214 alloy 8.05 


HAYNES 242 alloy 9.06 




(g/cm 3 ) 

Haynes International (cont’d) 

HAYNES 617 alloy 8.36 



HAYNES D-205 alloy 

N12160 HAYNES ® HR-160 ® alloy 8.01 

N08120 HAYNES HR-120 ® alloy 8.07 

N07041 HAYNES R-41 alloy 8.25 

HAYNES Ti-3Al-2.5V 

N07750 HAYNES X-750 alloy 8.25 

R30155 MULTIMET ® alloy 8.19 

R31233 ULTIMET ® alloy 8.47 

N07001 Waspaloy alloy 8.20 

Kubota Metal Corporation 

KCR13C 

KCR13CA 

KCR13CB 

KCR12N 

KCR20N 

KCR8NA 

KCR8NB 

KCR8NC 

KCR8NMB 

KCR8NMC 

KCRD183 

KCRD283 

Outokumpu 

S31803 Avesta 2205 7.80 

S30415 Avesta 153MA 

S30815 Avesta 253MA 

S31254 Avesta 254SMO 8.00 

S32654 Avesta 654SMO 8.00 

S31726 317LMN 8.00 

34LN 

RMI Titanium 

R50250 Ti Gr 1 4.52 

R50400 Ti Gr 2 4.52 

R50550 Ti Gr 3 4.52 

R50700 Ti Gr 4 

R56400 Ti Gr 5 4.44 

R52400 Ti Gr 7 4.52 

R56320 Ti Gr 9 4.52 

R52250 Ti Gr 11 4.52 

R53400 Ti Gr 12 4.43 

R52402 Ti Gr 16 4.52 

R58640 Beta C Ti (ST) 4.82 

Beta C Ti (STA) 4.82 


(g/cm 3 ) 

Rolled Alloys 

RA17-4 

RA188 

S30815 RA 253 MA ® 7.80 

S35315 RA 353 MA ® 

S30908 RA309 7.89 

S30909 RA309H 

S31008 RA310 7.86 

S31009 RA310H 

S32100 RA321 

N08330 RA330 ® 7.94 

N06333 RA333 ® 8.14 

S44600 RA446 7.47 

RA62 

S30615 RA85H ® 7.59 

N08811 RA800H/AT 

N08825 RA825 

N06600 RA600 8.47 

N06601 RA601 8.11 

RA625 

RA718 

S32205 RA2205 

S32760 Zeron 100 ® 7.84 

Sandusky International Inc. 

Alloy 86 7.78 

Alloy EPV 7.78 

1N Bronze 9.02 

Sandvik Steel 

G10550 11L - (AISI 1055) 

13C 

G10740 15LM - (AISI 1074) 

15N2/15N2C 

G10950 20C - (AISI 1095) 

9H574 

15W12C1 

S42000 6C27 - (AISI 420) 

7C27Mo2 

12C27; 12C27 Mod. 

13C26 

19C27 

S30403 3R12 - (AISI 304L) 

S30200 12R10 - (AISI 302) 

S30100 12R11 - (AISI 301) 

S30100 11R51 - (AISI 301) 

9RU10 - (AISI 631) 

13RM19 

S32750 SAF 2507 8.00 

Special Metals 

N02200 Nickel 200 8.89 

N02201 Nickel 201 8.89 

N02205 Nickel 205 8.89 

Nickel 212 

N02270 Nickel 270 




(g/cm 3 ) 

Special Metals (cont’d) 

BRIGHTRAY ® alloy 35 8.30 

N06004 BRIGHTRAY ® alloy B 8.30 

N06003 BRIGHTRAY ® alloy C 8.30 

BRIGHTRAY ® alloy F 8.30 

N06003 BRIGHTRAY ® alloy S 8.30 

Electroformed Nickel 

N03301 DURANICKEL ® alloy301 8.19 

FERRY ® alloy 

INCOCLAD ® 671/800HT® 

N08020 INCOLOY ® alloy 020 8.08 


N08926 INCOLOY ® alloy 25-6MO 8.20 



N08810 INCOLOY ® alloy 800H 7.94 

N08811 INCOLOY ® alloy 800HT 7.94 

S35045 INCOLOY ® alloy 803 7.86 


INCOLOY ® alloy 840 7.83 

S35135 INCOLOY ® alloy 864 TM 8.02 


N09908 INCOLOY ® alloy 908 


N09925 INCOLOY ® alloy 925 TM 8.08 

S66286 INCOLOY ® alloy A-286 7.94 

INCOLOY ® alloy DS 7.86 

S67956 INCOLOY ® alloy MA956 7.25 

N06950 INCONEL ® alloy 050 8.39 



INCONEL ® alloy 601GC 8.11 




INCONEL ® alloy625LCF 8.44 





N07719 INCONEL ® alloy 718SPF TM 

N07725 INCONEL ® alloy 725 TM 8.30 

N07750 INCONEL ® alloy X-750 8.28 


N07754 INCONEL ® alloy MA754 8.55 

INCONEL ® alloy MA758 8.55 

R30783 INCONEL ® alloy 783 

N10276 INCONEL ® alloy C-276 8.89 

N06985 INCONEL ® alloy G-3 8.14 

N06002 INCONEL ® alloy HX 8.22 

INCOTHERM TM alloy TC 

INCOTHERM TM alloy TG 

KOTHERM ® alloy KP 

KOTHERM ® alloy KN 

N04400 MONEL ® alloy 400 8.80 

N04405 MONEL ® alloy R-405 8.80 

N05500 MONEL ® alloy K-500 8.44 

K93600 NILO ® alloy 36 8.11 

NILO ® alloy 365 


(g/cm 3 ) 

Special Metals (cont’d) 

K94100 NILO ® alloy 42 8.11 

NILO ® alloy 475 

K94800 NILO ® alloy 48 8.11 

K94610 NILO ® alloy K 8.16 

NILOMAG ® alloy 77 8.77 

N06075 NIMONIC ® alloy 75 8.36 

N07080 NIMONIC ® alloy 80A 8.19 

NIMONIC ® alloy 86 



NIMONIC ® alloy 105 8.01 




NIMONIC ® alloy PE16 

NIMONIC ® alloy PK33 

NIOTHERM ® alloy NP 

NIOTHERM ® alloy NN 

N09902 NI-SPAN-C ® alloy 902 8.11 

RESISTOHM ® alloy 30 


N06604 RESISTOHM ® alloy 60 







RESISTOHM ® alloy Y 

K92890 UDIMAR ® alloy 250 

K93120 UDIMAR ® alloy 300 

S13800 UDIMET ® alloy 13-8Mo 

R30188 UDIMET ® alloy 188 

N07500 UDIMET ® alloy 500 

UDIMET ® alloy 520 

R30605 UDIMET ® alloy 605 



N09979 UDIMET ® alloy D-979 

N07041 UDIMET ® alloy R41 

Stainless Foundry & Engineering, Inc. 

ILLIUM 98 

ILLIUM 98HF 

ILLIUM B 

ILLIUM G 

ILLIUM P 

ILLIUM PD 

Teledyne Allvac 

N06110 Allvac ® Allcorr ® 8.33 

N13017 Allvac ® Astroloy 7.91 

N07041 Allvac ® Rene 41 8.24 

N07001 Allvac ® Waspaloy TM 8.19 

R56320 Allvac ® 3-2.5 4.48 

R54520 Allvac ® 5-2.5 4.45 


(g/cm 3 ) 

Teledyne Allvac (cont’d) 

R54620 Allvac ® 6-2-4-2 4.54 

R56260 Allvac ® 6-2-4-6 4.65 

R56400 Allvac ® 6-4 4.43 

R56402 Allvac ® 6-4 ELI 4.48 

R56620 Allvac ® 6-6-2 4.54 

R56700 Allvac ® 6-7 4.51 

R54810 Allvac ® 8-1-1 4.31 

R50250 Allvac ® 30, Ti CP-1 4.51 

R30035 Allvac ® 35N 8.41 

R50400 Allvac ® 40, Ti CP-2 4.51 

R50550 Allvac ® 50, Ti CP-3 4.51 

R50700 Allvac ® 70, Ti CP-4 4.51 

R58650 Allvac ® Ti-17 4.65 

R52400 Allvac ® Grade 7 4.51 

R53400 Allvac ® Grade 12 4.51 

R58153 Allvac ® Grade 15-3-3-3 4.76 

R58640 Allvac ® 38-644 4.81 

N08330 Allvac ® 330 8.00 

Allvac ® 520 8.22 

N09706 Allvac ® 706 8.08 

N07718 Allvac ® 718-OP ® 8.19 

Allvac ® 720 8.08 

N07252 Allvac ® M-252 8.24 

T11350 Allvac ® M-50 7.78 

S66286 Nickelvac ® A-286 7.92 

N06022 Nickelvac ® C 22 8.02 

N10276 Nickelvac ® C-276 8.89 

N10665 Nickelvac ® H-B-2 9.22 

N06002 Nickelvac ® H-X 8.22 

N05500 Nickelvac ® K-500 8.47 

R31537 Nickelvac ® TJA-1537 TM 8.30 

N08020 Nickelvac ® 23 8.06 

N07080 Nickelvac ® 80 A 8.16 

N04400 Nickelvac ® 400 8.83 

N06600 Nickelvac ® 600 8.41 

N06601 Nickelvac ® 601 8.05 

Nickelvac ® 606 8.36 

N06625 Nickelvac ® 625 8.44 

N06690 Nickelvac ® 690 8.13 

N08800 Nickelvac ® 800 7.94 

N08810 Nickelvac ® 800-H 7.94 

N08825 Nickelvac ® 825 8.14 

N09901 Nickelvac ® 901 8.22 

N07263 Nickelvac ® C-263 8.35 

N10276 Nickelvac ® HC-276 8.94 

N10003 Nickelvac ® H-N 8.77 

N10004 Nickelvac ® H-W 8.99 

R30605 Nickelvac ® L-605 9.22 

N07090 Nickelvac ® N-90 8.11 

S31600 Nickelvac ® R-26 8.19 

N07722 Nickelvac ® W-722 8.24 

N07750 Nickelvac ® X-750 8.30 

N07751 Nickelvac ® X-751 8.24 

S20910 Nickelvac ® XM-19 7.86 

S31675 REX 734 TM 7.89 

S41800 Vasco Greek Ascoloy 7.86 

K91238 Vasco ® 9-4-30 7.83 

G43400 Vasco ® 4340 7.83 




(g/cm 3 ) 

Teledyne Allvac (cont’d) 

G93106 Vasco ® 9310 7.86 

Vasco ® X-2M 7.75 

K24728 Vasco ® D6AC 7.78 

S64152 Vasco ® Jethete M152 7.75 

T20811 VascoJet ® 1000 7.75 

K92890 Vascomax ® C-250 8.00 

K93120 Vascomax ® C-300 8.00 

Vascomax ® C-350 8.08 

Vascomax ® T-200 8.00 

Vascomax ® T-250 8.00 

Timken Latrobe 

R30035 MP35N 8.41 

R30159 MP159 8.36 

S44004 440C 7.75 

S42700 BG42 7.75 

S64152 Jethete M152 7.75 

410Cb 7.77 

S15500 15-5 PH 7.81 

S17400 17-4 PH 7.75 

S13800 PH 13-8 Mo 7.76 

440N-DUR 7.67 

CSS-42L 7.89 

420 Stainless 7.64 

422 Stainless 7.77 

ThyssenKrupp VDM 

N08926 Cronifer 1925hMo 8.10 

N08031 Nicrofer 3127hMo 8.10 

N08020 Nicrofer 3620Nb 8.05 


N10276 Nicrofer 5716hMoW 8.89 


R20033 Nicrofer 3033 7.90 

N06025 Nicrofer 6025HT 7.90 

N06045 Nicrofer 45TM 8.00 

N10629 Nimofer 6629 9.20 

N10665 Nimofer 6928 9.20 

Usinor Industeel 

4003 

Abroclad 

Creusabro ACR 

Creusabro ® 4000 

Creusabro ® 8000 

Creusabro ® M 

CLC 18.9 (H) 

CLC 18.9 L 

CLC 18.10 L 

CLC 18.10 Ti 

CLC 18.10 Nb 

CLC 18.10 N 

CLC 18.10 LN 

CLC 18.12.4 LN 

CLC 18.14.3 L 


(g/cm 3 ) 

Usinor Industeel (cont’d) 

CLC 18.15.4 L 

CLC 17.12.2 (H) 

CLC 17.12.2 L 

CLC 17.12.2 Ti 

CLC 17.12.2 Nb 

CLC 17.12.3 L 

CLC 17.13.3 

CLC 17.13.3 LN 

CLC 17.13.5 LN 

FAST 17.12.2.2 

FAST 18.10 

FAST 17.12.3 

Fora 250 bc 

Fora 360 bc 

Fora 400 bc 

Fora 500 

M 200 

M 250 

M 300 

NUCL 18.10 

NUCL 18.10 Nb 

NUCL 18.10 B 

NUCL 167 SPH 

SIRIUS S12 

SIRIUS S15 

SIRIUS 309 (S) 

SIRIUS 310 (S) 

SIRIUS 314 

SIRIUS 800 (H) 

SIRIUS 600 

Soleil A2 

Soleil A4 

Soleil B2 

Soleil B3 

Soleil B4 

Soleil C5 

SP 300 

SP 400 

SP 400 S 

R50250 Titanium 

UR 16 

UR 35N - 2304 

UR 45N - 2205 

UR 45N Mo - 2205 Mo 

UR 45N - 2306 Mo 

UR 47N - SAF 2507 

UR 51 

UR 52N - 2507 Cu 

UR 65 

UR 76N 

UR 625 

UR 825 

UR B6 (N) 

UR B25 

UR B26 

UR B28 

UR B46 

UR B66 


(g/cm 3 ) 

Usinor Industeel (cont’d) 

UREA 25.22.2 

UREA 316 L mod 

Virgo 39 

Virgo 17.4 PH 

Virgo 15.5 PH 

R60001 Zirconium 

Waukesha Foundry Inc. 

3 WM 8.85 

23 BIWM 8.58 

54C 8.58 

88 WM 8.58 

119 WM 8.58 

EM-27 7.75 

HC250 8.02 



Technical Information Regarding Corrosion Testing - By A. S. Krisher 

Corrosion Testing, Why 

Corrosion tests are conducted for a number of reasons, 

some of which are: 

1. To provide an insight into corrosion mechanisms. 

2. To compare resistance of one alloy to another under 

standard conditions (in alloy development work for 

example). 

3. As a quality control test for a given heat of alloy. 

4. To provide a basis for estimating service life of process 

equipment. 

The discussion which follows relates primarily to reason 

# 4, although the same principles apply in tests conducted 

for other reasons. 

General Requirements for Coupon Tests 

There are a number of “good practice” requirements which 

apply to all coupon testing. 

1. The chemistry and processing history of the material in 

the coupon must be known. 

2. The coupon must be positively identified, usually by 

code numbers stenciled into the specimen. 

3. Data about the specific coupon test should be recorded 

in a permanent log book. Items which must be recorded 

are detailed information on the coupon (chemistry, 

mechanical properties, and processing history), dimensions 

of the coupon, initial weight of the coupon, and 

initial surface condition. Location, condition of exposure, 

and time of exposure must also be recorded. 

Type of Tests 

Data of value in estimating the probable service life of a 

piece of process equipment can be generated in a number 

of ways. 

1. Operating Experience - The most reliable information 

is generated by actual operating experience with equipment 

in identical service. In a sense the equipment is 

being used as a large, complex, expensive coupon. This 

is a costly and slow testing method, especially when 

data on several materials is needed. 

2. Model Equipment - Model equipment installed parallel 

with actual equipment or in a small scale (pilot plant) 

operation can generate information almost as reliable 

as full scale equipment. Care must be exercised to assure 

that important variables are adequately simulated. 

3. Coupons - Field - Coupons exposed in operating equipment 

are widely used. Care must be taken to install 

the coupons so that they are exposed to the corrosive 

conditions of interest. 

4. Coupons - Laboratory - Coupons exposed to laboratory 

solutions from plant operations, or less reliable 

synthetic solutions which approximate the chemistry of 

plant streams, generate useful information if the tests 

are properly designed and conducted. Such tests allow 

study of the affect of changes in process chemistry on 

corrosion. 

5. Instrumental Test Methods - Advanced methods, 

including electrical resistance and linear polarization 

scans, are valuable additions to corrosion testing 

methods. They can generate a continuous record of 

corrosion rate. They also can be used to gain insight 

into corrosion mechanisms. The precautions noted with 

regard to coupon tests also apply with these methods. 

Surface Condition of Coupons 

Surface condition for coupons is a subject of substantial 

debate. A typical vessel as installed in the plant will have 

large surface areas in original mill condition, smaller 

areas of weld heat-affected zone, and areas that have been 

ground during the fabrication process. It is possible to 

replicate all of these conditions on a coupon. However, in 

the interest of simplicity and consistency, it is fairly common 

to machine the coupon surface flat, leaving a standard 

ground surface as defined by the size grading of the 

grinding media. An example would be the “120 grit finish” 

achieved by grinding with a 120 grit belt. This leaves a flat 

surface with clearly detectable scratches, all in a consistent 

direction. Any deviation from this standard initial surface 

is attributable to the exposure in the environment. Any 

effect on corrosion due to the initial finish, or the as welded 

heat-affected zone finish, or the ground surface will be very 

temporary in a corrosive system. 

It is also worth noting that if the surface condition (i.e., the 

mill finish) does provide an improved corrosion resistance 

over the metal without this surface condition, such a situation 

will have questionable reliability in an operating system. 

When this surface condition is damaged mechanically 

or chemically, the corrosion resistance will revert to that of 

the parent metal without the special surface treatment. 

Coupon Mounting 

Coupons should be mounted in such a way that they are 

securely held and are electrically isolated from contact with 

all other metals (except when the purpose of the test is to 

study galvanic corrosion). Mounting materials (brackets, 

bolts, etc.) and insulating materials should be selected to be 

fully resistant to the environment. Failure of any of these 

components will lead to loss of data or loss of electrical 

isolation.

Time of Test 

In general, coupon tests should be run for a minimum of 1 

week. In many cases, it will be worthwhile and desirable to 

evaluate the effect of time of exposure which can be done 

by means of a controlled interval test. 

Economics of Corrosion Testing 

Corrosion testing is not cheap. More specifically, materials 

for a field rack with ten coupons will cost about $150 

with 316 hardware or $250 with Hastelloy C-276 hardware. 

If a field test program required ten such racks, the total 

cost would be $1500 to $2500 plus the direct costs (rack 

assembly, rack installation and removal, record keeping, 

evaluation, reporting, etc.) These costs should be evaluated 

in terms of the benefits derived from the information generated 

by the tests. 

In today’s process industry, direct maintenance costs associated 

with a premature corrosion failure usually run to (at 

least) tens of thousands of dollars, and frequently into the 

hundreds of thousands. The business losses associated with 

such failures can easily be ten times the direct maintenance 

costs. 

Considered in this fashion, it seems evident that the expenses 

of corrosion coupon testing can be easily justified. 

Coupon Evaluation after Exposure 

At the end of the test, observations of the coupon before 

cleaning should be recorded (photographically if appropriate). 

Samples are cleaned by various means (detailed 

in appropriate specifications) to remove all deposits and 

corrosion products from the unreacted metal. After cleaning, 

the coupon is weighed again and the corrosion rate is 

calculated from the weight loss. 

Corrosion 

Rate (CR) 

= 

The constant can be varied to calculate the corrosion rate in 

various units: 

Desired Corrosion Rate Unit (CR) Area Unit (A) K-Factor 

mils/year (mpy) in 2 5.34 x 10 5 

mils/year (mpy) cm 2 3.45 x 10 6 

millimeters/year (mmy) cm 2 8.75 x 10 4 

Metal 

Loss (ML) 


Alloy Density (g/cm 3 ) * Exposed Area (A) * Exposure Time (hr) 

= 


Alloy Density (g/cm 3 ) * Exposed Area (A) 

Desired Metal Loss Unit (ML) Area Unit (A) K-Factor 

mils in 2 61.02 

mils cm 2 393.7 

millimeters cm 2 10.0 

Note that this calculation yields an average rate, assuming 

perfectly even metal loss from all surfaces. Examine 

coupons under low power magnification and record 

evidence of localized attack. End grain attack, localized 

weld attack, intergranular corrosion, accelerated attack 

in stressed area (at the stenciled numbers), and localized 

attack associated with the mounting hardware should be 

noted if present. The depth of penetration of localized 

attack should be determined by means of microscopic 

examination or metallographic examination. 

Advantages of Coupon Testing 

Coupon tests are low in cost, simple to conduct, and allow 

the simultaneous evaluation of numerous materials and 

variations of a single material. Alloy chemistry variations 

and metallurgical variations (ie., the effect of heat treatment, 

microstructure, welding and stress) can be considered. 

Coupon tests are easily adapted to evaluate specific 

types of corrosion, such as crevice corrosion and galvanic 

corrosion. 

Summary 

Coupon testing remains a powerful tool in the corrosion 

engineer’s tool kit. Intelligent and systematic use of this 

tool provides data which allows a knowledgeable and 

experienced engineer to make reliable predictions of field 

performance. 

To Dig Deeper 

There is a large body of literature dealing with corrosion 

coupon testing. The references listed below will serve as a 

useful introduction. 

1. Ailor, W.H. Ed. Handbook on Corrosion Testing and 

Evaluation J. Wiley, 1971. 

2. ASTM G1-81, “Preparing, Cleaning, and Evaluating 

Corrosion Test Specimens.” * 

3. ASTM G4-84, “Conducting Corrosion Coupon Tests in Plant 

Equipment.” * 

4. ASTM G-30. 

5. ASTM G31-72, “Laboratory Immersion Corrosion Testing of 

Metals.” * 

6. ASTM G46-76, “Examination and Evaluation of Pitting Corrosion.” 

* 

7. ASTM G-58. 

8. ASTM G78-83, “Crevice Corrosion Testing of Iron-Base and 

Nickel-Base Stainless Alloys in Seawater and Other Chloride 

Containing Aqueous Environments.” 

* American Society for Testing and Materials, Philadelphia, PA.

Corrosion Coupon Testing 

By John E. Orth for Metal Samples Company 

Corrosion coupons are an inexpensive, effective method for monitoring the corrosion rate in any system 

or structure. However, obtaining meaningful results from these tests is not always as simple as 

measuring the weight loss and calculating the uniform corrosion rate. Surface finish, coupon placement, 

and test duration significantly affect the caliber of your data. The following is designed to be an 

overview of corrosion coupon testing and how to obtain the most reliable data. 

Corrosion coupon testing is an in-line monitoring technique; coupons are placed directly in the process 

stream and extracted for measurement. This monitoring technique provides a direct measurement of 

metal loss that allows you to calculate the general corrosion rate. Also, when using corrosion coupons, 

your results are not dependent on the phase of the environment in which the measurement is performed. 

Benefits of Corrosion Coupon Testing 

✓ Simple and straightforward principle 

✓ Provides specimens for post-test examinations 

✓ Allows comparison between different alloys and inhibitors 

✓ Assesses all forms of corrosion 

✓ Low cost 

Corrosion coupons are most frequently used to investigate general corrosion and determine the corrosion 

rate based on weight loss of the coupon. However, various other forms of corrosion can be examined 

with these coupons: 

✓ Crevice corrosion - Special washers/spacers are available to simulate crevices where the coupon 

surface is partially blocked from the liquid. 

✓ Pitting - This type of attack may be evaluated by visual or microscopic examination of the coupon. 

Use large surface area coupons since the number of initiated pits is proportional to the surface 

area of the specimen. 

✓ Galvanic corrosion -Coupons of different alloys may be placed in electrical contact. 

✓ Susceptibility to stress corrosion cracking - Special coupons such as C-rings and U-bends are 

available to investigate the occurrence of this form of corrosion. 

✓ Scaling - Special coupons with various hole diameters are used to visually assess the extent and 

severity of scaling problems. 

Limitations of Corrosion Coupon Testing 

✓ Measures only the average corrosion rate during the time of exposure. 

✓ Corrosion rates can only be calculated after coupon removal. 

✓ Short exposure periods can yield unrepresentative corrosion rates, especially for alloys that form 

passive films, such as stainless steels. Normal exposure periods frequently approach 90 days. For 

example, ASTM G31 1 recommends minimum exposure time, in hours, as: 

Exposure Time (hours) = 

2000 

expected corrosion rate

Therefore, if a corrosion rate of one mil per year (0.001 inches) is expected, the minimum recommended 

exposure time would be 2,000 hours or 83 1/3 days. 

Selecting Coupons and Exposure Locations 

Selecting the correct alloy to use as your corrosion coupon is by far the most important step in this 

process. If concerned with the general corrosion rate of some system or structure, designate a material 

that is identical, or as close as possible, to the material of construction. For example, select mild 

steel coupons (UNS G10100 or G10200) for use in most cooling towers and copper coupons (UNS 

C11000 or C12200) for service in copper heat exchangers. If unsure of the material of construction, 

consult your vendor. Also, test duplicate specimens to validate your results. 

To obtain the most meaningful results, the surface finish and stress condition of the coupon should 

be identical to that of the structure of interest. This is usually impossible because it is difficult to 

duplicate mill scale and heat treatments of large structures in individual coupons. The best advice is 

to be consistent in your tests and specify a particular surface finish, such as 120 grit or glass beaded. 

Contaminants from surface preparation may also affect the accuracy of your results. Many coupons 

are polished on aluminum oxide or silicon carbide abrasive paper. During polishing, these particles 

may become imbedded in the coupon, modifying the chemistry of the surface. A finishing technique 

that employs vitrified stone grinding wheels, such as double disc grinders, will minimize the contamination 

of the coupon surface. Frequently, coupons are sand or glass bead blasted during finishing. 

The blasting material penetrates the surface and remains imbedded in the coupon. This is especially 

true for softer metals and alloys such as aluminum or copper. Glass beading is preferred 

because it reduces surface damage; it is less abrasive than sand blasting. 2 

The location of the coupon in the process often dictates coupon size and dimensions. Obviously, if 

the coupon must be inserted into the process through a one inch full port valve, the coupon width 

must be less than one inch. Test racks allow for the simultaneous testing of multiple coupons. Be 

sure that the test rack can be inserted and retrieved at appropriate times. Confirm that test racks and 

insertion rods are resistant to corrosive attack from the test environment. Also, to eliminate any 

galvanic effects, check that the coupons are electrically isolated from the test rack. Broken test racks 

or loose coupons can destroy pumps, mixers, and tanks. For example, consider a coupon that, for 

whatever reason, has broken away from its test rack. The coupon drops to the bottom of the pipeline 

or storage tank. Galvanic corrosion and/or crevice corrosion sites can be created, resulting in the 

rapid attack of the pipeline or storage tank. 

The corrosion behavior of many alloys depends significantly on the presence of dissolved oxygen. 

Place corrosion coupons in locations that are representative of the degree of aeration normally encountered 

in the environment of interest. 

The accumulation of corrosion products on the test coupons, whether it is from corroding plant equipment 

or other coupons, can adversely influence the results. For example, the presence of cupric ions in 

solution, resulting from the corrosion of heat exchangers or coupons, will enhance the corrosion resistance 

of stainless steel coupons. 

Additional guidelines for selecting coupon geometries and locations are detailed in ASTM G4-84. 3

Post Exposure Inspections 

Test coupons should be rinsed with distilled water or a suitable solvent, air dried, and placed in a sealed 

bag. Plastic bags treated with vapor phase corrosion inhibitors are useful. Weigh the cleaned coupon to 

a tenth of a milligram. Specific cleaning and weighing procedures are outlined in ASTM G-1. 4 The 

formula for calculating the corrosion rate in mils per year is: 

Corrosion Rate (mpy) = 

534 * W 

D * A * T 

where W is the weight loss in milligrams, D is the density of the coupon in grams/cm 3 , A is the exposed 

area in square inches, and T is the exposure time in hours. 5 

Occasionally, users will obtain the weight loss data and then dispose of the coupon. This is unfortunate; 

important information may be obtained from these coupons. For example, a visual or microscopic 

inspection shows whether the attack was uniform or localized (pitting or crevice corrosion) in nature. 

Maintain a record of the condition and appearance of the coupons, especially if any coatings or films 

are present. 

Advanced Test Methods 

Planned Interval Tests are somewhat more involved than individual coupon analyses, but the additional 

information obtained justifies the additional effort. This technique identifies the accumulated 

effects of corrosion at several time intervals such as: the initial corrosion rate of fresh metal, the initial 

corrosion rate of fresh metal after long exposures; and the corrosion rate of metal after long exposures. 

Essentially, this technique allows you to monitor the corrosiveness of the liquid and the metal corrodibility 

as a function of time. It is an effective tool for monitoring inhibitor effectiveness over time. Specific 

guidelines and procedures for conducting planned interval tests are detailed elsewhere. 6, 7 

Additional Uses for Corrosion Coupon Analyses 

Although the primary reason for coupon testing and analyses may be to monitor corrosion rates, several 

other “real-world” reasons exist: 

• Defend yourself against the competition’s claims of inferior corrosion control program. A competitor 

may try to discredit the effectiveness of your corrosion control program by placing a coupon in a 

process that uses your inhibitors and comparing its appearance and weight loss to a coupon from a 

similar process that uses his chemicals. Find out where these coupons were placed in each process. 

It is likely that the coupon from your process was suspended from a copper wire into a high velocity 

turbulent location whereas your competitor’s coupon was fixed to an insulating insertion rod into a 

deaerated reservoir. 

• Oversee the effectiveness of your vendor’s corrosion control program. If you employ a vendor for 

corrosion control services, installing your own coupons may be a cost-effective method of evaluating 

their results, thus insuring that you are getting what you are paying for. 

• Evaluate inhibitor performance and dosing levels. Microscopic examinations of the coupon surface 

and weight loss data are valuable tools for evaluating the long term performance of inhibitors. 

• Monitor cleaning procedures and shutdowns. Inserting coupons at the beginning of cleaning or 

shutdown and removing them before startup identifies any corrosive damage that may have occurred 

during these periods.

Summary 

Several ASTM Standards have been referenced in this document. Recommended practices for field 

coupon corrosion testing and surface finish on corrosion coupons are currently being written by the 

National Association of Corrosion Engineers and ASTM, respectively. These standards and practices 

attempt to cover applications ranging from the oil patch to chemical process plants to water treatment 

facilities. Reviewing these documents and applying their recommendations will aid you in obtaining 

meaningful results from corrosion coupon testing, whatever your area of specialization. 

Survey your needs and requirements in your business and explore opportunities where corrosion coupon 

testing and analyses may be beneficial to you. When you perform coupon tests, ask “Why am I 

conducting these tests and what do I hope to gain from this work”, then design your experiments 

accordingly. Record your results in a database to assist in making accurate comparisons and recommendations 

for future projects. 

1. ASTM G31 -90, “Standard Method for Conducting Corrosion Coupon Tests in Plant Equipment”, 

Annual Book of ASTM Standards. Vol. 3.02, ASTM, Philadelphia, PA., 1993. 

2. ASTM Committee Gl: Workshop on the Effects of Surface Finish on Corrosion Testing, ASTM Fall 

Meeting, Dallas, TX, Nov., 1993. 

3. ASTM G4-84, “Standard Method for Conducting Corrosion Coupon Tests in Plant Equipment”, 

Annual Book of ASTM Standards. Vol. 3.02, ASTM, Philadelphia, PA., 1993. 

4. ASTM G1-90, “Standard Practice for Preparing, Cleaning, and Evaluating Corrosion Test Specimens”, 

Annual Book of ASTM Standards, Vol. 3.02, ASTM, Philadelphia, PA., 1993. 

5. M. Fontana, Corrosion Engineering. Third Edition, McGraw-Hill, New York, NY., 1986, p. 14. 

6. ASM Handbook on Corrosion(ED. Vol. 13, ASM International, Metals Park, OH, 1992, pp 223-4. 

7. A. Wachter and R. Treseder, “Corrosion Testing of Metals for Process Equipment”, Chemical 

EngineeringProgress, Vol. 43, 1947, pp. 315-326.


Introduction to Electrical Resistance Monitoring 

ER Probes 

ER Instrumentation 

Return to Corrosion Monitoring menu

Electrical Resistance Monitoring 

(ER) Introduction 

The electrical resistance (ER) technique is an “on-line” method of monitoring the rate of corrosion 

and the extent of total metal loss for any metallic equipment or structure. The ER technique measures 

the effects of both the electrochemical and the mechanical components of corrosion such as 

erosion or cavitation. It is the only on-line, instrumented technique applicable to virtually all types of 

corrosive environments. 

Although universally applicable, the ER method is uniquely suited to corrosive environments having 

either poor or non-continuous electrolytes such as vapors, gases, soils, “wet” hydro-carbons, and 

nonaqueous liquids. Examples of situations where the ER approach is useful are: 

• Oil/gas production and transmission systems 

• Refinery/petrochemical process streams 

• External surfaces of buried pipelines 

• Feedwater systems 

• Flue gas stacks 

• Architectural structures 

An ER monitoring system consists of an instrument connected to a probe. The instrument may be 

permanently installed to provide continuous information, or may be portable to gather periodic data 

from a number of locations. The probe is equipped with a sensing element having a composition 

similar to that of the process equipment of interest. 

Principles of Operation 

The electrical resistance of a metal or alloy element is given by: 

R = r • 

L 

A 

where: 

L = Element length 

A = Cross sectional area 

r = Specific resistance 

Reduction (metal loss) in the element’s cross section due to corrosion will be accompanied by a 

proportionate increase in the element’s electrical resistance. 

Practical measurement is achieved using ER probes equipped with an element that is freely 

“exposed” to the corrosive fluid, and a “reference” element sealed within the probe body. Measurement 

of the resistance ratio of the exposed to reference element is made as shown in Figure 1.

Figure 1. Probe / Instrument 

Since temperature changes effect the resistance of both the exposed and reference element equally, 

measuring the resistance ratio minimizes the influence of changes in the ambient temperature. 

Therefore, any net change in the resistance ratio is solely attributable to metal loss from the exposed 

element once temperature equilibrium is established. 

All standard Metal Samples Corrosion Monitoring Systems ER probes incorporate a third element 

called the “check” element. Because the check element is also sealed within the probe body, the ratio 

of its resistance to that of the reference element should remain unchanged. Any significant change in 

this ratio indicates a loss of probe integrity. 

Measurement of the ER probe may either be taken periodically using a portable instrument, or on a 

continuous basis using a permanently installed unit. In either case, Metal Samples Corrosion Monitoring 

Systems ER instruments will produce a linearized signal which is proportional to the metal 

loss of the exposed element. The rate of change in the instrument output is a measure of the corrosion 

rate. Continuously monitored data is usually transmitted to a computer/data-logger and treated 

to give direct corrosion rate information. Manual graphing techniques are usually used to derive 

corrosion rate from periodically obtained data as illustrated in Figure 2. 

100 

75 

50 

25 

MPY 

5 

MPY 

12 

MPY 

25 

0 2 4 6 8 10 12 

14 

Time (Days) 

Time (Days) 

Figure 2. Graph plotting measurement versus time to derive corrosion rate. 

ER-2

ER Sensing Elements 

Sensing elements are available in a variety of geometric configurations, thicknesses, and alloy 

materials. Available element types are shown in Figure 3. 

Figure 3. E/R Sensing Elements 

Wire loop elements are the most common element available. This type of element has high sensitivity 

and low susceptibility to system noise, making it a good choice for most monitoring installations. 

Wire loops are generally glass-sealed into an endcap which is then welded to the probe body. The 

glass seal, which is chemically inert in most environments and has a good pressure and temperature 

rating, makes a good choice for most applications. Alloys commonly glass sealed are Carbon Steel, 

AISI 304 and 316 stainless steels. Where glass may be susceptible to corrosion problems, Teflon ® - 

sealed elements are also available. Probes with wire loop elements are normally equipped with a 

flow deflector (or velocity shield) to protect the element from floating debris in the piping system. 

Tube loop elements are recommended where high sensitivity is required to rapidly detect low corrosion 

rates. Tube loop elements are manufactured from a small bore, hollow tube formed into the 

above loop configuration. Carbon Steel is the alloy most commonly used. Tube loops sealed into the 

probe by a Teflon ® pressure seal are also available. Probes using the tubular loop element can be 

equipped with a flow deflector to minimize possible distortion in fast flowing systems. 

Strip loop elements are similar to the wire and tube loop configurations. The strip loop is a flat 

element formed in a loop geometry. The strip loop may be glass or epoxy sealed into the endcap 

depending on the required application. The strip loop is a very sensitive element. Strip loops are 

very fragile and should only be considered for very low flow applications. 

ER-3

Cylindrical elements are manufactured by welding a reference tube inside of a tube element. This 

element has an all welded construction which is then welded to the probe body. Because of this 

element’s all welded construction, exotic alloy elements can be produced relatively easily. This 

probe is ideally suited to harsh environments including high velocity and high temperature systems, 

or anywhere a glass-sealed element is not an option. 

Spiral loop elements consist of a thin strip of metal formed on an inert base. The element is particularly 

rugged and ideal for high-flow regimens. Its comparatively high resistance produces a high 

signal-to-noise ratio, which makes the element very sensitive. 

Flush mount elements are designed to be mounted flush with the vessel wall. This element is very 

effective at simulating the true corrosion condition along the interior surfaces of the vessel wall. 

Being flush, this element is not prone to damage in high velocity systems and can be used in pipeline 

systems that are subject to pigging operations. 

Surface strip elements are thin rectangular elements with a comparatively large surface area to 

allow more representative results in non-homogeneous corrosive environments. Strip elements are 

commonly used in underground probes to monitor the effectiveness of cathodic protection currents 

applied to the external surfaces of buried structures. 

Corrosion Rate Calculation 

When measuring the ER probe, the instrument produces a linearized signal (S) that is proportional to 

the exposed element’s total metal loss (M). The true numerical value being a function of the element 

thickness and geometry. In calculating metal loss (M), these geometric and dimensional factors are 

incorporated into the “probe multiplier” (P), and the metal loss is given by: 

M = 

S x P 

1000 

Both S and P are dimensionless. Metal loss is conventionally expressed in mils (0.001 inches), as is 

element thickness. 

Corrosion rate (C) is derived by: 

C = 

P x 365 (S 2 

- S 1 

) 

T x 1000 

T being the lapse time in days between instrument readings S 1 

and S 2 

. 

ER-4

Table 1 lists element types, thicknesses, probe life, and identification numbers. For temperature and 

pressure ratings see respective probe data sheets. When selecting an element type for a given application, 

the key parameters (apart from the fundamental constraints of temperature and pressure) in 

obtaining optimum results are response time and required probe life. Element thickness, geometry, 

and anticipated corrosion rate determine both response time and probe life. Response time, defined 

as the minimum time in which a measurable change takes place, governs the speed with which useful 

results can be obtained. Probe life, or the time required for the effective thickness of the exposed 

element to be consumed, governs the probe replacement schedule. 

Element 

Wire 

Tube 

Strip 

Type 

loop 

loop 

loop 

Cylindrical 

Spiral 

loop 

Flush (small) 

Flush (large) 

Surface 

Strip 

Thickness 

40 mil 

80 mil 

4 mil 

8 mil 

5 mil 

10 mil 

10 mil 

20 mil 

50 mil 

10 mil 

20 mil 

4 mil 

8 mil 

20 mil 

5 mil 

10 mil 

20 mil 

40 mil 

10 mil 

20 mil 

40 mil 

Probe 

Life 

10 mil 

20 mil 

2 mil 

4 mil 

1.25 mil 

2.5 mil 

5 mil 

10 mil 

25 mil 

5 mil 

10 mil 

2 mil 

4 mil 

10 mil 

2.5 mil 

5 mil 

10 mil 

20 mil 

5 mil 

10 mil 

20 mil 

Element ID 

WR40 

WR80 

TU04 

TU08 

SL05 

SL10 

CT10 

CT20 

CT50 

SP10 

SP20 

FS04 

FS08 

FS20 

FL05 

FL10 

FL20 

FL40 

SS10 

SS20 

SS40 

Table 1. Probe Life and Element ID 

Since probe life and response time are directly proportional, element selection is a compromise 

between data frequency and probe replacement frequency. The graphical relationship between corrosion 

rate, probe life, and response time for all elements normally available from Metal Samples 

Corrosion Monitoring Systems is shown in Figure 4. 

ER-5

ER-6 

Figure 4. Element Selection Guide

Probe Features 

Metal Samples Corrosion Monitoring Systems ER probes are available in a variety of configurations 

and are discussed in detail in later pages of this catalog. The brief summary provided here, gives only 

a broad overview of probe construction. 

The standard material of construction for all Metal Samples Corrosion Monitoring Systems probe 

bodies is AISI 316L stainless steel which conforms with NACE specification MR-0175 for sour 

service conditions. Other materials may be available for extremely aggressive environments. Contact 

our sales department to discuss alternative options. 

The primary pressure sealing mechanism for Metal Samples Corrosion Monitoring Systems E/R 

probes is the element seal, which varies with the precise element specification. However, all Metal 

Samples Corrosion Monitoring Systems process probes incorporate, at the instrument end, a glasssealed, 

pressure-rated, electrical connector. The connector provides a backup seal should leakage 

develop in the element seal. 

The simplest of all probe body configurations is the fixed version, shown in Figure 5. Typically 

equipped with an NPT pipe plug or flange connection, the fixed probe is screwed or bolted into 

place. Probe installation or removal can only be performed during shut-down, unless the probe is 

installed in a side-stream which may be isolated and depressurized. The frequency of shut-down 

should be a factor in the selection of probe life criteria. 

Shield 

Wire, Tube, or Strip 

Loop Element 

Figure 5. Fixed Probe 

Retractable probes are supplied with a 1-inch FNPT packing gland to allow probe insertion and 

removal through a customer-supplied ball valve, in systems with pressures not exceeding 1500 psi. A 

safety frame of rods and plates may be attached to the probe to prevent “backing out” in systems 

with high vibration. Metal Samples Corrosion Monitoring Systems requires the Easy Tool for probe 

insertion or retraction in systems with pressure over 150 pounds. 

ER-7

Retractable probes find wide applications in refinery and petrochemical industries. A typical probe is 

shown in Figure 6. 

Retrievable probes are employed in process systems operating at pressures up to 3600 psi. These 

probes must be used in conjunction with specially designed fittings, retrieval tools and service 

valves, all of which are described in the High Pressure Access Systems section. The retrievable 

design is the industry standard for oil production systems. A typical installation is shown in Figure 7. 

Safety Clamp 

Nipple 

Bleed Valve 

Heavy Duty 

Cover w/ Hole, 

Bleed Valve & 

Pressure Gauge 

1" Full Port 

Valve 

HP Hollow 

Plug Assembly 

HP Access 

Fitting 

Safety Nut 

Retrievable 

ER Probe 

Figure 6. Retractable Probe 

Figure 7. Retrievable Probe 






ER Probes 

ER0250 - Atmospheric Probe 

ER0500 - Surface Strip Element and Cylindrical 

Element Types 

ER1000 - NPT Pipe Plug & Loop Element 

ER2000 - Fixed Length with 3/4" NPT Pipe Plug & 

Loop Element 

ER2100 - Fixed Length with 3/4" NPT Pipe Plug & Cylindrical Element 

ER3000 - Adjustable Length with 3/4" NPT Pipe Plug & Loop Element 

ER3100 - Adjustable Length with 3/4" NPT Pipe Plug & Cylindrical Element 

ER3200 - Adjustable Length with 1 1/2" NPT Pipe Plug & Flush Element 

ER4000 - Retractable with Packing Gland & Loop Element 

ER4100 - Retractable with Packing Gland & Cylindrical Element 

ER4200 - Retractable with Packing Gland & Small Flush Element 

ER4210 - Retractable with Packing Gland & Large Flush Element 

ER6000 - Fixed Length with Flange & Loop Element 

ER6100 - Fixed Length with Flange & Cylindrical Element 

ER6200 - Fixed Length with Flange & Flush Element 

ER7000 - Retrievable w/ Loop Element for High Pressure Access Systems 

ER7100 - Retrievable w/ Cylindrical Element for High Pressure Access Systems 

ER7200 - Retrievable w/ Flush Element for High Pressure Access Systems 

ER7210 - Retrievable w/ Large Flush Element for High Pressure Access Systems 

ER7220 - Retrievable w/ Large Adjustable Flush Element for High Pressure Access Systems 

ER7300 - Retrievable Spiral Loop for High Pressure Access Systems 

Return to ER menu

Model ER0250 

Atmospheric Probe 

Model ER0250 is a probe used to monitor corrosion in atmospheric environments. The probe consists 

of an element which is mounted onto an epoxy board. One side of the element is exposed to the 

corrosive environment while the other side is covered, acting as a reference element. The ER0250 

connects to a special cable that allows it to be used with electrical resistance probe instrumentation. 

Replacement elements may be ordered without cable. The probe comes with a 3/16" hole for easy 

mounting. 


Probe Body - Epoxy 

Temperature Rating - 250°F / 121°C 

Standard Element Sizes - 4 or 8 mils (useful range is half of thickness) 






ER0250 Ordering Information 

Model 

AP21 

Atmospheric Probe 

Element Thickness 

04 

4 mil thickness (2 mil useful probe life ) 

08 8 mil thickness (4 mil useful probe life) 

Element Alloy 

XXX 


Cable Length 

00 

10 

20 

No cable 

10 ft cable 

20 ft cable 

AP21 

08 

375 

20 

Example of Probe Ordering # 


Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 

Note: Not all alloys are available with all element types and seals. 

Atmospheric Probe Extension Cable Assembly 

6-Position 

RE Edge 

Connector 

PVC Atmospheric 

Probe Header 

6-Pin Male 

Amphenol Connector 

6-Conductor Cable 

20#AWG 

Telescoping Boot 

Part # : PS5602XXX 

where XXX = length in feet (Ex: 020 = 20 feet)

Model ER0500 

Electrical Resistance Probe 

Surface Strip Element and Cylindrical Element Types 

Surface Strip Element 

Cylindrical Element 

Model ER0500 probes are designed for heavy duty service conditions such as underground and 

structural monitoring of pipelines, vessels, above and below ground storage tanks and structures - 

whether cathodically protected or not. The surface strip element assembly is suited to the “construction 

site” environment. The cylindrical element is economical and durable. Its slim profile is convenient 

for locations with restricted access such as concrete bridge structures and other infrastructure 

applications. Both probes provide good sealing of the reference element and the check element provides 

confidence in the continued performance of the corrosion sensor. Either probe may or may not 

be connected to a cathodically protected structure. Connection of a ground cable allows the probe 

to measure the effectiveness of the Cathodic Protection (C.P.) System under all the operating conditions. 

If unconnected to the structure, the probe monitors the direct corrosivity of the soil or environment. 

The probes may be ordered with or without a grounding lead for a C.P. System. The lead may 

be installed at the probe or connector end, whichever is most convenient. In most cases, a lead at 

the monitoring connector end is preferred, with a separate lead running to the vessel or C.P. System. 

This enables connection to the C.P. System to be made as required - even after probe installation. 


Surface Strip 

Cylindrical 

Probe Body Epoxy Block All Welded Element 

Cable Connection Heavy Duty Length Heavy Duty Length with Bonded 

Heat Shrink Sleeving onto Element 







Model 

AP 


Type 

31 

40 

61 

70 

Under ground surface strip without ground strap 

Under ground cylindrical with ground strap 

Under ground surface strip with ground strap 

Under ground cylindrical without ground strap 

Element Thickness 

10 

20 

40 

50 

10 mil thickness (5 mil useful probe life) - cylindrical or surface strip 

20 mil thickness (10 mil useful probe life) - cylindrical or surface strip 

40 mil thickness (20 mil useful probe life) - surface strip only 

50 mil thickness (25 mil useful probe life) - cylindrical only 

Element Alloy 

XXX 


Cable Length 

10 

20 

10 ft cable 

20 ft cable 

4 375 

20 


AP 

31 

0 


Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 

Note: Not all alloys are available with all element types and seals.

Model ER1000 


with 1/2" NPT Pipe Plug and Loop Element 

(1 3/8") Std. Length 

(1.6") 

1/2" NPT 

1/2" 

Shield 

Wire, Tube or Strip 

Loop Element 

I.L. 

(1 1/8") 1" Min 

Model ER1000 is a fixed-length, electrical resistance probe with a 1/2" NPT pipe plug. The probe 

requires process isolation or process shutdown to install and a threaded pipe fitting to mount. With a 

diameter of 1/2", the probe is ideal for applications where space is limited. The probe assembly consists 

of an insertion rod with an element, a hermetically sealed connector, a 1/2" NPT pipe plug, and 

a velocity shield, which are all welded in place. The insertion length (I.L.) is calculated to the end of 

the shield and can be specified by the customer. For standard probes, the maximum insertion length 

is given in the chart below. Several standard loop elements are available to meet your specific needs. 


Probe Body - 316 Stainless Steel 

Element Seal - Glass or Teflon ® 

Fill Material - Ceramic 



Mounting - 1/2" NPT Pipe Plug 


5 " 

3.08" 

8 " 

6.08" 

12" 

10.08" 

18" 

16.08" 







Model 

EP21 

Electrical Resistance 1/2" NPT Pipe Plug Probe 

Probe Body Material 

22 

316 

44 C276 

E/R Element Options 

00 

10 

20 

30 

WR40 Wire Loop - 40 mil thickness (10 mil useful probe life) 


TU04 Tube Loop - 4 mil thickness (2 mil useful probe life) 


Seal Type 

1 

2 

3 

Glass 

® 

T eflon 

Epoxy 

Length 

05 

08 

12 

18 





Element Alloy 

XXX 


E/R Probe Options 

00 

03 

No shield 

Shield 

0 375 

03 


EP21 

22 

10 

1 8 


Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 


Model ER2000 


Fixed Length with 3/4" NPT Pipe Plug and Loop Element 


(1.6") 

3/4" 

Shield 


Loop Element 

I.L. 

3/4" NPT 

(1.2") 1" Min 


requires process isolation or process shutdown to install and a threaded pipe fitting to mount. The 

probe assembly consists of an insertion rod with an element, a hermetically sealed connector, and a 

3/4" NPT pipe plug, which are all welded in place. A velocity shield can be provided if required. The 

insertion length (I.L.) is calculated to the end of the shield and can be specified by the customer. For 

standard probes, the maximum insertion length is given in the chart below. Several standard loop elements 

are available to meet your specific needs. 




Fill Material - Ceramic or Epoxy 




Std. Length IL (max) 

6" 5.13" 

8" 7.13" 

12" 11.13" 

18" 17.13" 







Model 

ER2 

Electrical Resistance Fixed Length Pipe Plug Probe 

Pipe Plug Size 

2 3/4" NPT Pipe Plug 

3 1" NPT Pipe Plug 


22 316 

44 C276 


00 WR40 Wire Loop - 40 mil thickness (10 mil useful probe life) 


20 TU04 Tube Loop - 4 mil thickness (2 mil useful probe life) 


80 SL05 Strip Loop - 5 mil thickness (1.25 mil useful probe life) 


Seal Type 

1 Glass 

® 

2 T eflon 

3 

Epoxy 

Length 

06 

ER2 

2 22 

10 

1 8 


08 

12 

18 




Element Alloy 

XXX 



00 

03 

No Shield 

Shield 

0 375 

03 



Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 


Model ER2100 


Fixed Length with 3/4" NPT Pipe Plug and Cylindrical Element 

(4 1/8") Std. Length (1.6") 

Shield 

Cylindrical 

Element 

I.L. 

3/4" NPT 

(1.2") 1" 

Min 


requires process isolation or process shutdown to install and a threaded pipe fitting to mount. The 

all-welded construction allows the probe to be used in harsh environments. The probe assembly consists 

of an insertion rod with an element, a hermetically sealed connector, and a 3/4" NPT pipe plug, 

which are all welded in place. A velocity shield can be provided if required. The insertion length 

(I.L.) is calculated to the end of the shield or to the end of the element if a shield is not present. 

Probe length can be specified by the customer. For standard probes, the maximum insertion length is 

given in the chart below. Several standard elements are available to meet your specific needs. 



Element Seal - Welded 





S td. Length IL (max) 

6 " 

8.38" 

8 " 

10.38" 

12" 

14.38" 

18" 

20.38" 






Model 

ER2 


Electrical Resistance Fixed Length Pipe Plug Probe 





22 316 

44 C276 


500 CT10 Cylindrical - 10 mil thickness (5 mil useful probe life) 



Length 





Element Alloy 

XXX 



00 No shield 

03 Shield 

ER2 

2 22 

500 

08 

375 

03 



Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 


Model ER3000 


Adjustable Length with 3/4" NPT Pipe Plug and Loop Element 

(1 1/8") Std. Length (1.6") 

Threads for Safety 

Shield or Safety Nut 

Shield 


Loop Element 

I.L. 

3/4" NPT 

(2") 

Model ER3000 is an adjustable-length, electrical resistance probe with a 3/4" NPT compression fitting. 

The compression fitting allows the probe to be inserted into the process to the required length. 

The probe requires process isolation or process shutdown to install and a threaded pipe fitting to 

mount. The probe consists of an insertion rod with an element, a hermetically sealed connector, a 

3/4" compression fitting, and a safety nut to prevent blow out. A velocity shield can be added to the 

assembly if required. The insertion length (I.L.) is calculated to the end of the shield or to the end 

of the element if a shield is not present. Probe length can be specified by the customer. For standard 

probes, the maximum insertion length is given in the chart below. Several standard elements are 

available to meet your specific needs. 







Mounting - 3/4" NPT Fitting 


6 " 

5.33" 

8 " 

7.33" 

12" 

11.33" 

18" 

17.33" 







Model 

ER3 

Electrical Resistance Adjustable Pipe Plug Probe 





22 316 

44 C276 








A0 FS04 Flush Mount Small - 4 mil thickness (2 mil useful probe life) 

Seal Type 

1 Glass 

® 

2 T eflon 

3 

Epoxy 

Length 

06 

ER3 

2 22 

10 

1 8 


08 

12 

18 




Element Alloy 

XXX 



00 

03 

No Shield 

Shield 

0 375 

03 



Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 


Model ER3100 


Adjustable Length with 3/4" NPT Pipe Plug and Cylindrical Element 

(4 1/8") Std. Length (1.6") 

Shield 

Cylindrical 

Element 

Threads for Safety 

Shield or Safety Nut 

I.L. 

3/4" NPT 

(2") 

Model ER3100 is an adjustable-length, electrical resistance probe with a 3/4" NPT compression fitting. 

The compression fitting allows the probe to be inserted into the process to the required length. 

The probe requires process isolation or process shutdown to install and a threaded pipe fitting to 

mount. The all-welded construction allows the probe to be used in harsh environments. The probe 

assembly consists of an insertion rod with an element, a hermetically sealed connector welded in 

place, a 3/4" compression fitting, and a safety nut to prevent blow out. A velocity shield can be added 

to the assembly if required. The insertion length (I.L.) is calculated to the end of the shield or to the 

end of the element if a shield is not present. Probe length can be specified by the customer. For standard 











6 " 

8.58" 

8 " 

10.58" 

12" 

14.58" 

18" 

20.58" 






Model 

ER3 


Electrical Resistance Adjustable Length Pipe Plug Probe 





22 316 

44 C276 





Length 





Element Alloy 

XXX 



00 No shield 

03 Shield 

ER3 

2 22 

500 

08 

375 

03 



Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 


Model ER3200 


Adjustable Length with 1½" NPT Pipe Plug and Flush Element 

Std. Length 

(1.6") 

A 

A 

I.L. 

1 1/2" NPT x 3/4" 

NPT Adapter 

3/4" NPT Male 

Connector 

View A - A 

Model ER3200 is an adjustable-length, electrical resistance probe with a 3/4" NPT compression 

fitting combined with a 3/4" to 1½" adapter. The compression fitting allows the probe to be inserted 

into the process to the required length. The probe requires process isolation or process shutdown to 

install and a threaded pipe fitting to mount. The probe assembly consists of an insertion rod with 

an element, a hermetically sealed connector welded in place, a 3/4" compression fitting, and a 3/4" 

to 1½" adapter. The adapter can not be removed from the compression fitting. The insertion length 

(I.L.) is calculated to the end of the element. Probe length can be specified by the customer. For standard 





Element Seal - Epoxy 

Fill Material - Epoxy 



Mounting - 1½" NPT Pipe Plug 


6 " 

3" 

8 " 

5" 

12" 

9" 

18" 

15" 








Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 


Model ER4000 


Retractable with Packing Gland and Loop Element 

(1 1/8") 

Std. Length 

1" NPT 

(1.6") 

Shield 

Wire, Tube or 

Strip Loop 

Element 

(1.83") 

I.L. 

(5.9") 

Model ER4000 is a retractable, electrical resistance probe commonly used in field and plant applications. 

A specially designed packing gland is used with the probe for insertion into or retraction from 

a pressurized system without a process shutdown. Standard packing material in the packing gland 

is Teflon ® . Grafoil packing can be provided if requested. When the probe element requires replacement, 

the packing gland assembly may be reused. (Probe packing should also be replaced at this 

time.) The probe is designed to mount onto a 1" piping system, but can easily be adapted to fit your 

specific requirements. The probe assembly consists of a replaceable insertion rod with an element, 

a hermetically sealed connector welded in place, and a packing gland. A safety chain and safety nut 

are also provided to prevent blowout. A velocity shield can be added to the assembly if required. The 

insertion length (I.L.) is calculated to the end of the shield or to the end of the element if a shield is 

not present. Probe length can be specified by the customer. For standard probes, the maximum insertion 

length is given in the chart below. Several standard elements are available to meet your specific 

needs. 





Temperature Rating - 500° F / 260° C 




24" 

17.60" 

30" 

23.60" 

36" 

29.60" 

42" 

35.60" 









Model 

ER45 

ER75 

ER00 

® 

E lectrical Resistance 1" Female NPT Probe, Packing Gland with Teflon 

Electrical Resistance 1" Female NPT Probe, Packing Gland with Grafoil 

Electrical Resistance Replacement Insertion Rod 


2 316 

4 C276 

Packing Gland Material 

0 

2 

4 

N/A (replacement insertion rod) 

316 

C276 


00 

10 

20 

30 

80 

90 





SL05 Strip Loop - 5 mil thickness (1.25 mil useful probe life) 

SL10 Strip Loop - 10 mil thickness (2.5 mil useful probe life) 

Seal Type 

1 

2 

3 

Glass 

® 

T eflon 

Epoxy 

Length 

24 

30 

36 




42 35.60 inches max 

Element Alloy 

insertion length 

XXX 



00 

01 

02 

03 

No Shield 

Shield, coupon adaptor (118), hardware 

Shield, coupon adaptor (220), hardware 

Shield 

ER45 

2 2 10 

1 36 

375 

02 



Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 


Model ER4100 


Retractable with Packing Gland and Cylindrical Element 


(1.6") 

1" NPT 

Shield 

Cylindrical 

Element 

Threads for 

Safety Shield 

or Safety Nut 

(I.L.) 

(5.9") 

(1.83") 

Model ER4100 is a retractable, electrical resistance probe commonly used in field and plant applications. 

The all-welded design allows the probe to be used in harsh environments. A specially designed packing gland 

is used with the probe for insertion into or retraction from a pressurized system without a process shutdown. 

Standard packing material in the packing gland is Teflon ® , however, grafoil packing can be provided for high 

temperature applications*. When the probe element requires replacement, the packing gland assembly may 

be reused. (Probe packing should also be replaced at this time.) The probe is designed to mount onto a 1" 

piping system, but can easily be adapted to fit your specific requirements. The probe assembly consists of a 

replaceable insertion rod with an element, a hermetically sealed connector welded in place, and a packing 

gland. A safety chain and safety nut are also provided to prevent blowout. A velocity shield can be added 

to the assembly if required. The insertion length (I.L.) is calculated to the end of the shield or to the end of 

the element if a shield is not present. Probe length can be specified by the customer. For standard probes, the 

maximum insertion length is given in the chart below. Several standard elements are available to meet your 

specific needs. 






850°F / 454°C - Grafoil* 




24" 

20.85" 

30" 

26.85" 

36" 

32.85" 

42" 

38.85" 

* Applications above 500°F / 260°C require the use of a high-temperature element. Contact our sales 

department for further details. 

The Easy Tool is required for probe insertion or retraction 

in systems with pressure over 150 pounds. 







Model 

ER45 

® 

E lectrical Resistance 1" Female NPT Probe, Packing Gland with Teflon 

ER75 Electrical Resistance 1" Female NPT Probe, Packing Gland with Grafoil 

ER00 Electrical Resistance Replacement Insertion Rod 


2 316 

4 C276 

Packing Gland Material 

0 N/A (replacement insertion rod) 

2 316 

4 C276 


500 CT10 Cylindrical - 10 mil thickness (5mil useful probe life) 



Length 





Element Alloy 

XXX 



00 No shield 

01 Shield, coupon adaptor (118), hardware 

02 Shield, coupon adaptor (220), hardware 

03 Shield 

ER45 

2 2 700 

36 

375 

02 



Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 


Model ER4200 


Retractable with Packing Gland and Small Flush Element 

Std. Length 

(1.6") 

I.L. 

(5.9") 

A 

A 

.75 

(1.88") 

View A - A 

Model ER4200 is a retractable, flush-mount, electrical resistance probe ideally suited for applications 

where the probe element needs to be flush with the wall of the pipe. A specially designed 

packing gland is used with the probe for insertion to or retraction from a pressurized system without 

a process shutdown. Standard packing material in the packing gland is Teflon ® . Grafoil packing can 

be provided if requested. The probe is designed to mount into a 1" piping system, but can easily be 

adapted to fit your specific requirements. The probe consists of an insertion rod with an element, a 

hermetically sealed connector welded in place, and a packing gland. The insertion length (I.L.) is 

calculated to the end of the element. Probe length can be specified by the customer. For standard 

probes, the maximum length is given in the chart below. Several standard elements are available to 

meet your specific needs. 





Temperature Rating - 500° F / 260° C 




24" 

16.22" 

30" 

22.22" 

36" 

28.22" 

42" 

34.22" 








Model 

ER45 

ER75 


Electrical Resistance 1" Female NPT Probe, Packing Gland with Teflon ® 

Electrical Resistance 1" Female NPT Probe, Packing Gland with Grafoil 


22 

44 

316 

C276 

ER Element Options 

A0 

B0 

H0 

FS04 Flush Mount - 4 mil thickness (2 mil useful probe life) 



Seal Type 

3 Epoxy 

Length 

24 

30 

36 

42 





Element Alloy 

XXX Use Code in Alloy Chart 

ER Probe Options 

00 N/A 

ER45 22 A0 3 36 375 00 Example of Probe Ordering # 


Safety clamp must be ordered separately. 

Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 


Model ER4210 


Retractable with Packing Gland and Large Flush Element 

Std. Length 

A 

I.L. 

(5.9") 

(1.6") 

1.25" 

A 

(1.88") 

View A - A 

Model ER4210 is a retractable, flush-mount, electrical resistance probe ideally suited for applications 

where the probe element needs to be flush with the wall of the pipe. A specially designed packing 

gland is used with the probe for insertion to or retraction from a pressurized system without a 

process shutdown. Standard packing material in the packing gland is Teflon ® . The probe is 

designed to mount into a 1½" piping system, but can easily be adapted to fit larger requirements. 

The probe consists of an insertion rod with an element, a hermetically sealed connector welded in 

place, and a packing gland with a 1" to 1½" swage nipple. The insertion length (I.L.) is calculated to 

the end of the element. Probe length can be specified by the customer. For standard probes, the maximum 

length is given in the chart below. Several standard elements are available to meet your specific 

needs. 






Pressure Rating - 1500 PSI /102 bar 

Mounting - 1½" Full Port Valve (Min.) 


24" 

16.22" 

30" 

22.22" 

36" 

28.22" 

42" 

34.22" 








Model 

ERB 


Electrical Resistance Pipe Plug Probe with Packing Gland & Swage Nipple 



7 1 1/2" NPT Pipe Plug 


22 316 

44 C276 


C03 S5 Flush Mount - 5 mil thickness (2.5 mil useful probe life) 

D03 S10 Flush Mount - 10 mil thickness (5 mil useful probe life) 

E03 S20 Flush Mount - 20 mil thickness (10 mil useful probe life) 

F03 S40 Flush Mount - 40 mil thickness (20 mil useful probe life) 

Length 





Element Alloy 

XXX 



00 

N/ A 

ERB 

6 22 

C03 

24 

375 

00 



Safety clamp must be ordered separately. 

Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 


Model ER6000 


Fixed Length with Flange and Loop Element 

(1 1/8") 

Std. Length 

(1.6") 

(1" Min.) 

Shield 

3/4" 

Wire, Tube, or Strip 

Loop Element 

Flange 

I.L. 

Model ER6000 is a fixed-length, flange-mounted, electrical resistance probe. The probe is ideally 

suited for use in high pressure and/or hazardous applications where threaded fittings are not available 

or not recommended. Process shutdown or process isolation is required for installation and inspection. 

The probe assembly consists of an insertion rod with an element, a hermetically sealed connector, 

and a flange (as specified by customer), which are all welded in place. A velocity shield can be 

added to the assembly if required. A mechanical seal can also be added for additional safety. Insertion 

length (I.L.) is calculated to the end of the shield and, in this case, is based on a 1" total flange 

thickness. Customers can specify any length required. For standard probes, the maximum insertion 

length is given in the chart below. Several standard elements and flange sizes are available to meet 

your specific needs. 






Pressure Rating - According to Flange Rating 

Mounting - Mating Flange 


8 " 

7.125" 

12" 

11.125" 

18" 

17.125" 

24" 

23.125" 






Model 

ER6 


Electrical Resistance Fixed Length Probe with Flange 

Flange Size 

1 1” Flange 

2 1 1/2” Flange 

3 2” Flange 

4 3” Flange 

5 4” Flange 

7 6” Flange 


22 316 

44 C276 








Flange Pressure Rating 

1 150 lbs. 

2 300 lbs. 

3 600 lbs. 

4 1200 lbs. 

5 1500 lbs. 

6 900 lbs. 

Seal Type 

1 Glass 

2 Teflon ® 

3 Epoxy 

Length 





Element Alloy 



00 No shield 

01 Shield, coupon adapter (118), hardware 


03 Shield 

ER6 2 22 3 1 2 08 375 03 Example of Probe Ordering # 


Alloy Chart 

Code 

D escription 

UNS 

# Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 


Model ER6100 


Fixed Length with Flange and Cylindrical Element 

(4 1/8") Std. Length (1.6") 

Cylindrical 

Element 

Shield 

Flange 

I.L. 

1" Min. 



or not recommended. Process shutdown or process isolation is required to install and inspect. The 


of an insertion rod with an element, a hermetically sealed connector, and a flange (as specified 

by customer), which are all welded in place. A mechanical seal and a velocity shield can be added if 

required. The insertion length (I.L.) is calculated to the end of the shield or to the end of the element 

if a shield is not present. Probe length can be specified by the customer. For standard probes, the 

maximum insertion length is given in the chart below and, in this case, is based on a 1" total flange 

thickness. Several standard elements are available to meet your specific needs. 









8 " 

10" 

12" 

14" 

18" 

20" 

24" 

26" 






Model 

ER6 



Flange Size 

1 1” Flange 

2 1 1/2” Flange 

3 2” Flange 

4 3” Flange 

5 4” Flange 

7 6" Flange 


22 316 

44 C276 






10 150 lbs. 

20 300 lbs. 

30 600 lbs. 

40 1200 lbs. 

50 1500 lbs. 

60 900 lbs. 

Length 

08 10 inches max. insertion length 




Element Alloy 



00 No shield 



03 Shield 

ER6 2 22 7 20 08 375 03 Example of Probe Ordering # 


Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 


Model ER6200 


Fixed Length with Flange and Flush Element 

Std. Length (1.6") 

A 

1.25" 

A 

Flange 

I.L. 

1" Min. 

View A -A 



or not recommended. Process shutdown or process isolation is required to install and inspect. The 


of an insertion rod with an element, a hermetically sealed connector, and a flange (as specified 

by customer), which are all welded in place. A mechanical seal can be added if required. The insertion 

length (I.L.) is calculated to the end the element. Probe length can be specified by the customer. 

For standard probes, the maximum insertion length is given in the chart below and, in this case, is 

based on a 1" total flange thickness. Several standard elements are available to meet your specific 

needs. 









8 " 

6" 

12" 

10" 

18" 

16" 

24" 

22" 






Model 

ER6 



Flange Size 

2 1 1/2” Flange 

3 2” Flange 

4 3” Flange 

5 4” Flange 

7 6” Flange 


22 316 

44 C276 


C S05 Flush Mount - 5 mil thickness (2.5 mil useful probe life) 

D S10 Flush Mount - 10 mil thickness (5 mil useful probe life) 

E S20 Flush Mount - 20 mil thickness (10 mil useful probe life) 

F S40 Flush Mount - 40 mil thickness (20 mil useful probe life) 


13 150 lbs. 

23 300 lbs. 

33 600 lbs. 

43 1200 lbs. 

53 1500 lbs. 

63 900 lbs. 

Length 





Element Alloy 



00 No shield 

ER6 2 22 C 13 08 375 00 Example of Probe Ordering # 


Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 


Model ER7000 

Electrical Resistance Probe, Retrievable with Loop Element 


I.L. 2" 

1 1/8" 

A 

3/4" 

Shield 

Wire or Tube Loop 

Element 

1-14 UNS-2A (L.H.) 

A 

B 

Std. 6-Pin 

Configuration 

Small 6-Pin 

Configuration 

B 

View A-A 

View B-B 

Model ER7000 is a fixed-length, retrievable, electrical resistance probe for use with HP and 

MH high pressure access systems. The probe assembly consists of an insertion rod with an element, 

a hermetically sealed connector, and a hollow plug nut, which are all welded in place. A velocity 

shield can be added to the assembly if required. The hollow plug nut on the probe screws into 

the hollow plug of the access system. This allows the probe to be installed in the process, using a 

retrieval tool and service valve, without process shutdown. The insertion length (I.L.) can range from 

2.875" up to any length specified by the customer in 1/8" increments. Insertion length is calculated 

by the formula: 

I.L. = PD + WT + 1.75" 

(where PD = penetration depth, WT = wall thickness) 

Note: Formula valid for access fitting heights of 5.25" (HP) and 5.5" (MH). 

Several standard elements are available to meet your specific needs. Probe adaptors are available and 

must be ordered separately. 



Element Seal - Glass 




Mounting - High Pressure (HP TM or MH TM ) Access System with Hollow Plug 







Model 

HR 

Electrical Resistance Probe for High Pressure (HP TM and MH TM ) Access Systems 

Mounting Material 

2 

3 

316 

C276 

Connector Type 

1 

2 

Small connector 

Standard connector 


0 

1 

2 

3 





Seal Type 

1 

2 

3 

Glass 

Teflon ® 

Epoxy 


XXXX Length in inches, stated in 2 decimal place format 

(Ex: 6 1/8" = 0612) 

Element Alloy 



00 

01 

02 

03 

No shield 

Standard shield 

Hi-velocity shield 

Coupon holding shield 

HR 2 2 3 1 0612 375 03 Example of Probe Ordering # 


Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 


Model ER7100 

Electrical Resistance Probe, Retrievable with Cylindrical Element 


4 1/8" 

Cylindrical Element 

1-14 UNS-2A (L.H.) 

A 

Shield 

I.L. 

2" 

A 

Std. 6-Pin 

Configuration 

Small 6-Pin 

Configuration 

B 

View A - A 

View B - B 

B 

Model ER7100 is a fixed-length, retrievable, electrical resistance probe for use with HP and 

MH high pressure access systems. The all-welded construction of the element makes it ideal for 

harsh environments. The probe assembly consists of an insertion rod with an element, a hermetically 

sealed connector, and a hollow plug nut, which are all welded in place. A velocity shield can be 

added to the assembly if required. The hollow plug nut on the probe screws into the hollow plug of 

the access system. This allows the probe to be installed in the process, using a retrieval tool and service 

valve, without process shutdown. The insertion length (I.L.) can range from 5" up to any length 

specified by the customer in 1/8" increments. Insertion length is calculated by the formula: 

I.L. = PD + WT + 1.75" 

















Model 

HR 




2 

3 

316 

C276 


1 

2 




50 

J0 

60 

70 

CT10 Cylindrical - 10 mil thickness (5 mil useful probe life) 

CT10 Cylindrical (2") - 10 mil thickness (5 mil useful probe life) 





(Ex: 6 1/8" = 0612) 

Element Alloy 



00 

01 

02 

03 

No shield 

Standard shield 

Hi-velocity shield 

Coupon holding shield 

HR 2 2 60 0612 375 03 Example of Probe Ordering # 


Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 


Model ER7200 

Electrical Resistance Probe, Retrievable with Small Flush Element 


I.L. 

Connector 

D 

A 

.75 5/8" 

D 

Insertion Rod 

A 

C 

C 

Epoxy Seal 

Small 6-Pin 

Configuration 

Std. 6-Pin 

Configuration 

View D - D 

View C - C 

View A - A 

Model ER7200 is a fixed-length, flush-mount, retrievable, electrical resistance probe for use with 

HP and MH high pressure access systems. These probes are ideally suited for applications 

where the probe element needs to be flush with the wall of the pipe. The probe assembly consists 

of an insertion rod with an element, a hermetically sealed connector, and a hollow plug nut, which 

are all welded in place. The hollow plug nut on the probe screws into the hollow plug of the access 

system. This allows the probe to be installed in the process, using a retrieval tool and service valve, 

without process shutdown. The insertion length (I.L.) can range from a minimum of 1.75" up to any 

length specified by the customer in 1/8" increments, using the formula: 

I.L. = PD + WT + 1.75" 


For top-of-the-line, flush-mount monitoring, PD = 0. 


Several standard elements are available to meet your specific needs. Probe adaptors are available 

and must be ordered separately. 














Model 

HR 



2 

3 

316 

C276 


1 

2 




A 

B 

H 

S4 Flush Mount - 4 mil thickness (2 mil useful probe life) 



Seal Type 

3 Epoxy 



(Ex: 6 1/8" = 0612) 

Element Alloy 



00 No shield 

HR 2 2 B 3 0612 375 00 Example of Probe Ordering # 


Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 


Model ER7210 

Electrical Resistance Probe, Retrievable with Large Flush Element 


C 

1-14 UNS-2A (L.H.) 

B 

1.25" 

C 

A 

B 

I.L. 

(2") 

A 

Small 6-Pin 

Configuration 

Std. 6-Pin 

Configuration 

View B - B 

View C - C 

View A - A 

Model ER7210 is a fixed-length, flush-mount, retrievable, electrical resistance probe for use with 

HP and MH high pressure access systems. These probes are ideally suited for applications 

where the probe element needs to be flush with the wall of the pipe. The probe assembly consists 

of an insertion rod with an element, a hermetically sealed connector, and a hollow plug nut, which 

are all welded in place. The hollow plug nut on the probe screws into the hollow plug of the access 

system. This allows the probe to be installed in the process, using a retrieval tool and service valve, 

without process shutdown. The insertion length (I.L.) can range from a minimum of 1.75" up to any 

length specified by the customer in 1/8" increments, using the formula: 

I.L. = PD + WT + 1.75" 


















Model 

HR 




2 

3 

316 

C276 


1 

2 




C3 

D3 

E3 

F3 

S05 Flush Mount - 5 mil thickness (2.5 mil useful probe life) 






(Ex: 6 1/8" = 0612) 

Element Alloy 



00 No shield 

HR 2 2 C3 0612 375 00 Example of Probe Ordering # 


Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 


Model ER7220 


Retrievable with Large Adjustable Flush Element 


B 

1-14 UNS-2A (L.H.) 

A 

B 

C 

1.25" 

A 

I.L. (2") 

Small 6-Pin 

Configuration 

C 

Std. 6-Pin 

Configuration 

View A-A 

View B-B 

Model ER7220 is an adjustable-length, flush-mount, retrievable, electrical resistance probe for use 

with HP and MH high pressure access systems. These probes are ideally suited for applications 

where the probe element needs to be flush with the wall of the pipe to prevent any obstructions. The 

probe assembly consists of an insertion rod with an element, a hermetically sealed connector, and 

a hollow plug nut, which are all welded in place. The hollow plug nut on the probe screws into the 

hollow plug of the access system. This allows the probe to be installed in the process, using a 

retrieval tool and service valve, without process shutdown. The insertion length (I.L.) can range from 

a minimum of 1.75" up to any length in 1" increments (specify lengths over 1.75" as 2", 3", 4", etc.) 

specified by the customer, using the formula below. The adjustable flush element allows for a total 

adjustment of 1". 

I.L. = PD + WT + 1.75" 



View C-C 








O-Ring Material - Viton (other materials available) 










Model 

HR 



2 

3 

316 

C276 


1 

2 




C3 

D3 

E3 

F3 

S05 Flush Mount - 5 mil thickness (2.5 mil useful probe life) 




Length (Round calculated length down to the nearest inch) 


(Ex: 6" = 0600) 

Element Alloy 



AD No shield, adjustable 

HR 2 2 C3 0600 375 AD Example of Probe Ordering # 


Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 


Model ER7300 

Electrical Resistance Probe, Retrievable Spiral Loop 


I.L. 

A 

1 1/2" 

A 

Std. 6-Pin 

Configuration 

View A-A 

Model ER7300 spiral loop probe is a retrievable, electrical resistance probe designed for use with 

both the HP and MH high pressure access systems. The element is a spiral wound strip encased 

in epoxy. This approach to element construction offers several advantages over other element geometries: 

• High intrinsic resistance - provides highly stable readings with low susceptibility to noise. 

• High element strength - allows use in very high flow rate regimes such as a gas transmission. 

• Wide spacing of element loops - minimizes the risk of iron sulphide scaling and bridging. 

While the spiral loop probe is ideally suited to fast flowing, sour systems, its high stability makes it a 

suitable choice for all oil and gas systems. 

Insertion length (I.L.) can range from a minimum of 3.75" up to any length (in 1/8" increments) 

specified by the customer, using the formula: 

I.L. = PD + WT + 1.75" 






Element Material - AISI 1018 









Model 

HR 



Mounting Material & Connector Type 

22 316 stainless steel with standard connector 


K 

L 

SP10 Spiral Loop - 10 mil thickness (5 mil useful probe life) 

SP20 Spiral Loop - 20 mil thickness (10 mil useful probe life) 

Seal Type 

3 Epoxy 



(Ex: 6 1/8" = 0612) 

Element Alloy 



00 No shield 

HR 22 K 3 0612 375 00 Example of Probe Ordering # 


Code 

D escription 

UNS 

# 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

159 

316L 

SS 

S31603 

538 

5Cr 

1/2Mo 

K42544 

A12 

C276 

N10276 

541 

9Cr 

1Mo 

K90941 

602 

Alloy 625 

N06625 

186 

410 

SS 

S41000 

419 

CDA110 

C11000 

141 

304 

SS 

S30400 

434 

CDA443 

C44300 


ER Instrumentation 

MS0500 - 

is a battery-powered, portable corrosion meter that is easy to operate, interprets all 

types of ER probes, and enables readings to be taken from a variety of different 

locations. 

MS1500E - is a hand-held, battery-powered, intrinsically safe corrosion data logger that takes 

ER probe measurements and stores the data to be downloaded to your computer for 

analysis. 

MS2500E - is a loop-powered ER transmitter which transmits measurements to a receiver. 

MS2510 Receiver 

Wireless Radio Option for MS2500E 

MS3500E - is a data logger used to continuously monitor ER probes in remote locations, 

automatically read the probes at selected intervals, and store the readings in its 

memory. 

MS4500E - is a high-resolution data logger which stores vast amounts of data from ER probes. 

Stored data can be downloaded to a PC or Flash drive via a USB port. Features 

non-volatile Flash memory and a backlit LCD display with on-screen charting. 

Return to ER menu


Corrosion Monitoring Systems 

MS0500 ER Corrosion Meter 

The MS0500 is a battery-powered, portable 

corrosion meter capable of measuring all 

types of electrical resistance (ER) corrosion 

probes. Combining light weight with ease 

of operation, the MS0500 is a simple and 

effective tool for gathering corrosion data 

from one or many probe locations. 

Corrosion rate measurements are made using 

the electrical resistance method. Essentially, 

the instrument measures the resistance of the 

probe element which changes over time as 

metal loss occurs. The rate of change is 

directly proportional to the corrosion rate. This 

Probe shown in photo not 

included with corrosion meter 

method finds a wide variety of applications 

since it can be used in conductive and nonconductive environments, such as petroleum, 

chemical, water, soil, or even atmosphere. 

The MS0500 has a permanently attached cable assembly which mates directly to any standard 

ER probe. A switch is provided on the front panel of the instrument for selecting the probe type 

to be measured (wire loop, tube loop, cylindrical, etc.). Readings are taken using the dial and 

analog meter on the front panel. 

The MS0500 also offers a built-in battery test function, and comes in a convenient carrying case.

Technical Specifications 

Model 

MS0500 - ER Corrosion Meter (Ordering # IN0500) 

Physical Data 

Instrument Weight: 

Total Weight w/ Carrying Case 

and Accessories: 

Instrument Dimensions: 

Carrying Case Dimensions: 

Operating Temperature: 

Storage Temperature: 

2.38 lb. (1.08 Kg) 

3.6 lb. (1.63 Kg) 

3”H x 5”W x 6.75”D (7.62cm x 12.7cm x 17.15cm) 

6.0”H x 6.0”W x 8.75”D (15.24cm x 15.24cm x 22.23cm) 

32° to 122°F (0° to 50°C) 

32° to 122°F (0° to 50°C) 

Performance Data 

Measurement Type: 

ER measurement using any standard ER probe type (Wire Loop, 

Tube Loop, Cylindrical, Flush, Strip, etc.) w/ check reading. 

Range: 

0-1000 digits representing 0-100% of probe life 

Resolution: 

1 digit 

Electrical Data 

Power Requirements: 

Two 9V Batteries 

Maximum Probe Cable Distance: 100 ft (30.48 m) * 

Special Features 

• Simple user interface 

• Built-in battery check 

• Portable 

Accessory Items 

Carrying Case, 6’ Probe Cable (attached), Meter Prover, Operation Manual 

* May vary with element type. 








MS1500E Handheld ER Corrosion Data Logger 

The MS1500E is a hand-held, battery-powered, 

corrosion meter capable of measuring and 

storing data from all types of electrical resistance 

(ER) corrosion probes. The instrument is 

light weight, microprocessor-based, and features 

a simple, menu-driven interface using a 

12-key keypad and a 4-line LCD display. 

Corrosion rate measurements are made using 

the electrical resistance method. Essentially, 

the instrument measures the resistance of the 

probe element which changes over time, as 

metal loss occurs. The rate of change is 

directly proportional to corrosion rate. This 



method finds a wide variety of applications since it can be used in conductive and nonconductive 

environments such as petroleum, chemical, water, soil, or even atmosphere. 

After taking a reading, the instrument displays metal loss in mils and corrosion rate in mils per 

year (mpy). The reading can then be stored to memory or discarded. All stored readings are 

automatically time and date stamped, and are protected by a lithium back-up battery. The instrument 

can store a maximum of 3,100 readings on up to 150 different probes. 

Stored data can be uploaded to any IBM compatible PC as a comma-delimited ASCII text file. 

Because the data is in ASCII text format, it can be imported into any standard data analysis program 

such as Microsoft Excel, Lotus 123, or Corel Quattro Pro. Data can also be reviewed on the 

instrument’s LCD display for quick reference. 

The MS1500E may also be used as a data transfer unit (DTU) for the MS3500E Remote Data 

Logger. Data may be transferred from multiple MS3500E field-based units to the MS1500E, then 

later transferred to a PC for analysis.


Model 

MS1500E - Handheld ER Corrosion Data Logger (Ordering # IN1500) 

Physical Data 










Range: 

Resolution: 

1.4 lb. (0.64 Kg) 

5.26 lb. (2.39 Kg) 

7.63"H x 4.15"W x 2.0"D(19.38cm x 10.54cm x 5.08cm) 

10"H x 11.75"W x 5.4"D (25.40cm x 29.85cm x 13.72cm) 

32° to 122°F (0° to 50°C) 

-4° to 158°F (-20° to 70°C) 

ER measurement using any standard ER probe type (Wire 

Loop, Tube Loop, Cylindrical, Flush, Strip, etc.) 


1 digit 



Three 1.5V AA Batteries 

Maximum Probe Cable Distance: 6 ft (1.83 m) 

Output Specifications: 

RS-232 Output in Comma-Delimited ASCII Text Format 

Optional: Class I, Division 1 

Intrinsic Safety 

Groups A, B, C, and D 

Temperature Code T3C 

Class I, Zone 0, 

Group IIC, T3C 

Conforms to ANSI/UL Std. 913 

Intrinsic safety option must be specified when ordering. 


• Microprocessor-based electronics 

• Data storage capacity of 3,100 readings on 150 different probes, with battery backup 

• Menu-driven interface using a 12-key keypad and a 4-line LCD display 

• Low-battery detection 

• Portable 


Carrying Case, 6' Probe Cable (attached), Meter Prover, Communications Cable and Connector, 

Operation Manual, Corrosion Data Management Software 








MS2500E Loop-Powered ER Transmitter 

The MS2500E is an intrinsically safe, microprocessorbased 

corrosion transmitter capable of measuring and 

transmitting data from all types of electrical resistance 

(ER) corrosion probes. 

Corrosion rate measurements are made using the 

electrical resistance method. Essentially, the instrument 

measures the resistance of the probe element 

which changes over time, as metal loss occurs. The 

rate of change is directly proportional to corrosion 

rate. This method finds a wide variety of applications 

since it can be used in conductive and nonconductive 

environments such as petroleum, chemical, water, soil, 

or even atmosphere. 


included with corrosion transmitter 

Measurements are transmitted via 4-20mA current loop. Since current loop signals are not as 

sensitive to line loss as other types of data signals, the MS2500E may be located up to ten miles 

away from the data receiver under proper conditions. 

The MS2500E is completely loop-powered, so installation is simple. A two-wire connection is all 

that is required for both instrument power and data transmission. Setup is also simple, using a set 

of switches to select the probe type to be measured (wire loop, tube loop, cylindrical, etc.). 

The MS2500E is housed in a NEMA rated explosion-proof and weather-proof enclosure, and the 

probe cable is connected through a water-tight, explosion-proof cable gland. This makes the 

MS2500E suitable for use in almost any indoor or outdoor environment.


Model 

MS2500E - Loop-Powered ER Transmitter (Ordering # IN2500) 

Physical Data 


Total Weight w/ Accessories: 


Case Specifications: 

5.02 lb. (2.28 Kg) 

7.08 lb. (3.21 Kg) 

5.81"H x 4.5"W x 4.81"D (14.76cm x 11.43cm x 12.22cm) 

Explosion Proof (FM, CSA, CENELEC, UL) 

Class I, Groups B, C, D, Class II, Groups E, F, G, Class III, 

CENELEC: Eexd IIC 

NEMA 4, 7BCD, 9EFG 

Mounting Specifications: 0.728"H x 1.756"W (1.85cm x 4.46cm) Bolt Pattern with 1/4-20 

Tapped Mounting Holes, or May Be Mounted on a 1/2" to 2" (1.27cm 

to 5.08cm) Pipe Using Supplied Hardware 



0° to 140°F (-18° to 60°C) 

-40° to 176°F (-40° to 80°C) 



Range: 

Resolution: 

Cycle Time: 

ER measurement using any standard ER probe type (Wire Loop, Tube 

Loop, Cylindrical, Flush, Strip, etc.) 

0-100% of probe life 

0.4% of Full Scale 

1 Minute 



10 to 35 VDC 



4-20mA Current Loop Output 

Intrinsic Safety: 

Certified to CAN/CSA 

STD E79-0-95 & E79-11-95 

Class I, Division 1, 

Groups C and D, T4 


• Switch selectable probe type (wire loop, tube loop, cylindrical, etc.) 

• Loop powered 


5' Probe Cable (attached), Meter Prover, Mounting Hardware, Operation Manual 






Wireless Radio Option for MS2500E/MS2500L 

The integrated wireless radio and I/O module eliminates cable and conduit 

used by the standard 4-20 mA current loop version of the MS2500E/ 

MS2500L, making it better equipped for harsh industrial environments. 

The wireless radio utilizes 900-928 MHz ISM band spread spectrum, 

frequency-hopping technology to guarantee a license free, interference 

free link between remote devices and the control room. 

Costly cable and conduit runs on new projects, or retrofitting of existing 

systems, are eliminated and replaced with a maintenance free, reliable and 

versatile wireless solution. 

The set consists of an outdoor transmitter, receiver, and two antennas. 

Features of the Wireless Radio 

• Interference free, frequency-hopping, spread spectrum technology 

• License free 900-928 MHz band 

• Easy to use, wire in/wire out, no setup or programming 

• 180-300 m (600 to 1000 ft.) range in plant without line of sight with included antennas 

• Range with optional omni-directional antenna --- receiver and transmitter = 6-8 km (4-5 mi.) 




12 to 35 VDC 

Class I, Division 2 approved for hazardous area 

600' to 1000' 3.09inUsing 

Supplied Antenas* 

Wireless 

Receiver 

MS2500E/MS2500L with 

Wireless Transmitter 

Output to 

DCS/SCADA 

12-30VDC 

Supply 

Probe 

*Greater distance can be achieved 

with the use of directional antennas. 









The MS2510 receiver is designed to be used with 

MS2500 transmitters to provide a single channel 

stand-alone system. The MS2500 transmitter is 

mounted close to a corrosion monitoring probe. 

Only a single twisted pair cable is required to 

connect the transmitter to the MS2510 receiver. 

The color touch screen of the MS2510 receiver 

provides a local display of the corrosion monitoring 

data received from the transmitter. The transmitter/ 

receiver system is especially useful where a process 

monitoring computer is not readily accessible. 

Transmitter-to-receiver distances up to 10,000 feet with safety barriers are possible. 

The MS2510 receiver is powered by 100-240 VAC and provides the 24 VDC supply for powering 

the MS2500 transmitter’s 4-20 mA loop. The receiver processes the 4-20 mA signal to 

provide a digital readout of the cumulative metal loss and the probe corrosion rate based on the 

monitoring period set by the user (48 hours, 7 days, 15 days or 30 days). 

The MS2510 also offers an integrated web server. This feature allows users to access the 

MS2510 from any PC on the network using a standard web browser. Through this interface 

users can view data and make setup changes to the MS2510.

Receiver & Transmitter System 


Input: 

Maximum transmitter to 

receiver distance: 

Output: 

Resolution: 

Mounting: 

POWER SUPPLY 

Voltage: 

Current: 

SIGNAL 

Input: 

Voltage: 

Input Impedance: 

One probe 

10,000 feet 

Color touch screen; 

Metal loss (mils) or Corrosion Rate (mpy) 

+/- 0.1 mpy or 0.01 mil 

Panel or Rack Mount 

100 - 240 V AC, 1 phase, 50/60 Hz 

< 2 Amps 

4 - 20 mA current loop 

24V DC 

250 Ohms 


Operating Temp: 32° to 122° F (0° to +50° C) 

Weight: 

Size: 

Panel cutout: 

4 lbs. (1.9 kg) 

8.25” x 10” x 6” (20.95 cm x 25.40 cm x 15.24 cm) 

8.25” x 10” (20.95 cm x 25.40 cm) 

NETWORK 

Use a Crossover cable to connect the instrument directly to a PC. 

Use a Straight cable to connect the instrument to a network switch or router. 








MS3500E Remote ER Data Logger 

The MS3500E is a battery-powered, intrinsically safe, 

remote data-logger capable of measuring and storing 

data from all types of electrical resistance (ER) corrosion 

probes. The instrument is microprocessor-based 

and features a simple, menu-driven interface using a 

2-key keypad and a 2-line LCD display. 


electrical resistance method. Essentially, the instrument 

measures the resistance of the probe element which 

changes over time, as metal loss occurs. The rate of 

change is directly proportional to corrosion rate. This 

method finds a wide variety of applications since it can be used in conductive and nonconductive environments 

such as petroleum, chemical, water, soil, or even atmosphere. 

The MS3500E takes probe readings on a user-programmable logging interval. Readings are time and date 

stamped as they are taken, then stored to memory. Between readings, the instrument remains in a “sleep” mode 

to conserve main battery power. The instrument’s memory is capable of storing 3,100 readings, and is protected 

by a lithium back-up battery. 

Stored data can be uploaded to any IBM compatible PC as a comma-delimited ASCII text file. Because the 

data is in ASCII text format, it can be imported into any standard data analysis program such as Microsoft 

Excel, Lotus 123, or Corel Quattro Pro. Data can also be reviewed on the instrument’s LCD display for quick 

reference. 

Stored data can also be uploaded to a Metal Samples model MS1500E Handheld ER Data Logger for transfer 

to a PC. This handy feature eliminates the need to remove the MS3500E from its site, or to bring a laptop PC 

to the site. This can be particularly useful when collecting data from multiple MS3500E Data Loggers. And 

since both the MS3500E and the MS1500E are intrinsically safe, data can be uploaded from the MS3500E to 

the MS1500E even in hazardous locations. 

The MS3500E also offers an optional 4-20mA current loop output (model MS3510E). This feature allows 

data from the instrument to be fed directly to any industrial process computer that accepts analog inputs. 

The instrument is housed in a NEMA-4 enclosure, and all external connections are weather-proof. This makes 

the MS3500E suitable for use in almost any indoor or outdoor environment.


Model 

MS3500E - Remote ER Data Logger (Ordering # IN3500) 

MS3510E - Remote ER Data Logger w/ 4-20mA Current Loop Output (Ordering # IN3510) 

Physical Data 





Mounting Specifications: 





Range: 

Resolution: 

Cycle Time: 

11.94 lb. (5.42 Kg) 

13.64 lb. (6.19 Kg) 


NEMA-4 

10.75"H x 6"W (27.31cm x 15.24cm) Bolt Pattern 

0.3" (0.76cm) Diameter Bolt Holes 

32° to 122°F (0° to 50°C) 

-4° to 158°F (-20° to 70°C) 

ER measurement using any standard ER probe type (Wire 

Loop, Tube Loop, Cylindrical, Flush, Strip, etc.) 


1 digit 

1 Hour to 99 Days 



Six 1.5V AA Batteries 




4-20mA Current Loop Output (MS3510E Only) 

Intrinsic Safety: Class I, Division 1 


Temperature Code T3C 


Group IIC, T3C 




• Data storage capacity of 3,100 readings, with battery backup 




10' Probe Cable, Meter Prover, Communications Cable and Connector, Current Loop Connector (MS3510E 

only), Operation Manual, Corrosion Data Management Software 








New! 

MS4500E High-Resolution ER Data Logger 

The MS4500E is a hand-held, batterypowered, 

corrosion meter capable of 

measuring and storing data from all 

types of electrical resistance (ER) 

corrosion probes. The instrument is 

light weight, microprocessor-based, 

and features a simple, menu-driven 

interface using a keypad and a backlit 

graphical LCD display. 

Corrosion rate measurements are made 

using the electrical resistance method. 

Essentially, the instrument measures the 

resistance of the probe element which 

changes over time, as metal loss occurs. 

The rate of change is directly proportional 



to corrosion rate. This method finds a wide variety of applications since it can be used in conductive 

and nonconductive environments such as petroleum, chemical, water, soil, or even atmosphere. The new 

high-resolution measurement of the MS4500E detects smaller increments of metal loss, providing faster 

response than traditional ER instruments. 

After taking a reading, the instrument displays metal loss in mils and corrosion rate in mils per year 

(mpy). The reading can then be stored to memory or discarded. All stored readings are automatically 

time and date stamped. Readings are stored to non-volatile Flash memory which retains data without the 

need for a battery backup. 

On-screen charting 

Transfer data directly to USB Flash drive 

The MS4500E can store 16,000 readings per probe on up to 250 different probes (4 million total). Stored 

data can be downloaded to a PC via the USB cable or downloaded directly to a USB Flash (“jump”) 

drive. Data can be opened and charted using the provided CDMS software, or can be imported into any 

standard data analysis (spreadsheet) program such as Microsoft Excel. Data can also be reviewed and 

charted on the instrument’s LCD display for quick reference.

Model 

MS4500E - Handheld ER Corrosion Data Logger 


Physical Data 

Instrument Weight (w/ boot): 

Instrument Weight (w/o boot): 



Instrument Dimensions (w/ boot): 

Instrument Dimensions (w/o boot): 






Range - Standard: 

Range - High: 

Resolution - Standard: 

Resolution - High: 

Repeatability: 

1.00 lb. (0.45 kg) 

1.45 lb. (0.66 kg) 

6.70 lb. (3.04 kg) 

8.75"L x 4.50"W x 1.75"D (22.23cm x 11.43cm x 4.45cm) 



-4° to 130°F (-20° to 54°C) 

-4° to 158°F (-20° to 70°C) 

ER measurement using any standard ER probe types 

(Wire Loop, Tube Loop, Cylindrical, Flush, Strip, etc.) 

0 - 1,000 probe units 


0.1% of Probe Life 


± 0.1% of Full Scale 



Four AA Batteries 

Maximum Probe Cable Distance: 200 ft (61 m) 

Download Method: 

To PC via USB cable or directly to USB Flash drive 

Intrinsic Safety Certification 

US, CSA, ATEX 


• High resolution ER measurement for rapid response 

• Data storage capacity of 16,000 readings per probe on 250 different probes (4 million total) 

• Backlit graphical LCD display (320 x 240 pixel resolution) 

• On-screen charting 

• Non-volatile Flash memory 

• Multilingual menu (English, Spanish, Portuguese, French) 

• Portable 


Carrying Case, Probe Cable (1' coiled - 6' extended), USB Cable, Meter Prover, Operation Manual, 

Corrosion Data Management Software 







Introduction to Linear Polarization Resistance Monitoring 

LPR Probes 

LPR Instrumentation 


Linear Polarization Resistance Monitoring 

(LPR) Introduction 

The electrochemical technique, commonly referred to as Linear Polarization Resistance, is the only 

corrosion monitoring method that allows corrosion rates to be measured directly, in real time. Although 

limited to electrolytically conducting liquids, the response time and data quality of this 

technique make it clearly superior, where applicable, to all other forms of corrosion monitoring. 

Linear polarization resistance is particularly useful as a method to rapidly identify corrosion upsets and 

initiate remedial action, thereby prolonging plant life and minimizing unscheduled downtime. The technique is 

utilized to maximum effect when installed as a continuous monitoring system. 

This technique has been used successfully for over thirty years, in almost all types of water-based, 

corrosive environments. Some of the more common applications are: 

• Cooling water systems 

• Secondary recovery system 

• Potable water treatment and distribution systems 

• Amine sweetening 

• Waste water treatment systems 

• Pickling and mineral extraction processes 

• Pulp and paper manufacturing 

• Hydrocarbon production with free water 

Principle of Measurement 

When a metal/alloy electrode is immersed in an electrolytically conducting liquid of sufficient 

oxidizing power, it will corrode by an electrochemical mechanism. This process involves two simultaneous 

complementary reactions. 

At anodic sites, metal will pass from the solid surface into the adjacent solution and, in so doing, leave a 

surplus of electrons at the metal surface. The excess electrons will flow to nearby sites, designated cathodic 

sites, at which they will be consumed by oxidizing species from the corrosive liquid. A simple example of 

iron dissolving in acidic solution is illustrated in Figure 1. 

SOLID METAL 

CORROSIVE SOLUTION 

ANODIC 

SITE 

Icorr 

2e - Fe 2+ 

CATHODIC 

SITE 

H + 

H 2 

H + Fe Fe 2+ + 2e - 

2H + + 2e - H 2 

Figure 1.

The corrosion current (I CORR 

), generated by the flow of electrons from anodic to cathodic sites, could be 

used to compute the corrosion rate by the application of a modified version of Faraday’s Law: 

C = 

ICORR x E 

A x D 

x 128.67 (1) 

where: 

C = Corrosion rate in “mils per year” (MPY) 

E = Equivalent weight of the corroding metal (g) 

A = Area of corroding electrode (cm 2 ) 

d = Density of corroding metal (g/cm 3 ) 

However, anodic and cathodic sites continually shift position, and they exist within a continuously conductive 

surface, making direct measurement of I CORR 

impossible. Small, externally-imposed, potential shifts (∆E) will 

produce measurable current flow (∆I) at the corroding electrode. The behavior of the externally imposed 

current is governed, as is that of I CORR 

, by the degree of difficulty with which the anodic and cathodic 

corrosion processes take place. The greater the difficulty, the smaller the value of I CORR 

, and the smaller the 

value of ∆I for a given potential shift. In fact, at small values of ∆E, ∆I is directly proportional to I CORR 

, and 

hence to the corrosion rate. This relationship is embodied in the theoretically derived Stern-Geary equation: 

∆E/∆I = 

ba bc 

2.3 ICORR (ba + bc) 

(2) 

The numbers ba and bc are empirical rate constants, the Tafel constants, so the relationship can be more 

simply expressed as: 

ICORR = ∆I/ ∆E x constant (3) 

The value ∆E/ ∆I is known as the Polarization Resistance. In principle it is most easily measured by placing 

a second electrode (auxiliary) in the liquid, and connecting it to the corroding electrode (test) through an 

external power supply. This is illustrated in Figure 2. 

T 

R P 

E 

R s 

R P 

A 

R P 

= Polarization Resistance 

R S 

= Solution Resistance 

C E 

= Electrode Capacitance 

C E 

I 

C E 

Figure 2. 

LPR-2

The applied potential, in this simple type of two-electrode measurement, is required to over-come the 

solution resistance as well as the polarization resistance of the corrosion reactions. Consequently, the 

polarization resistance will be overestimated by ∆I(Rs), and the corrosion rate will be underestimated to an 

extent given by: 

C M 

= 

C A 

2R P 

2R P 

+ ∆I(R S 

) 

(4) 

where: 

C M 

= Measured corrosion rate 

= True corrosion rate 

C A 

Metal Samples Corrosion Monitoring Systems has largely overcome the problem of solution resistance 

error by using a three-electrode measurement (the PAIR technique). This uses separate circuits for the 

measurement of ∆I and ∆E. The circuit in which the ∆E measurement is made has an extremely high input 

impedance, consequently solution resistance has negligible effect on the value of potential shift applied to the 

test electrode. The basis of the PAIR technique is illustrated in Figure 3. 

10 mV 

E 

V A I 

Reference 

Test 

Auxiliary 

(R) (T) (A) 

Figure 3. 

PAIR is a trademark of Metal Samples Corrosion Monitoring Systems. 

LPR-3

When a measurement is made, the PAIR instrument will initially null any residual potential 

difference between the reference electrode (R) and the test electrode (T). After which, current will 

flow from the auxiliary electrode (A) onto the test electrode. The flow of current, between the 

auxiliary electrode and the test electrode, will increase until the test electrode potential is shifted 10 

mV with respect to the reference electrode. The current (∆I) required to sustain the 10 mV potential shift is 

proportional to the corrosion rate of the test electrode. 

The polarizing voltage of 10 mV, that is used in PAIR instrumentation, has been chosen as being 

well within the limits for which the linear relationship between I CORR 

and ∆E/∆I holds. Additionally, the value 

is sufficiently small as to cause no significant, or permanent disruption of the corrosion process, so that 

subsequent measurements remain valid. 

The instrument reading is given directly as “mils per year.” The constant of proportionality, incorporated 

into the PAIR instrumentation, is an empirical number determined by comparison of ∆E/∆I values 

with weight loss measurements for several hundred alloy/environment systems. This ensures a sound, 

experimental basis for instrument calibration. 

Individual corrosion rate measurements will show a decay characteristic, due to capacitative effects, 

that exist, to some degree, at all corroding electrode surfaces. This decay pattern is illustrated in 

Figure 4. 

CORROSION 

RATE 

C e 

T c 

TIME 

Figure 4. 

The true value of corrosion rate is the equilibrium value (Ce) that is established after a time interval Tc. This 

time lag will vary, depending on the specific characteristics of the metal/environment system, between 

approximately 30 seconds and several hours. Since the decay characteristic is asymptotic, even systems 

with extreme “capacitative inertia” will closely approach equilibrium within 15-20 minutes; so that most 

practical measurements can be concluded within a 0.5-20 minute duration. A variable “time cycle” feature is 

incorporated into most PAIR instrumentation to accommodate this capacitative time-lag. 

LPR-4

Probe/Electrode Selection 

Three-electrode probes are available with a triangular or linear-pin configuration, and in a concentric-ring, 

flush arrangement. When solution resistances reach extremely high values (10kΩ/cm), the choice of 

electrode configuration becomes important. This is due to the spreading effect produced by high resistivity 

on the current field between the test and auxiliary electrode that, at some point, will allow current to impinge 

on the reference electrode and displace its potential. The effect is illustrated in Figure 5. 

T 

TRIANGULAR 

A ELECTRODE 

CONFIGURATION 

R 

LINEAR 

ELECTRODE 

CONFIGURATION 

R T A 

FLUSH ELECTRODE 

CONFIGURATION 

REFERENCE 

AUXILIARY 

TEST 

Figure 5. 

LPR-5

Clearly, a linear-pin electrode configuration is less effected by “current spread” than is a triangular 

array. Concentric ring, flush, electrode configurations are essentially immune from “current spread” 

effects, due to mutual interference of current fields on opposite quadrants of the disc. As an approximate 

guide, a triangular electrode array can be used in solutions having specific resistances up to 10kΩ/cm, 

and the linear configuration up to 50kΩ/cm. In principle, the flush array will operate successfully as long as 

the environment offers some electrolytic conductance, however, 500kΩ/cm is a good guide to practical 

working limits. Electrode configuration is, therefore, of primary importance in selecting a probe type for a 

given application. 

Most other criteria for probe selection relate to the physical characteristics of the system, such as 

temperature and pressure ratings, and whether probe insertion/removal must be undertaken without 

system depressurization. Metal Samples Corrosion Monitoring Systems offers a wide variety of 

probe body styles, addressing these various needs. The simplest probe body style is the fixed length 

version, an example of which is shown in Figure 6. 

NPT Pipe Plug 

Figure 6. Fixed Length PAIR TM PROBE 

Typically equipped with an NPT bushing, the fixed PAIR probe is screwed into place. Probe 

installation requires system depressurization, unless an isolatable side-stream device is employed. 

Versions of this probe with 1" NPT, 1½" NPT, and 2" NPT entry bushing are available, with a maximum 

operating pressure of 3600 psi. An adjustable length version (shown in Figure 7) is also available with a 

movable entry bushing that will operate up to 1500 psi. 

1" NPT 

Pipe Plug 

Figure 7. Adjustable Length PAIR TM Probe 

LPR-6

Retractable probes, supplied with a 1" FNPT packing gland are available. Used in conjunction with a 1" , 

full-port, ball-valve these probes can be inserted and removed without system depressurization at pressure 

up to 1500 psi. 

Retractable probes can be supplied with a safety frame that prevents probe “backout” in high vibration 

systems, and aids the insertion/removal process at the high end of the pressure operating range 

(above 150 psi). 

For insertion/removal at high operating pressures, Metal 

Samples Corrosion Monitoring Systems offers the retrievable 

probe. This style probe can be inserted and removed, without 

system depressurization, at operating pressures up to 3600 

psi. To accomplish high-pressure retrieval, the probe is used 

in conjunction with a special range of fittings, plugs, tools, 

and valves that are discussed in the High Pressure Access 

Fittings section of this catalog. The retrievable installation, a 

standard for the oil and gas production industries, is illustrated 

in Figure 8. 

All probe body configurations discussed are for industrial 

use, and are constructed of AISI 316L stainless steel. As 

such, they meet NACE material standard MR-0175 for sour 

service use. Additionally, all industrial quality PAIR 

probes have a glass-sealed, electrical connector that has an 

operating pressure rating of 6000 psi, to provide a “backup” seal 

in the unlikely event that the primary electrode seals fail. 

ELECTRICAL 

ADAPTER 

HEAVY DUTY 

COVER 

HOLLOW PLUG 

ACCESS FITTING 

RETRIEVABLE 

PAIR ELECTRODE 

Metal Samples Corrosion Monitoring Systems also offers a 

range of laboratory PAIR probes and cells, side-stream 

devices, custom test-loops for laboratory investigation. 

Figure 8. 

Instrumentation 

Metal Samples Corrosion Monitoring Systems offers a wide range of PAIR instrumentation to suit 

almost any customer application. Instrument products offered include: 

• Handheld Meters and Data Loggers 

• Field-Mounted Data Loggers 

• Field-Mounted Transmitters 

LPR-7

Replacement Electrodes 

Replacement of electrodes by the user is a convenient feature of Metal Samples Corrosion Monitoring 

Systems probes. Field changes are quickly made without special tools or techniques. 

Comparisons of metals and alloys under operating conditions can be conveniently and economically 

accomplished. Substitution of identical fresh electrodes of the same material for badly corroded or 

contaminated electrodes is a practical approach to evaluating changes in process conditions or inhibitor 

effectiveness from the same starting conditions of surface quality and dimensions. 

The use of the replacement electrodes for weight loss measurements is an attractive possibility for 

many experimenters. The fact that both polarization and gravimetric measuring methods are made 

on the same test specimen eliminates several variables from comparative evaluations. 

With the 3-electrode system, surface areas of the different metals and alloys are adjusted to compensate for 

variations in chemical activity and density. Thus a direct mpy meter readout is obtained in each case for the 

electrodes listed. 

Electrodes are sold as a single unit. In most cases, the electrodes used will be of the same metal 

alloy; however, some users may wish to vary the electrodes. Each electrode is enclosed in an inhibited 

paper package along with a gasket. Viton ® gaskets are standard and supplied unless another 

material is specifically requested. 

Electrodes can be provided from many alloys with material supplied either by Metal Samples Corrosion 

Monitoring Systems or by the customer. Electrodes from the customer’s weld metal can be 

machined by Metal Samples Corrosion Monitoring Systems. Inquiries for electrodes of special 

alloys are encouraged. 

Viton ® is a registered trademark of DuPont Dow Elastomers. 






LPR Probes 

LP1000 - NPT Pipe Plug & 2-Electrode Endcap 

LP1100 - NPT Pipe Plug & 3 Electrodes 

LP2000 - Fixed Length with NPT Pipe Plug & 

2-Electrode Endcap 

LP2100 - Fixed Length with 1" NPT Pipe Plug & 3-Electrode Endcap 

LP3000 - Adjustable Length with 3/4" NPT Fitting & 2-Electrode Endcap 

LP3010 - Epoxy Probe 

LP3100 - Adjustable Length with 1" NPT Fitting & 3-Electrode Endcap 

LP4000 - Retractable with Packing Gland and 2-Electrode Endcap 

LP4100 - Retractable with Packing Gland and 3-Electrode Endcap 

LP6000 - Fixed Length with Flange and 2-Electrode Endcap 

LP6100 - Fixed Length with Flange and 3-Electrode Endcap 

LP7000 - Retrievable with 2-Electrode Endcap for High Pressure (HP & MH) 

Access Systems 

LP7100 - Retrievable with 3-Electrode Endcap for High Pressure (HP & MH) 


LP7210 - Retrievable with Flush-Mount 3-Electrode Endcap for High Pressure 

(HP & MH) Access Systems 

TF0221 - Lazaran Ag/AgCl Half-Cell Reference Electrode 

TF0222/TF0220 - PAIR Laboratory Probes 

Return to LPR menu

Model LP1000 

Linear Polarization Resistance Probe 

with NPT Pipe Plug & 2-Electrode Endcap 

NPT Pipe Plug 


Model LP1000 is a linear polarization resistance probe commonly used in laboratory, bypass-loop, 

and field applications. The assembly consists of an NPT pipe plug (1", 1½”, or 2"), a two-electrode 

endcap, and a six-pin military connector mounted in place. Electrodes are ordered separately. Several 

standard electrodes are available to meet your specific needs. 



Endcap Seal - Glass 




Mounting - 1", 1-1/2", or 2" NPT Pipe Plug 






Model 

LP13 

LP16 

LP17 

LP1000 Ordering Information 

Linear Polarization 1" NPT Pipe Plug Probe 

Linear Polarization 2" NPT Pipe Plug Probe 

Linear Polarization 1 1/2" NPT Pipe Plug Probe 


02 316 

03 C.S. 

04 C276 

LP Electrode Option 

20100 

Two-electrode integral type with glass seal 

Options 

000 

None 

LP13 

02 

20100 

000 


Electrode Part Number - EL400XXX2800000 (XXX - use Code in Alloy Chart) 

LPR probe electrodes are replaceable and sold separately. See Electrodes. 

Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

419 

CDA110 

C11000 

434 

CDA443 

C44300 

159 

316L 

S.S. 

S31603 



Model LP1100 


with NPT Pipe Plug and Three Electrodes 

1" NPT Pipe Plug 

1 1/2" or 2" NPT 

Pipe Plug 

A 

A 

A 

A 


1" NPT 1½" NPT 2" NPT 

View A - A 


and field applications. The assembly consists of a 1", 1½", or 2" pipe plug, and a five-pin military 

connector mounted in place. Replaceable mounting studs can be ordered with 1½" and 2" pipe plugs. 

Electrodes are ordered separately. Several standard electrodes are available to meet your specific 

needs. 







Mounting - 1", 1½", or 2" NPT Pipe Plug 






Model 

LP13 

LP16 

LP17 


Linear Polarization 1” NPT Pipe Plug Probe (LP13 cannot be used with replaceable mounting studs) 

Linear Polarization 2” NPT Pipe Plug Probe 

Linear Polarization 1 1/2” NPT Pipe Plug Probe 


02 

03 

04 

316 

C.S. 

C276 

LP Electrode Options 

10 

30 

Three-electrode plug type (replaceable mounting studs) 

Three-electrode integral type (non-replaceable mounting studs) 

Seal Type 

100 Glass 

Option 

000 None 

LP13 02 30 100 000 Example of Probe Ordering # 



Alloy Chart 


377 C1018 G10180 

159 316L S.S. S31603 

419 CDA110 C11000 

434 CDA443 C44300 



Model LP2000 


Fixed Length with NPT Pipe Plug & 2-Electrode Endcap 


Std. Length 

3/4" NPT 

Pipe Plug 

I.L. 

(1.2") 

3/4" 

1" Min. (1.6") 

Model LP2000 is a fixed-length, linear polarization resistance probe with an NPT pipe plug. The 

probe requires process isolation or process shutdown to install and a threaded pipe fitting to mount. 

The probe assembly consists of an insertion rod with a two-electrode endcap, a hermetically sealed 

connector, and an NPT pipe plug which are all welded in place. The insertion length (I.L.) is calculated 

to the end of the electrode and can be specified by the customer. For standard probes, the maximum 

insertion length is given in the chart below. Electrodes are ordered separately. Several standard 

electrodes are available to meet your specific needs. 


Probe Body - 316 Stainless Steel or C276 





Mounting - 3/4" or 1" NPT Pipe Plug 


6 " 

5.05" 

8 " 

7.05" 

12" 

11.05" 

18" 

17.05" 







Model 

LP2 

Linear Polarization Fixed Length Pipe Plug Probe 


2 3/4" NPT 

3 1" NPT 


22 

44 

316 

C276 


20 

Two-electrode integral type 

Seal Type 

1 Glass 

Length 

06 

08 

12 

18 

5.05" max. insertion length 




Options 

000 

None 

LP2 

2 22 

20 

1 08 

000 




Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

419 

CDA110 

C11000 

434 

CDA443 

C44300 

159 

316L 

S.S. 

S31603 



Model LP2100 


Fixed Length with 1" NPT Pipe Plug & 3-Electrode Endcap 


.90" 

A 

1" NPT 

Pipe Plug 

Std. Length 

5/8" 

A 

I.L. 

(1.325") 1" Min. 

2.22" 

VIEW A-A 

Model LP2100 is a fixed-length, linear polarization resistance probe with a 1" NPT pipe plug. The 

probe requires process isolation or process shutdown to install and a threaded pipe fitting to mount. 

The probe assembly consists of an insertion rod with a three-electrode endcap, a 1" NPT pipe plug, 

and a five-pin military connector mounted in place. The insertion length (I.L.) is calculated to the 

end of the electrode and can be specified by the customer. For standard probes, the maximum insertion 

length is given in the chart below. This maximum I.L. is based on the length of a carbon steel 

electrode. Electrode lengths may vary depending on the alloy. Electrodes are ordered separately. 







Mounting - 1" NPT Pipe Plug 


8 " 

6.92" 

12" 

10.92" 

18" 

16.92" 






Model 

LP2 

Linear Polarization Fixed 



Length Pipe Plug Probe 

3 1" NPT 


22 

316 


10 

30 

Three-electrode plug type 

Three-electrode integral type 

Seal Type 

1 Glass 

Length 

08 

12 

18 




Options 

000 

None 

LP2 

3 22 

30 

1 08 

000 




Alloy Chart 

Code 

D escription 

UNS # 

377 

C1018 

G10180 

159 

316L 

S.S. 

S31603 

419 

CDA110 

C11000 

434 

CDA443 

C44300 



Model LP3000 


Adjustable Length with 3/4" NPT Fitting & 2-Electrode Endcap 


3/4" NPT 

Compression 

Fitting 

Std. Length 

3/4" 

I.L. (2") (1.6") 


and field applications. The assembly consists of a 3/4" NPT compression fitting, an insertion rod 

with a hermetically sealed two-electrode endcap, and a six-pin connector welded in place. The insertion 

length (I.L.) is calculated to the end of the electrode and can be specified by the customer. For 

standard probes, the maximum insertion length is given in the chart below. Electrodes are 

ordered separately. Several standard electrodes are available to meet your specific needs. 







Mounting - 3/4" NPT Fitting 


6 " 

5.25" 

8 " 

7.25" 

12" 

11.25" 

18" 

17.25" 






Model 

LP3 


Linear Polarization Adjustable 


2 

3 


3/4" NPT 

1" NPT 


22 

316 


20 

Two-electrode integral type 

Seal Type 

1 Glass 

Length 

06 5.25" max. insertion length 




Options 

000 

None 

LP3 

2 22 

20 

1 08 

000 




Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

419 

CDA110 

C11000 

434 

CDA443 

C44300 

159 

316L 

S.S. 

S31603 



Model LP3010 

Epoxy Probe 

I.L. 

(2") 

0.75" 

3/4" NPT Nylon 

Fitting (Optional) 

(7.5") (3.219") 


and field applications. The probe (with additional instrumentation) can be used to monitor corrosion 

rates, evaluate materials, and screen corrosion inhibitors. The assembly consists of a glass epoxy 

probe with an optional 3/4" NPT nylon compression fitting for insertion into the system. The studs 

for mounting the electrodes and the six-pin connector are held in place by the epoxy fill material. 

The maximum insertion length (I.L.) is 6.75" when the compression fitting is used and 8.75" when 

the fitting is not used. Electrodes are ordered separately. 


Probe Body - Glass Epoxy 

Endcap Seal - Epoxy 


Temperature Rating (w/ Nylon compression fitting) - 150°F / 65°C 

(w/out Nylon compression fitting) - 300°F / 150°C 









Model 

LP3 

LP0 

Linear Polarization Adjustable Length PIpe Plug Probe 

Linear Polarization Insertion Rod 


0 N/A (when ordering only Insertion Rod - LP0) 

2 3/4" NPT 


7 Epoxy 

Mount (PIpe Plug) Material 

0 

E 

N/A (when ordering only Insertion Rod - LP0) 

Nylon 


20 Two-electrode integral type 

Seal Type 

3 Epoxy 

Length 

11 11" 

Options 

000 None 

LP3 2 7 E 20 3 11 000 Example of Probe Ordering # 



Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

419 

CDA110 

C11000 

434 

CDA443 

C44300 

159 

316L 

S.S. 

S31603 



Model LP3100 


Adjustable Length with 1" NPT Fitting & 3-Electrode Endcap 

A 

.90" 


Std. Length 

1" NPT 

Pipe Plug 

5/8" 

A 

I.L. 

(3.45") 

2.22" 

View A - A 


and field applications. The assembly consists of a 1" NPT compression fitting, an insertion rod with 

a hermetically sealed three-electrode endcap, and a five-pin military connector mounted in place. 

The insertion length (I.L.) is calculated to the end of the electrode and can be specified by the customer. 

For standard probes, the maximum insertion length is given in the chart below. This maximum 

I.L. is based on the length of a carbon steel electrode. Electrode lengths may vary depending 

on the alloy. Electrodes are ordered separately. 







Mounting - 1" NPT Fitting 


8 " 

5.8" 

12" 

9.8" 

18" 

15.8" 






Model 

LP3 


Linear Polarization Adjustable 


3 1" NPT 



22 

316 


10 

30 

Three-electrode plug type 


Seal Type 

1 Glas s 

Length 

08 

12 

18 




Options 

000 

None 

LP3 

3 22 

30 

1 08 

000 




Code 

Alloy Chart 

D escription 

UNS # 

377 

C1018 

G10180 

159 

316L 

S.S. 

S31603 

419 

CDA110 

C11000 

434 

CDA443 

C44300 



Model LP4000 


Retractable with Packing Gland and 2-Electrode Endcap 

Std. Length 

(1.6") 

2-Electrode 

Endcap 

1" NPT 

.75" 

5/8" 

I.L. 

(5.9") 

Model LP4000 is a retractable, linear polarization resistance probe commonly used in field and plant 

applications. A specially designed packing gland is used with the probe for insertion into or retraction 

from a pressurized system without a process shutdown. The packing gland is designed to mount 

easily on a 1" piping system, but it can be modified for your specific mounting requirements. 

The probe assembly consists of a packing gland, an insertion rod with a hermetically sealed twoelectrode 

endcap, and a six-pin connector welded in place. A safety chain is also provided to prevent 

blowout. Standard packing material in the packing gland is Teflon ® , however, grafoil packing can be 

provided for high temperature applications. The insertion length (I.L.) is calculated to the end of the 

electrode and can be specified by the customer. For standard probes, the maximum insertion length is 

given in the chart below. Electrodes for the probe can be ordered separately. Several standard electrodes 

and probe lengths are available to meet your specific needs. 






Grafoil available upon request 




24" 17.53" 

30" 23.53" 

36" 29.53" 

42" 35.53" 









Model 

LP45 

LP75 

Linear Polarization 1" Female NPT Probe, Packing Gland with Teflon ® 

Linear Polarization 1" Female NPT Probe, Packing Gland with Grafoil 


22 316 

44 C276 



Seal Type 

1 Glass 

Length 

24 

30 

36 

42 





Options 

000 None 

LP45 22 20 1 24 000 Example of Probe Ordering # 



Alloy Chart 

Code 

D escription 

UNS # 

375 

C1010 

G10100 

419 

CDA110 

C11000 

434 

CDA443 

C44300 

159 

316L 

S.S. 

S31603 



Model LP4100 


Retractable with Packing Gland and 3-Electrode Endcap 

A 

I.L. 

1" NPT 

5.9" 

.90" 

5/8" 

A 

View A - A 

3-Electrode 

Endcap 

Std. Length 

1 1/2" 

Model LP4100 is a retractable, linear polarization resistance probe commonly used in field and 

plant applications. A specially designed packing gland is used with the probe for insertion into or 

retraction from a pressurized system without a process shutdown. The packing gland is designed to 

mount easily on a 1" piping system, but it can be modified for your specific mounting requirements. 

The probe assembly consists of a packing gland, an insertion rod with a hermetically sealed threeelectrode 

endcap, and a five-pin military connector mounted in place. A safety chain is also provided 

to prevent blowout. Standard packing material in the packing gland is Teflon ® , however, grafoil 

packing can be provided for high temperature applications. The insertion length (I.L.) is calculated to 

the end of the electrode and can be specified by the customer. For standard probes, the maximum 

insertion length is given in the chart below. This maximum I.L. is based on the length of a carbon 

steel electrode. Electrode lengths may vary depending on the alloy. Electrodes are ordered 

separately. 






Grafoil available upon request 




24" 

17.53" 

30" 

23.53" 

36" 

29.53" 

42" 

35.53" 








Model 

LP45 

LP75 

LPB7 

LPC7 


L inear Polarization 1" Female NPT 

® 

Probe, Packing Gland w/ Teflon (for integral type) 

Linear Polarization 1" Female NPT Probe, Packing Gland w/ Grafoil (for integral type) 

L inear Polarization 1" Female NPT 

® 

Probe, Packing Gland w/ Teflon (for plug type) 

Linear Polarization 1" Female NPT Probe, Packing Gland w/ Grafoil (for plug type) 


22 

44 

316 

C276 


10 

30 

Three-electrode plug type with 1 1/2" swage nipple 


Seal Type 

1 Glas s 

Length 

24 

30 

36 

42 





Options 

000 

None 

LP45 

22 

30 

1 24 

000 




Code 

Alloy Chart 

D escription 

UNS # 

377 

C1018 

G10180 

159 

316L 

S.S. 

S31603 

419 

CDA110 

C11000 

434 

CDA443 

C44300 



Model LP6000 


Fixed Length with Flange & 2-Electrode Endcap 

Std. Length 

2" min. 

1.6" 


A 

3/4" 

5/8" 

A 

I.L. 

Flange 

View A - A 

Model LP6000 is a fixed-length, flange-mounted, linear polarization resistance probe. The probe 

is ideally suited for use in high pressure and/or hazardous applications where threaded fittings are 

not available or not recommended. Process shutdown or process isolation is required for installation 

and inspection. The probe assembly consists of an insertion rod with a two-electrode endcap, a 

hermetically sealed connector, and a flange (as specified by customer), which are all welded in place. 

Insertion length (I.L.) is calculated to the end of the electrodes and, in this case, is based on a 1” total 

flange thickness. Customers can specify any length required. For standard probes, the maximum 

insertion length is given in the chart below. Electrodes are ordered separately. Several standard 

electrodes are available to meet your specific needs. 


Probe Body: 316 Stainless Steel or C276 

Endcap Seal: Glass 

Fill Material: Epoxy 

Temperature Rating: 500°F / 260°C 

Pressure Rating: According to Flange Rating 

Mounting: Mating Flange 


12" 10.12" 

18" 16.12" 

24" 22.12" 







Model 

LP6 Linear Polarization Fixed Length Probe with Flange 

Flange Size 

1 1” Flange 

2 1 1/2” Flange 

3 2” Flange 

4 3” Flange 

5 4” Flange 

7 6” Flange 

8 2 1/2" Flange 

9 3/4" Flange 


22 316 

44 C276 




1 150 lbs. 

2 300 lbs. 

3 600 lbs. 

4 1200 lbs. 

5 1500 lbs. 

6 900 lbs. 

Seal Type 

1 Glass 

Length 




Options 

000 None 

LP6 2 22 2 1 1 12 000 Example of Probe Ordering # 



Alloy Chart 


375 C1010 G10100 

419 CDA110 C11000 

434 CDA443 C44300 

159 316L S.S. S31603 


Note: Not all alloys are available with all electrode types and seals.

Model LP6100 


Fixed Length with Flange & 3-Electrode Endcap 

Std. Length 

2" min. 


A 

.90" 

5/8" 

A 

2.22" 

I.L. 

Flange 

View A - A 

Model LP6100 is a fixed-length, flange-mounted, linear polarization resistance probe. The probe 

is ideally suited for use in high pressure and/or hazardous applications where threaded fittings are 

not available or not recommended. Process shutdown or process isolation is required for installation 

and inspection. The probe assembly consists of an insertion rod with a three-electrode endcap, a 

hermetically sealed connector, and a flange (as specified by customer), which are all welded in place. 

Insertion length (I.L.) is calculated to the end of the electrodes and, in this case, is based on a 1" total 

flange thickness. Customers can specify any length required. For standard probes, the maximum 

insertion length is given in the chart below. Several standard electrodes are available to meet your 

specific needs. Electrodes are ordered separately. 









12" 

10.25" 

18" 

16.25" 

24" 

22.25" 







Model 

LP6 Linear Polarization Fixed Length Probe with Flange 

Flange Size 

1 1” Flange 

2 1 1/2” Flange 

3 2” Flange 

4 3” Flange 

5 4” Flange 

7 6” Flange 

8 2 1/2" Flange 


22 316 


10 Three-electrode plug type 

30 Three-electrode integral type 


1 150 lbs. 

2 300 lbs. 

3 600 lbs. 

4 1200 lbs. 

5 1500 lbs. 

6 900 lbs. 

Seal Type 

1 Glass 

Length 




Options 

000 

LP6 2 22 30 1 1 18 000 Example of Probe Ordering # 



Alloy Chart 

Code 

D escription 

UNS # 

377 

C1018 

G10180 

159 

316L 

S.S. 

S31603 

419 

CDA110 

C11000 

434 

CDA443 

C44300 



Model LP7000 


Retrievable with 2-Electrode Endcap 


1.25" 

2-Electrode 

Endcap 3/4" 

1-14 UNS-2A (L.H.) 

A 

I.L. 

(2") 

A 

Small 6-Pin 

Configuration 

Std. 6-Pin 

Configuration 

B 

View B - B View A - A 

B 

Model LP7000 is a fixed-length, linear polarization resistance probe for use with HP and MH 

high pressure access systems. The probe assembly consists of an insertion rod with a hermetically 

sealed two-electrode endcap, a hollow plug nut, and a standard six-pin connector, which are all 

welded in place. The hollow plug nut on the probe screws into the hollow plug of the access system. 

This allows the probe to be installed in the process, using a retrieval tool and service valve, without 

process shutdown. The insertion length (I.L.) can range from 3.000" up to any length specified by 

the customer in 1/8" increments, using the formula below. (This includes 1.25" for the length of the 

electrode.) 

I.L. = PD + WT + 1.75" 



Several standard electrodes are available to meet your specific needs. Probe adaptors are also available 

and must be ordered separately. 













Model 

HL 


Linear Polarization Two-Electrode Probe for High Pressure Access System 


2 316 

3 C276 


1 Small connector 

2 Standard connector 



Seal Type 

0 Glass 

1 Epoxy 

Length (Round calculated length to the nearest 1/8") 


(Ex: 6 1/8" = 0612) 

Options 

000 None 

HL 2 2 0 0 0612 000 Example of Probe Ordering # 



Alloy Chart 


375 C1010 G10100 

419 CDA110 C11000 

434 CDA443 C44300 

159 316L S.S. S31603 



Model LP7100 


Retrievable with 3-Electrode Endcap 


Electrode 

I.L. 2" 

C 


A 

.90" 

C 

Std. 6-Pin 

Configuration 

1-14 UNS-2A (L.H.) 

Small 6-Pin 

Configuration 

A 

B 

B 

View C-C 

View A-A 

View B-B 

Model LP7100 is a fixed-length, linear polarization resistance probe for use with HP and MH 

high pressure access systems. The probe assembly consists of an insertion rod with a hermetically 

sealed three-electrode endcap, a hollow plug nut, and a standard six-pin connector, which are all 

welded in place. The hollow plug nut on the probe screws into the hollow plug of the access system. 


process shutdown. Several standard electrodes are available to meet your specific needs. Probe 

adaptors are also available and must be ordered separately. The insertion length (I.L.) can range from 

2.000" up to any length specified by the customer in 1/8" increments, using one of the following 

formulas. 

Top-of-the-line monitoring: I.L. = WT + 1.75 

Middle-of-the-line monitoring: I.L. = PD + WT + 1.75 - ½EL 

Bottom-of-the-line monitoring: I.L. = PD + WT + 1.75 - EL 

(where PD = penetration depth, WT = wall thickness, 

EL = electrode length - see Alloy Chart on back) 















Model 

HL Linear Polarization Three-Electrode Probe for High Pressure Access System 


2 316 

3 C276 


1 Small connector 



1 Three-electrode integral type 

Seal Type 

0 Glass 



(Ex: 6 1/8" = 0612) 

Options 

000 None 

HL 2 2 1 0 0612 000 Example of Probe Ordering # 



Alloy Chart 


375 C1010 G10100 

419 CDA110 C11000 

434 CDA443 C44300 

159 316L S.S. S31603 



Model LP7210 


Retrievable with Flush-Mount 3-Electrode Endcap 


I.L. 

A 

B 

A 

3-Electrode 

Endcap 

Insertion Rod 

B 

Epoxy Seal 

Std. 6-Pin 

Configuration 

View A-A 

Flush Mount 

Electrode 

View B-B 

Model LP7210 is a fixed-length, flush-mount, three-electrode, retrievable, linear polarization resistance 

probe for use with HP and MH high pressure access systems. These probes are ideally 

suited for applications where the probe electrodes need to be flush with the wall of the pipe. The 

probe assembly consists of an insertion rod, a flush-mount three-electrode endcap, and a six-pin military 

connector. The hollow plug nut on the probe screws into the hollow plug of the access system. 


process shutdown. The probe’s three-electrode endcap is filled with an epoxy seal. Electrodes are 

not replaceable. The insertion length (I.L.) can range from a minimum of 1.75" up to any length 

specified by the customer in 1/8" increments, using the formula: 

I.L. = PD + WT + 1.75" 






Endcap Seal - Epoxy 











Model 

HL 

Linear Polarization Three-Electrode Probe for High Pressure Access System 


2 316 

3 C276 




4 

6 

Three-electrode integral flush type 

Three-electrode integral flush adjustable type 

Seal Type 

1 Epoxy 



(Ex: 6 1/8" = 0612) 

Electrode Alloy 


HL 2 2 4 1 0612 XXX Example of Probe Ordering # 

Alloy Chart 


375 C1010 G10100 

419 CDA110 C11000 

434 CDA443 C44300 

159 316L S.S. S31603 



Model TF0221 

Lazaran Ag/AgCl Half-Cell Reference Electrode 

The TF0221 Ag/AgCl Reference Electrode is of 

a specially rugged design for use in severe 

environmental conditions, such as high flow and 

pressure regimens. Its size and thread design are 

compatible with all Metal Samples Corrosion 

Monitoring Systems electrochemical probes, 

laboratory test cells and autoclaves systems 

which use the EL412 series of pin electrodes. It 

is unique in providing a stable reference potential 

in almost all industrial applications where 

electrochemical measurements are made. 

The electrode consists of a silver wire coated 

with silver chloride immersed in an electrolyte of 

saturated potassium chloride and silver chloride. 

The half cell and electrolyte are contained in a 

Teflon ® outer casing with a portion composed of 

25% glass filled Teflon ® . This provides the 

conductive bridge to the external sample. The 

electrode assembly is attached to the probe or 

extension rod by a 5 - 40 UNC internal thread to 

provide a mechanically strong connection. 

INSTALLATION 

Locate the pin which is attached to the “A” line 

connection on the industrial probe. This may be 

done using any continuity test between the “A” 

pin on the military connector of the probe and 

one of the outside threaded pins for attaching the 

electrodes. 

Using one (1) Viton ® or Teflon ® gasket between 

the probe body and the electrode, screw the 

TF0221 electrode firmly onto the “A” pin. A 

liquid-tight seal must be made at the rim of the 

electrode base by the gasket to prevent the silver 

body of the electrode from making electrical 

contact with the solution. The electrode must be 

attached to pin “A” on the probe which is the 

reference electrode pin. Remember to remove 

the vinyl boot covering from the active area of 

the TF0221 electrode before installing the probe 

into the system. 

When removing the TF0221 electrode from the 

probe, it is important that both the electrode 

body and the Viton ® gasket be grasped, then turn 

both counter-clockwise. If the electrode is 

removed by turning the electrode body only, 

then the silver internal element may be unscrewed 

from the electrode casing. 

STORAGE & REJUVENATION 

The TF0221 electrode is a sealed unit filled with 

saturated KCl electrolyte. No external reservoir 

for electrolyte is required. The electrode is 

shipped in a 2 molar KCl solution with the active 

area covered with a vinyl boot. This solution is 

not highly corrosive but excessive contact with 

the skin should be avoided. When stored, the 

electrode should be kept wet by immersion in 

water or a KCl solution with the vinyl boot in 

place. The silver body of the electrode can be 

protected from the storage solution by using the 

Teflon ® is a registered trademark of DuPont. 

Viton ® is a registered trademark of DuPont Dow Elastomers.

Nylon screw and Viton ® gasket provided. The 

internal cell should be kept filled with electrolyte 

with a few crystals of KCl present to ensure that 

the solution surrounding the silver-silver chloride 

element is saturated. 

Should the electrode dry out it can be rejuvenated 

by the following procedure. Remove the 

electrode body from the casing with a Phillips 

screwdriver. Wash the casing with distilled water 

or alternatively boil it in a concentrated solution 

of KCl for one hour. Shake the casing dry and 

add a few crystals of KCl (0.1 gram) to the 

cavity. Fill the casing to just below the internal 

thread with potassium chloride saturated with 

silver chloride solution. If the electrode is to be 

used under high pressure, the cavity must be 

filled completely with electrolyte. Screw the 

electrode body into the filled casing until the 

body is at or below the lip of the casing to ensure 

the body will be sealed with the electrode gasket 

when in use. A small amount of electrolyte 

should appear when tightening the body which 

confirms that the cavity is completely filled. 

If the electrode is compared to a commercially 

available Saturated Calomel electrode (glass 

body with porous ceramic junction) using a high 

impedance DC voltmeter a voltage of -0.050 to 

-0.055V should be obtained in tap water at 21°C. 

SPECIFICATIONS 

Electrode Potential: 

-0.199V vs. Std. hydrogen electrode 

Internal Half Cell: 

Silver/ Silver Chloride 

Operating Temperature Range: 

-5° C to +105° C @ 1 Atm 

Operating Pressure: 

0 to 150 psig 

Temperature Variation: 

+0.6 mV/ °C 

Note: The electrode has shown to provide stable 

readings at pressures up to 3600 psi provided the 

electrode cavity is completely filled with electrolyte. 






Model TF0222 / TF0220 

PAIR Laboratory Probes 

TF0222 Laboratory Probe 

Qty (3) 1/4" dia. x 10" 

FEP Plus Teflon® 

Coated Rods 

25% Glass Filled 

Teflon® 

Stopper 

45/50 Ground 

Glass Joint 

Mil. Electrical 

Fitting 

O-Ring 

View A - A 

Hole Pattern for 

Teflon® 

Stopper 

3 Holes on 

1.060" dia. B.C. 

500 mL Erlenmeyer Flask 

Each Metal Samples Corrosion Monitoring Systems laboratory probe is supplied with individual 

electrode extension rods which are ¼" in diameter and 11½" in length. A 5-40 thread is located at 

one rod end for electrode attachment. The other rod end is reduced to 1/16" diameter for connection 

to the supplied electrical harness. Rods have a two layer FEP coating, which is covered by plastic 

tubing to protect against chemical attack. 

A snap-on, three-wire electrical harness connects electrode extension rods to instrument cable 

through MIL environmental fittings. Connections are referenced by molded rubber knobs on harness 

fittings. 

The snap-on electrical harness arrangement is ideal for comparative testing of three different metals 

or alloys by switching test-reference-auxiliary electrode connections. Individual electrode rods are 

convenient for substitution of a calomel (or other) reference electrode into the PAIR system. 

TF0222 Laboratory Probe Assembly 

Model TF0222 laboratory probe is designed for insertion into a glass beaker (supplied) or retort 

through an easy-release tapered Teflon® stopper. The stopper is equipped with Swagelok fittings 

installed in three triangularly oriented ¼" diameter holes for electrode extension rods. 

Also included in the assembly are three electrode extension rods and one electrical harness. 

Size: 16" high (40 cm) 

Weight: 2 pounds (.9 kg)

TF0220 Lab Cell / Probe Assembly 

Model TF0220 consists of a one liter glass jar complete with a fitted Delrin top. The top is supplied 

with a series of holes, three with Swagelok fittings. The assembly also includes three coated electrode 

extension rods and a snap-on electrical harness. 

Size: 14" (36 cm) overall height 

Weight: 2 pounds (.9 kg) 

TF0220 Lab Cell 

11.00" 

8.00" 

Electrodes 

sold separately 

3.875" 

All probes will be supplied with MIL environmental electrical connectors unless specifically ordered 

otherwise. A wide range of replaceable electrodes (ordered separately) are available to meet your 

specific needs. 






Electrodes 

Metal Samples provides electrodes compatible with our 

various probes and instruments, as well as those of most 

other major manufacturers. Other electrodes not shown 

here are also available. Electrodes are made from a variety 

of materials (see Alloys list). 

P/N EL400 

Typically used for 2-electrode probes. 

1.250 

O .188 

P/N EL405 

Lapped Surface 

8-10 RMS 

one side only 

R .094 

4-40 UNC-2B Threads 

Surface Finish: Approx. 8 - 16 RMS Surface area: .736 in 2 

P/N EL410 

3-48 Tap 

P/N EL412 

1/16” 

O 5/8” 

or 1/8” 

Length & diameter vary by alloy. 


L 

(± .005) 

O ± .005 

Tap 5-40 NC 2B 

1/2” 

O 3/8” 

Centerless Grind O.D. Surface area: .700 in 2 


Gaskets Commonly used with Electro-Chemical Apparatus 

P/N MI2616 

Teflon ® gasket for use with EG&G 

O 5/8” disc holder 

P/N MI2604 

Teflon ® compression spacer for electrochemical 

electrode mounting (per ASTM G5) 

P/N MI2605 

Teflon ® compression gasket for electrochemical 


O 1/8” thru 

1/4” 

O 1/8” thru 

3/4” 

1/4” 

O 3/8” 

O 3/8” 

1/4” 

O 3/16”

LPR Instrumentation 

MS1000 - 

is a 2-electrode, hand-held corrosion meter with a zero 

resistance ammeter. 

MS1500L - is a hand-held, battery-powered, intrinsically safe corrosion data 

logger that takes LPR probe measurements and stores the data 

to be downloaded to your computer for analysis. 

MS2500L - is a loop-powered LPR transmitter which transmits 

measurements to a receiver. 


Wireless Radio Option for MS2500L 

MS3500L - is a data logger used to continuously monitor LPR probes in 

remote locations, automatically read the probes at selected 

intervals, and store the readings in its memory. 

Return to LPR menu



MS1000 LPR Corrosion Meter 

The MS1000 is a hand-held, battery-powered 

corrosion meter. This versatile instrument 

measures the instantaneous corrosion rate and 

electrochemical current between the electrodes 

of any standard 2-electrode linear polarization 

resistance (LPR) probe. 


linear polarization resistance technique. The instrument 

measures the current required to polarize the 

electrodes of a probe to a known potential. From 

the polarization potential and the measured current, 

polarization resistance can be calculated. Then, using 

Faraday’s law, instantaneous corrosion rate is calculated 

from polarization resistance. 

Probe shown in 

photo not included 

with corrosion meter 

The MS1000 is designed to calculate the corrosion 

rate in mils per year (mpy) for carbon steel. Multiplication 

factors for several common alloys have been included on 

the front panel of the instrument for quick reference. Multiplication 

factors for other alloys can be easily calculated using the formulas supplied in the 

operation manual. 

The MS1000 also offers a high precision zero resistance ammeter (ZRA) for measuring the 

electrochemical current between electrodes. This function may be used to measure the galvanic 

current between electrodes of dissimilar alloys. 

The MS1000 has a simple function key interface, using a 4-key keypad and a 4-line LCD display. 

The instrument also offers low-battery detection and an auto-shutoff feature to conserve 

battery life.


Model 

MS1000 - LPR Corrosion Meter (Ordering # IN1000) 

Physical Data 








0.84 lb. (0.38 Kg) 

5.20 lb. (2.36 Kg) 



32° to 122°F (0° to 50°C) 

-4° to 158°F (-20° to 70°C) 



2-Electrode LPR, Galvanic 

Range: 2-Electrode: 0-40 mpy Galvanic: 0-80 µA 

Resolution: 2-Electrode: 0.02 mpy Galvanic: 0.04 µA 

Cycle Time: Corrosion Rate: 60 sec ZRA: 30 sec 



One 9V Li-Ion Rechargeable Battery (see below) 




• Function key interface using 4-key keypad and 4-line LCD display 


• Portable 


Carrying Case, 10' Probe Cable, Battery Charger, Lightweight Protective Case, 

Meter Prover, Operation Manual 

New Li-Ion Rechargeable Battery 

Li-Ion battery charges faster & has a longer life than previous NiCad battery (400mAH as opposed to 120mAH.) 

Li-Ion Charger features: 

• Multi-voltage input for domestic & international use (100-240 VAC 50/60Hz) 

• Automatic cut-off when battery is charged (to prevent over-charging) 

• Red/Green LED’s to indicate when battery is charging/full 








MS1500L Handheld LPR Corrosion Data Logger 

The MS1500L is a hand-held, battery-powered, 

intrinsically safe corrosion meter capable of 

measuring and storing data from all types of 2- or 

3-electrode linear polarization resistance (LPR) 

corrosion probes. The instrument is light weight, 

microprocessor-based, and features a simple, 

menu-driven interface using a 12-key keypad and a 

4-line LCD display. 


linear polarization resistance technique. The 

instrument measures the current required to 

polarize the electrodes of a probe to a known 

potential. From the polarization potential and the 

measured current, polarization resistance can be 

calculated. Then, using Faraday’s law, the instantaneous 

corrosion rate can be calculated from polarization resistance. 



The MS1500L incorporates a high-precision zero-resistance ammeter (ZRA) for measuring 

galvanic current between electrodes. It also offers a high-precision voltmeter for measuring the 

open-circuit potential between electrodes. 

After performing a measurement, the instrument displays the corrosion rate, current, or potential, 

depending on the mode selected. The reading can then be stored to memory or discarded. All 

stored readings are automatically time and date stamped, and are protected by a lithium back-up 

battery. The instrument can store a maximum of 3,000 readings on up to 100 different probes. 

Stored data can be uploaded to any IBM compatible PC as a comma-delimited ASCII text file. 

Because the data is in ASCII text format, it can be imported into any standard data analysis program 

such as Microsoft Excel, Lotus 123, or Corel Quattro Pro. Data can also be reviewed on the 

instrument’s LCD display for quick reference. 

The MS1500L may also be used as a data transfer unit (DTU) for the MS3500L Remote Data 

Logger. Data may be transferred from multiple MS3500L field-based units to the MS1500L, then 

later transferred to a PC for analysis.


Model 

MS1500L - Handheld LPR Corrosion Data Logger (Ordering # IN1500L) 

Physical Data 








1.4 lb. (0.64 Kg) 

5.26 lb. (2.39 Kg) 

7.63"H x 4.15"W x 2.0"D(19.38cm x 10.54cm x 5.08cm) 


32° to 122°F (0° to 50°C) 

-4° to 158°F (-20° to 70°C) 


Measurement 

Type 

Range 

Resolutio n 

2-Electrode 

0 to 200 mpy 

0.01 mpy 

3-Electrode 

0 to 150 mpy 

0.01 mpy 

Galvanic 

± 999 µ A 1 µ A 

Potential 

± 999 mV 

1 mV 



One 9V Battery 






Temperature Code T2D 


Group IIC, T2D 




• Data storage capacity of 3,000 readings on 100 different probes, with battery backup 



• Portable 


Carrying Case, 6' Probe Cable (attached), Meter Prover, 6 to 5-Pin Adapter, Galvanic Adapter, 

Communications Cable and Connector, Operation Manual, Corrosion Data Management Software 








MS2500L Loop-Powered LPR Transmitter 

The MS2500L is a corrosion transmitter capable of 

measuring and transmitting data from all types of 3- 

electrode linear polarization resistance (LPR) corrosion 

probes. 

Corrosion rate measurements are made using the linear 

polarization resistance technique. The instrument 

measures the current required to polarize the electrodes 

of a probe to a known potential. From the polarization 

potential and the measured current, polarization resistance 

can be calculated. Then, using Faraday’s law, 

instantaneous corrosion rate is calculated from polarization 

resistance. 

Another feature of the MS2500L is its high-precision 

voltmeter. This is used to measure the open-circuit 

potential between electrodes. 


included with corrosion transmitter 

Measurements are transmitted via 4-20mA current loop. 

Since current loop signals are not as sensitive to line loss as other types of data signals, the 

MS2500L may be located up to ten miles away from the data receiver under proper conditions. 

The MS2500L is completely loop-powered, so installation is simple. A two-wire connection is all 

that is required for both instrument power and data transmission. Setup is also simple, using a set 

of switches to select the measurement function (corrosion rate or electrode potential). 

The MS2500L is housed in a NEMA rated explosion-proof and weather-proof enclosure, and the 

probe cable is connected through a water-tight, explosion-proof cable gland. This makes the 

MS2500L suitable for use in almost any indoor or outdoor environment.


Model 

MS2500L - Loop-Powered LPR Transmitter (Ordering # IN2500L) 

Physical Data 





5.02 lb. (2.28 Kg) 

7.08 lb. (3.21 Kg) 


Explosion Proof (FM, CSA, CENELEC, UL) 

Class I, Groups B, C, D, Class II, Groups E, F, G, Class III, 

CENELEC: Eexd IIC 

NEMA 4, 7BCD, 9EFG 

Mounting Specifications: 0.728"H x 1.756"W (1.85cm x 4.46cm) Bolt Pattern with 1/4-20 

Tapped Mounting Holes, or May Be Mounted on a 1/2" to 2" (1.27cm 

to 5.08cm) Pipe Using Supplied Hardware 



32° to 158°F (0° to 70°C) 

32° to 158°F (0° to 70°C) 



Range: 

Cycle Time: 

3-Electrode LPR, Potential 

3-Electrode: 0-100 mpy Potential: ± 1V 

0.1 to 99.9 minutes 



11 to 35 VDC 



4-20mA Current Loop Output 


• Switch selectable measurement type and cycle time 

• Loop powered 


10' Probe Cable (attached), Meter Prover, Mounting Hardware, Operation Manual 


























12 to 35 VDC 


600' to 1000' 3.09inUsing 


Wireless 

Receiver 



Output to 

DCS/SCADA 

12-30VDC 

Supply 

Probe 
































Input: 



Output: 

Resolution: 

Mounting: 

POWER SUPPLY 

Voltage: 

Current: 

SIGNAL 

Input: 

Voltage: 


One probe 

10,000 feet 



+/- 0.1 mpy or 0.01 mil 


100 - 240 V AC, 1 phase, 50/60 Hz 

< 2 Amps 


24V DC 

250 Ohms 



Weight: 

Size: 

Panel cutout: 

4 lbs. (1.9 kg) 

8.25” x 10” x 6” (20.95 cm x 25.40 cm x 15.24 cm) 

8.25” x 10” (20.95 cm x 25.40 cm) 

NETWORK 










MS3500L Remote LPR Data Logger 

The MS3500L is a battery-powered, intrinsically safe, 

remote data-logger capable of measuring and storing 

data from all types of linear polarization resistance 

(LPR) corrosion probes. The instrument is 

microprocessor-based and features a simple, 

menu-driven interface using a 2-key keypad and a 2-line 

LCD display. 

Corrosion rate measurements are made using the linear 

polarization resistance technique. The instrument 

measures the current required to polarize the electrodes 

of a probe to a known potential. From the polarization 

potential and the measured current, polarization resistance can be calculated. Then, using Faraday’s law, the 

instantaneous corrosion rate can be calculated from polarization resistance. 

The MS3500L incorporates a high-precision zero-resistance ammeter (ZRA) for measuring galvanic current 

between electrodes. It also offers a high-precision voltmeter for measuring the open-circuit potential between 

electrodes. 

The MS3500L takes probe readings on a user-programmable logging interval. Readings are time and date 

stamped as they are taken, then stored to memory. Between readings, the instrument remains in a “sleep” 

mode to conserve main battery power. The instrument’s memory is capable of storing 3,000 readings, and 

is protected by a lithium back-up battery. 

Stored data can be uploaded to any IBM compatible PC as a comma-delimited ASCII text file. Because the 

data is in ASCII text format, it can be imported into any standard data analysis program such as Microsoft 

Excel, Lotus 123, or Corel Quattro Pro. Data can also be reviewed on the instrument’s LCD display for quick 

reference. 

Stored data can also be uploaded to a Metal Samples model MS1500L Handheld ER Data Logger for transfer 

to a PC. This handy feature eliminates the need to remove the MS3500L from its site, or to bring a laptop PC 

to the site. This can be particularly useful when collecting data from multiple MS3500L Data Loggers. And 

since both the MS3500L and the MS1500L are intrinsically safe, data can be uploaded from the MS3500L to 

the MS1500L even in hazardous locations. 

The MS3500L also offers an optional 4-20mA current loop output (model MS3510L). This feature allows 

data from the instrument to be fed directly to any industrial process computer that accepts analog inputs. 

The instrument is housed in a NEMA-4 enclosure, and all external connections are weather-proof. This makes 

the MS3500L suitable for use in almost any indoor or outdoor environment.


Model 

MS3500L - Remote LPR Data Logger (Ordering # IN3500L) 

MS3510L - Remote LPR Data Logger w/ 4-20mA Current Loop Output (Ordering # IN3510L) 

Physical Data 





Mounting Specifications: 



11.94 lb. (5.42 Kg) 

13.64 lb. (6.19 Kg) 


NEMA-4 

10.75"H x 6"W (27.31cm x 15.24cm) Bolt Pattern 

0.3" (0.76cm) Diameter Bolt Holes 

32° to 122°F (0° to 50°C) 

-4° to 158°F (-20° to 70°C) 


Measurement 

Type 

Range 

Resolutio 

n Cycle Time 

2-Electrode 

0 to 200 mpy 

0.01 

mpy 

1 min to 99 hrs 

3-Electrode 

0 to 150 mpy 

0.01 

mpy 


Galvanic 

± 999 µ A 1 µ A 1 min to 99 hrs 

Potential 

± 999 mV 

1 mV 




Six 1.5V AA Batteries 




4-20mA Current Loop Output (MS3510L Only) 



Temperature Code T3 


Group IIC, T3 




• Data storage capacity of 3,000 readings, with battery backup 




10' Probe Cable, Meter Prover, 6 to 5-Pin Adapter, Galvanic Adapter, Communications Cable and Connector, 

Current Loop Connector (MS3510L only), Operation Manual, Corrosion Data Management Software 







New! Remote Corrosion Monitoring Telemetry System 

New! Wireless Radio Option for MS2500E/MS2500L 

Probes: 

Modular Probe System 

Sand (Erosion) Probe 

Remote Alarm Actuator / Indicator for Sand Probes 

Bio-Probe 

BIoGEORGE TM 

nanoCorr TM Coupled Multielectrode Sensor (CMS) 

Hydrogen Probe (Retractable) 

Hydrogen Probe (for High Pressure Access Systems) 

Instrumentation: 

MS3112 

is a hydrogen penetration monitoring system which provides a 

method for directly measuring the rate of hydrogen migration 

through a vessel or pipe wall. 




Remote Corrosion Monitoring 

Telemetry System 

Metal Samples’ remote telemetry system obtains 

real-time corrosion monitoring data via the Internet 

from anywhere in the world. The system features 

communications via Inmarsat IsatM2M satellite to a 

secure Web Monitor data server. With this powerful 

web-based back end, you can bring the data to your 

desk no matter where the site is located. 

System Benefits Include: 

• Eliminating costly travel to remote sites 

• Gathering important corrosion data at a low cost 

A small optional solar panel (4.5” x 6”) easily connects 

to the Base Station for use where no power is available. 

Using its internal ‘gel cell’ and charge control circuit, the 

unit functions in the ‘Monitor & Sleep’ mode. 

Remote corrosion monitoring 

telemetry system with solar panel 

Once the telemetry system is in place, just log in to the provided website to view your data. 

Above: Sample data as viewed on the Internet from a corrosion probe connected to the telemetry system.

Graphs of corrosion data can be viewed from 

the web site or can be copied into Excel for 

more detailed analysis. 

Specifications 

Base Station 

Power: 

Enclosure: 

115 / 230 VAC, 50-60 Hz or 8 - 30 volts DC or AC for ‘Always On’ Operation 

Optional 4.5” x 6” solar panel for autonomous ‘Monitor and Sleep’ Operation 

NEMA 4X case 

System Operating Environment 

Temperature: -20° to +70° C 

Humidity: 0 - 100% non-condensing 

System Features 

• Configurable from the website - no laptop necessary in the field 

• Worldwide communications 

• Easy-to-use web interface 

• Low monthly messaging costs 

Communications Via 

Skyware Inmarset ISatM2M 

Available Configurations 

Electrical Resistance Corrosion Monitor (single channel) 

Linear Polarization Resistance Corrosion Monitor (single channel) 

Sand (Erosion) Probe (4-channel) 

Call for special applications or configurations. 


























12 to 35 VDC 


600' to 1000' 3.09inUsing 


Wireless 

Receiver 



Output to 

DCS/SCADA 

12-30VDC 

Supply 

Probe 








Modular Probe System 

Replacement Sensor Inserts 

Electrical resistance (ER) replacement sensors are available in all standard configurations. All 

upper sensor bodies are constructed of AISI 316L stainless steel, while sensor elements are offered 

in AISI 1010 carbon steel. Teflon ® sealed wire configurations are offered with a wide range of 

sensor element metallurgies (consult your Metal Samples Corrosion Monitoring Systems 

representative); cylindrical elements are also available in AISI 316L/304L stainless steel. 

All replacement sensors are rated to 3600 psi and 400°F, except for the Teflon ® sealed varieties 

that are rated to 1000 psi and 300°F. 

Wire Loop Replaceable Insert 

Tube Loop Replaceable Insert 

Cylindrical Replaceable Insert 

Bio-probe replacement sensors, for sequential sampling of “bioactivity”, 

are constructed in Delrin and AISI 316L stainless steel. Bio 

sample elements (ordered separately) are available in either carbon 

steel or brass. These sensors can be used with any of the upper body 

modules, and are rated at 3600 psi and 400°F. 

Bio-probe Replaceable Insert 

Linear Polarization Resistance (LPR) replacement sensors are available in the pin and flush 

style, utilizing the three-electrode configuration. The upper sensor body is constructed of AISI 

316L stainless steel. The sensing elements for these units are available in AISI 1018 carbon steel 

only for the flush configuration; the pin type configuration utilizes “screw-on” electrodes (ordered 

separately), that are available in a wide range of metallurgies. 

Replacement galvanic sensors are also available with “screw-on” electrodes. These can be used to 

monitor the effect of dissimilar metal couples and changes in redox potentials. 

2-Electrode (Galvanic) LPR Replacement Insert 

(Electrodes not included) 

3-Electrode LPR Replacement Insert 

(Electrodes not included) 

Large Flush Replaceable Insert

Modular Probe Bodies 

Fixed Entry Bodies are constructed of AISI 316L stainless steel, have a ¾" NPT bushing entry, 

and can be used in conjunction with the full range of ER replacement sensors. Maximum operating 

parameters are 3600 psi and 400°F. Standard insertion lengths range from 5" to 12", any given 

probe length being adjustable over 1" range. 

Fixed Length Modular Upper Body Assembly 

Retractable bodies are constructed of AISI 316L stainless steel, and are designed for use in 

conjunction with a 1", full-port, ball-valve; attachment to the valve is effected via a 1" FNPT 

packing gland. These items are designed for use up to 1000 psi and 400°F. Standard probes are 

available with an overall length of 32" to 35" and a travel of 25" to 28", depending on the 

particular sensor used. The ER retractable body can be used in conjunction with the full range of 

electrical resistance and bio-probe sensors; the LPR retractable body can be used with the full 

range of LPR and bio-probe sensors. 

Retractable Modular Upper Body Assembly 

Retrievable bodies are compatible with high pressure access systems produced by most major 

manufacturers, including Metal Samples Corrosion Monitoring Systems proprietary (MH) and 

generic (HP) systems. These items are constructed from duplex stainless steel and can be used 

up to 3600 psi and 400°F. In conjunction with a length extender and replacement sensor, standard 

insertion lengths ranging from 1.5" to 11" are available, any given probe having a length 

adjustment over a 2" range. The ER retrievable body can be used in conjunction with the full 

range of electrical resistance and bio-probe sensors; the LPR retrievable body can be used with the 

full range of LPR and bio-probe sensors. 

L1 Extender 

High Pressure Modular 

Upper Body Assembly 

L2 Extender 

L3 Extender

Model HCA200 

Bio-probe 

Model HCA200 bio-probe was developed as a type of 

“Robbins Device”. Its purpose is to improve the sampling 

technique employed for assessment of biological 

activity. Conventional field methods for bio sampling 

are to take a bulk liquid sample of the process fluid 

and analyze this using any number of techniques in 

order to determine the presence of bacteria. 

The main problem with this approach is that most of 

the harmful species of bacteria (sulfate reducers) are 

sessile and grow as colonies on the internal surfaces of 

the pipeline or vessel. Bulk fluid samples only provide information on those bacteria which are “in 

the flow” and not apt to cause damage. Therefore to help prevent significant damage before it can 

occur, pipe wall monitoring is needed which can show signs of biological activity when the colonies 

are established. 

The concept of the bio-probe is to provide a series of (six) removable sample elements which are 

positioned via the probe body to be flush with the pipe or vessel wall. This allows a growth area 

for those bacteria which are going to colonize on the wall. The elements may be removed from the 

probe at regular intervals, and biological activity may be determined by several laboratory methods. 

Through regular monitoring, the operator will be alerted at the earliest stages of sessile colony 

growth so that treatment/actions may be taken. 

Actual determination of biological activity is beyond the Metal Samples scope of supply, however 

there are several laboratory methods used in determining biological activity. The simplest is through 

Serial Dilution Broth Bottles. An initial sample is obtained by transferring the deposit from the bio 

element (scraped with a knife blade) to bottles which contain nutrient material for bacterial growth. 

By diluting the sample and allowing culturing time, bacterial presence can be determined. (There are 

bottles specific for sulfate reducers, aerobic and anaerobic bacteria.) 

More sophisticated techniques include ATP Photometry and epifluorescence microscopy. These offer 

far better resolution than serial dilution and are more quantitative, but require expensive equipment 

and trained personnel - these measure the total biological activity rather than sulfate reducers only. 






Bio-Probe Ordering Information 

Part No. 

Description 

HCA2158XXXX 

Bio-probe Assembly with Delrin holder 

(XXXX = insertion length in inches, stated in 2 decimal place format) 

EL4383770900000 Biological Sample Elements, C.S. 

HA700645158 Solid Plug, MH High Pressure Access System, 316 

HA700644158 Solid Plug, HP High Pressure Access System, 316 

1 

2 

Item No. 

Description 

Material 

3 

1 Heavy duty cover 

Carbon steel 

8 

2 O-ring 

® 

V iton 

5 

4 

7 

3 Solid 

plug 

316 

4 

Primary packing 

(primary seal) 

5 Access 

fitting 

6 Bacteria 

sample holder 

® 

25% G.F. Teflon 

Carbon steel 

Delrin 

7 Bacteria 

fixtur e 

316 

(2) SET SCREW 

10-32 S/S 

9 

6 

8 O-ring 

9 Sample 

element "Bullet" 

® 

V iton 

Mild steel or brass 

(6) SET SCREW 

10-32 S/S

BIoGEORGE TM 

Biofilm Activity Monitoring System 

Metal Samples Corrosion Monitoring 

Systems in cooperation with Structural 

Integrity Associates, Inc., now offers the 

BIoGEORGE TM system - a simple, 

rugged, dependable system for real-time 

monitoring of: 

• Microbiologically influenced corrosion (MIC) 

• Biofouling of heat exchangers 

• Biocide effectiveness 

• Optimization of treatments: Selection, Timing, Concentrations 

The Problem 

Microbiologically Influenced Corrosion (MIC) is a significant degradation mechanism in nuclear and fossilfueled 

power plants, chemical processing, refineries, pulp and paper, oil and gas production and distribution 

and the armed services. Essentially all cooling water and process water applications may be susceptible to 

MIC. Further, biological fouling, which is always a precursor to MIC, can reduce the efficiency of heat 

exchangers and fluid distribution systems and can interfere with water-based processes. 

The most common approach to mitigation of MIC is chemical treatment. Chemical costs for a large process 

plant are often on the order of $1,000,000 per year. Chemical toxicity is always a concern for plant 

personnel and the environment. This results in close scrutiny and control of effluents and chemical inventories 

by regulators, environmental agencies, and plant owners. 

The Solution 

The BIoGEORGE system was developed to provide online 

and real-time indications of biofilm activity on typical metallic 

surfaces. The probe is designed and operated so that 

microorganisms in the environment are encouraged to settle 

on probe surfaces well before they settle on heat exchanger 

tubes or piping. 

Probe status is indicated on the integrated electronics 

enclosure by an LED display (red light/green light). 

By closely tracking biofilm activity on the probe, the operator 

is alerted to the need to treat the system, to assess the 

effectiveness of a treatment, to schedule maintenance 

activities, or to optimize chemical treatments.

The System 

The system consists of a probe, its integrated electronics, interconnecting cable, display software, User's 

manual, and product support. 

The probe is installed into a piping system, heat exchanger water box, cooling tower, or side stream via a 2- 

inch threaded connection. Special probes can also be built for "hot tap” type fittings or flow-through probes. 

The unit operates on a 110 or 220 VAC and has built-in battery backup. 

System data can be downloaded to the user's PC. Software is included with the system for analyzing the 

data and creating detailed trend plots. 

BIoGEORGE is a trademark of Structural Integrity Associates, Inc. 






nanoCorr TM Coupled Multielectrode Sensor (CMS) 

Analyzers and Probes 

Metal Samples Corrosion Monitoring Systems in association with 

Corr Instruments now offers nanoCorr TM coupled multielectrode 

sensor (CMS) analyzers and probesfor real-time and online localized 

corrosion monitoring and electrochemical studies. 

Used with CorrVisual TM software, a wide range of multielectrode 

probes, and innovative seals, Queon TM , the nanoCorr TM analyzer 

makes the online and real-time monitoring of localized corrosion and 

most types of general corrosions quick, easy and reliable in liquids, 

soils, concrete, and humid gases under normal temperature and 

pressure or high-temperature and high-pressure conditions. Our 

nanoCorr TM analyzers were developed on the basis of the coupled 

multielectrode array sensor technology patented by a major international 

research organization, and backed by several other U.S. and international pending patents. They are 

highly sensitive and reliable for all types of non-uniform corrosions including localized corrosions. They are 

also the only type of corrosion instruments in the world that have ever been claimed to be quantitative for 

monitoring localized corrosion below mill-per-year or micron-per-year levels. 

Principle of Coupled Multielectrode Sensor Analyzers 

When a metal undergoes non-uniform corrosion, particularly localized 

corrosion such as pitting corrosion or crevice corrosion, 

electrons are released from the anodic sites where the metal corrodes 

and travel to the cathodic sites where the metal corrodes less 

or does not corrode. In a coupled multielectrode sensor, there are 

multiple miniature electrodes made of materials identical to the 

engineering component of interest. Statistically, some of the electrodes 

have the properties that are close to the anodic sites and 

others have the properties that are close to the cathodic sites of the 

corroding metal. 

When the miniature electrodes are electrically isolated from each 

other but coupled together by connecting each of them to a common 

joint through an external circuit, the electrodes that have the properties 

close to the anodic sites simulate the anodic areas, and the electrodes that have the properties close to 

the cathodic sites simulate the cathodic areas of the corroding metal. The electrons released from the anodic 

electrodes are forced to flow through the external circuit to the cathodic electrodes. Thus there are anodic 

currents flowing into the more corroding electrodes and cathodic current flowing out of the less corroding or 

non-corroding electrodes. The resulting electrical currents are measured and the localized or non-uniform 

corrosion rates are determined by nanoCorrTM analyzers.

nanoCorr TM Analyzers 

Specifications for nanoCorr TM CMS Analyzers and 

Corrosion Monitoring System: 

• Number of independent probes for simultaneous 

measurements: up to 12 

• Number of electrodes on each probe: up to 100 

• Number of pH or ORP electrodes: up to 3 (S-Models 

only) 

• Number of channels to receive analog signals from other 

meters such as humidity, pressure or flow pressure 

transducers: up to 3 (S-Models only) 

• Corrosion current accuracy:

Model A-36: Measures up to 36 electrodes of one to four independent 

probes. Has six standard military connectors for different combinations of 

probes, an additional one channel for temperature, and four channels for the 

corrosion potentials of probes. 

Model S-36: In addition to the features of A-36, Model S-36 also measures 

up to three pH or three ORP probes, or three other transducers for 

parameters such as conductivity, humidity, flow, and pressure. 

Model A-50: Measures up to 50 electrodes of one to six independent 

probes. Has eleven standard military connectors for different combinations 

of probes, an additional one channel for temperature, and six channels for 

the corrosion potentials of probes. 

PittingCorr Model M-16: These analyzers are the economical version of 

the Coupled Multielectrode Sensor (CMS) Analyzers. Measures up to 16 

electrodes of one probe. Has one standard military connector for corrosion 

probe, one channel for temperature probe (thermocouple), and one channel 

for the corrosion potential of the probe (reference electrode). Corrosion 

rate: 1 µm/yr to 1 cm/yr (0.04 to 400 mil/yr) 

Coupled Multielectrode Sensor Probes 

CMS probes are made from user-specified sensing materials, 

including carbon steels, stainless steels, and nickel-, aluminum-, and 

copper-based alloys. They can also be made from customer supplied 

materials that have the same microstructure/heat treatment as 

the system component materials to be monitored. 

The size of the sensing electrode varies from 0.1 to 3 mm (0.004" to 

0.12") in diameter, depending on the application. Typical numbers of 

electrodes in a CMS probe are 9, 16 or 25 for online corrosion 

monitoring and vary from 8 to 100 for laboratory corrosion and 

electrochemical studies. Other sizes and numbers of electrodes are 

available.

CMS Probes with Flush Mounted Electrodes 

Typical Applications: 

Quantitative Corrosion Monitoring and Electrochemical Studies for: 

• Pitting corrosion 

• Crevice corrosion 

• Inhibitor evaluation 

• General corrosion (most types) 

• Cathodic/anodic protection 

in the following environments: 

• Aqueous solution 

• Humid gases 

• Soil 

• Oil-water mixture 

CMS Probes with Exposed Electrodes 


Quantitative Corrosion Monitoring of: 


• Cathodic/anodic protection effectiveness 

• Coating evaluation 




• Aqueous solution 

• Soil 

• Oil-water mixture 

• Under coating 

Exposed electrodes increase the sensing signal for an extremely low corrosion rate and reduce the effect of 

crevice between the electrodes and the insulation materials. An exposed electrode can be painted with 

coatings and be used for undercoating corrosion monitoring. 

CMS Probes for High Temperatures and High Pressures 


Quantitative or Qualitative Corrosion Monitoring of: 





• Super critical water systems 

• Furnaces 

• Steam generators 

• Fireside of boilers 

• High pressure pipelines 

• Flue gas stacks 

• High temprature and/or high pressure reactors 






Model SP7000 

Sand Probe 


Access Fitting 

with Appropriate Size Tee 

Sand Probe Nut 

1/4" x 4" Nipple Sch 80 

(Optional) 

Sand Probe 


(Optional) 

Shut-Off Valve 

(Optional) 

(HP model shown here) 

Model SP7000 sand probes are used to detect erosion in flow lines caused by abrasive particles such 

as sand. One end of the probe is attached to a tee-type, high pressure access fitting with a solid plug 

by means of a sand probe nut. The other end is a sealed, thin-walled tube placed within the process 

stream to be exposed to particulate flowing through the system. (To minimize the effects of corrosion 

and thus more accurately detect erosion within the stream, the exposed element is made of stainless 

steel.) As particulate impinges on the surface of the sensing element, a hole is eventually eroded 

through the element. Once penetration has occurred, the system pressure then travels up the tube, 

into the access fitting body, and through a nipple and valve to a pressure gage assembly. The pressure 

gage detects that the element has been breached. If required, electronic pressure sensors can be connected 

to alarm systems to signal the exact moment when failure occurs. The insertion length (I.L.) 

can range from 3 3/8” up to any length specified by the customer in 1/8” increments. 


Probe Body - Stainless Steel 



Mounting - High Pressure (HP TM or MH TM ) 

Access System with Solid Plug 

Sand Probe Parts 

MH Part No. HP Part No. Description 

See chart on back 

Nipple & Valve 

See chart on back 

Sand Probe Nut 

HA700603 HA700603 Pressure Gauge 

HA700645 HA700644 Solid Plug 






Model 

SP 

SP7000 Ordering Information 

Sand Probe for High Pressure (HP TM and MH TM ) Access Systems 


2 

4 

U 

316 

C276 

Duplex 2205 

Tube Material 

2 

4 

U 

316 

C276 

Duplex 2205 

Tube Wall Thickness 

1 

2 

3 

.016” 

.028” 

.035” 



(Ex: 6 1/8" = 0612) 

SP 2 2 3 0612 Example of Probe Ordering # 


Sizing Formulas: Shortest length available is 3.375”. 

Non-Flanged Access Fitting 

(FH + PD/2) - (2.04 + N) = L 

Flanged Access Fitting 

(FH + PD/2 + MF) - (2.04 + N) = L 

FH = Access Fitting Height N = Injection Nut Length L = Injection Tube Length MF = Mating Flange Height PD = Pipe Outer Diameter 

Nipple & Valve Chart: 


Tee Size 

1/4" 

1/2" 

3/4" 

1" 

Valve 

316 SS 

Part No. 

HA700022158 

HA700023158 

HA700027158 

HA700029158 

Nipple, 4 in (100 mm) 

316 SS Sch. 80 

Part No. 

HA700018158 

HA700019158 

HA700020158 

HA700021158 

Sand Probe Nut Chart: 

Model Length Probe End Thread Seal Material Alloy Code 

IQN --- ---- X ---- ---- X ---- ---- X ---- ---- XXX 

1 - 1.75" 

2 - 2.75" 

3 - 3.75" 

4 - 4.75" 

5 - 5.50" 

6 - MH (3.50") 

0 - N/A 

1 - 1/8" - 27 NPT 

2 - 1/4" - 18 NPT 

3 - 3/8" - 18 NPT 

4 - 1/2" - 14 NPT 

5 - 3/4" - 14 NPT 

6 - 3/8" - 24 UNF - 2B 

7 - 7/16" - 20 UNF - 2B 

8 - 1/2" - 20 UNF - 2B 

9 - 9/16" - 18 UNF - 2B 

A - 5/8" - 18 UNF - 2B 

0 - N/A 

1 - Viton® o-ring / 

Teflon® backing ring 

2 - Ethylene propylene / 


3 - Kalrez o-ring / 


4 - Hydrin o-ring / 


5 - Nitrile o-ring / 


6 - Teflon® o-ring / 


158 - 316 SS 

A12 - C276

Model PR6573158 

Remote Alarm Actuator / Indicator (RAAI) 

for use with Sand Probes 

End Knob 

RAAI Body 

Stem 

Input 

Exhaust 

Port 

RAAI 

Adapter Stem 

RAAI Body 

Output 

RAAI Adapter 

1/2" - 14 NPT 

Access 

Fitting 

1/2" x 4" Nipple 

Sch 80 (Optional) 

RAAI 

Adaptor 

Stem 

Exhaust 

Port 

Input 

RAAI 

Body 

Stem 

1/4" - 18 NPT 

Sand Probe 

Sand 

Probe 

Shut-Off Valve 

(Optional) 

Output End Knob 

RAAI Body 

Direct Mount 

Remote Mount 

Model PR6573158 is a remote alarm actuator / indicator (RAAI) which can be used with a sand 

probe to indicate when erosion penetrates the probe. The RAAI may be mounted directly on the 

probe or may be mounted remotely to a tee type access fitting body which is connected to the probe. 

As a sand probe is exposed to the flow of a system, a hole is eventually eroded through the 

probe’selement. Once penetration has occurred, the system pressure travels through the sand probe 

body andinto the RAAI Adapter Stem, which pushes out the End Knob to its extended position, 

revealing ared indicator on the RAAI Body Stem. 

To establish remote alarm activation, a control pressure must be applied at the RAAI Input connection. 

When the end knob is retracted, the RAAI Body Stem blocks the Input control pressure and 

bleeds the Output control pressure through the Exhaust Port. Various alarm components/devices 

maybe connected to the RAAI Output to remotely indicate when erosion penetrates the sand probe. 

An example of this would be a pressure switch connected to the Output which when triggered would 

activate a remote alarm. For a replacement seal kit order part # KR1012834. 


Probe Body - 316 SS 



Mounting - 1/2” NPT 

Input Control Pressure - 250 PSI max. 

Seals - Viton ® 

Viton® is a registered trademark of DuPont Dow Elastomers. 






Model HY4000 

Hydrogen Probe 


Model HY4000 is a high pressure hydrogen 

probe which can be used for pressures 

up to 1500 psi. Hydrogen probes are 

commonly used for monitoring hydrogen 

permeation in steels, which could lead 

to embrittlement, blistering, and 

decarburization resulting in the failure 

of the material. 

The probe assembly consists of three 

subassemblies: the gauge assembly, the insertion 

rod sensing element assembly, and the 

packing gland assembly. The gauge assembly 

consists of a gauge body, a pressure gauge (0-40 

psi), a temperature gauge, and a bleed valve. 

The sensing element is about 3.5 inches long 

and consists of a thin-walled tube which is 

sealed from the process and allows nascent 

hydrogen to permeate. 

The probe can be supplied with or without 

the gauge assembly, which can be bought 

separately if required. 

Temperature Gauge 

Gauge Block/Rod Assembly 

Bleed Valve 


Packing Gland 

Assembly 

Hydrogen Element 

Assembly 

PS5589158377XX 

Sensing Element 











Model 

HY0030 

HY4532 

HY4000 Ordering Information 

Hydrogen Probe w/ Gauge Assembly 

Hydrogen Probe 1" NPT Female Thread with Packing Gland & Gauge 

Hydrogen Element Diameter 

20 

5/8" 

Seal Type 

0 All welded 

Length 

24 

30 

36 

42 





HY4532 

20 

0 24 



Model HY7000 / HY7001 

Hydrogen Probes 

for High Pressure (HP TM and MH TM ) Access Systems or Direct Mount 


Temperature Gauge 

Gauge Block/Rod 

Assembly 

Bleed Valve 

HY7000 

HY7001 

Non-Intrusive 

Hydrogen Housing 

HA103001XXXXX 

Hollow Plug 

Assembly 

Hydrogen Sensing 

Element 

HA103158377XX 

Model HY7000 and HY7001 are high pressure hydrogen probes which can be used for pressures up to 

3600 psi. Hydrogen probes are commonly used for monitoring hydrogen permeation in steels, which 

could lead to embrittlement, blistering, and decarburization resulting in the failure of the material. 

The HY7000 probe assembly consists of three subassemblies: the gauge assembly, the hollow plug assembly, 

and the sensing element assembly. The gauge assembly consists of a gauge body, a pressure 

gauge (0-40 psi), a temperature gauge, and a bleed valve. The sensing element on the HY7000 probe 

is about 3 inches long and consists of a thin-walled tube which is sealed from the process and allows 

nascent hydrogen to permeate. The minimum insertion length (I.L.) of the probe is 6 inches and can be 

ordered in 1 inch increments. 

The HY7001 housing can be machined to fit the flat surfaces of tanks or radiused to fit pipe diameters. 

The HY7001 consists of two subassemblies: the gauge assembly and the non-intrusive housing that can 

be welded directly to the exterior of the pipe wall or vessel. 





Mounting - High Pressure (HP TM or MH TM ) 

Access System w/ Hollow Plug (HY7000) 

Direct Mount (HY7001) 

Gauge Assembly Parts 

Part No. Description 

PS5509 Gauge Assembly (complete) - 

contains all parts listed below 

PR6441158 Pressure Gauge 

PR6032 Temperature Gauge 

PR6034 Bleed Valve 

PS5603158 Gauge Block / Rod Assembly

Model 

HA103158377 


High Pressure Hydrogen Probe Rod Assembly 

Length (Round calculated length down to the nearest 1") 

XX Length in inches (Ex: 6" = 06). Available in 1" increments starting at 6". 

HA103158377 XX Example of Probe Ordering # 


Length formula: 

I.L. = PD + WT + 1.75" 



Model 

HA103001 

Non-Intrusive Hydrogen Housing 

Alloy 

377 

C25 

C1018 

A350 LF2 

Pipeline Size 

1 

2 

3 

4 

5 

6 

7 

8 


2" 

3" 

4" 

6" 

8 - 10" 

12 - 18" 

20 - 26" 

Flat 

Gauge Block / Rod Assembly 

0 

1 

Not included 

Included 

HA103001 C25 1 0 Example of Housing Ordering # 








MS3112 Hydrogen Penetration Monitoring System 

The Hydrogen Penetration Monitoring System provides a 

method for directly measuring the rate of hydrogen migration 

through a vessel or pipe wall. This method actually measures 

the penetration current set up by the hydrogen as it moves 

through the steel. By sensing and recording this data directly 

from the pipe wall, this system offers valuable data which can 

only be indirectly inferred by other methods. 

The Hydrogen Patch Probe can be mounted directly to the 

outside of the pipe wall by simple mechanical straps tightened 

with a screwdriver. No welding or tapping is required. The 

patch probe can be installed or moved to a new location in 

less than one hour. 

Operation 

One of the common corrosion products of iron or steel in a neutral or acidic medium is atomic hydrogen. 

Normally, these highly reactive species combine with other hydrogen atoms to produce a relatively harmless 

molecule, hydrogen gas (H 2 

). In the presence of some catalysts such as sulfur, arsenic, or tin, the hydrogen 

atoms dissolve into the steel to a significant degree. 

The Hydrogen Penetration Monitoring System measures hydrogen moving through a pipe or vessel wall. 

Since the hydrogen produced by the corrosion reaction occurring inside the pipe or vessel often produces 

severe structural damage to steel, especially in highly stressed or high strength alloys, it is valuable to be 

able to monitor the hydrogen penetration rate. 

Discussion 

The MS3112 instrument and the HYY00330100 Hydrogen Patch Probe are quickly and easily installed at 

virtually any corrosion monitoring site. The pipe to be monitored is first surface cleaned. Then a transfer 

medium (paraffin wax) and a small piece of .010" palladium foil are placed on the pipe to be monitored. 

The electrochemical patch probe is then mounted over the foil. A pair of gaskets and an insert, shaped to 

the general contours of the pipe, provide a leak-tight seal against the foil. The cell is then filled with a 

suitable electrolyte. When the palladium foil is polarized by the MS3112 instrument, the foil acts as a 

working electrode, quantitatively oxidizing the hydrogen as it emerges from the pipe wall. After an initial 

pumpdown period, the current indicated by the instrument is directly equivalent to the real-time hydrogen 

penetration rate. 

Since the instrument/probe is measuring the hydrogen penetration rate, the user gets fast response to 

changes in the system being monitored. Significant changes can be seen in less than two hours. 

The instrument instantaneously measures and records penetration current from a low of 10 microamps 

full scale to a high of 5000 microamps full scale. Its digital recorder charts the hydrogen penetration rate onscreen 

and stores the data to a compact flash memory card. Data can be reviewed on-screen, and can be 

downloaded to a PC for printing and analysis.


Model 

MS3112 - Hydrogen Penetration Monitoring System (Ordering # IN3112) 

Physical Data 




9.5 lb. (4.31 Kg) 

10.5 lb. (4.76 Kg) 

8"H x 16"W x 9"D (20.32cm x 40.64cm x 22.86cm) 



Hydrogen Penetration 

Range: Switch Selectable Ranges from 10µA to 5000µA 




120VAC (240VAC - optional), 50/60 Hz 

> 5 years of data storage (depends on configuration) 


• Integrated digital recorder 

• Data stored to compact flash memory card (up to 2GB) 

• On-screen data review 

• Switch selectable range 

• Portable 


Meter Prover, AC Power Cable, Operation Manual, 2GB Compact Flash Card (card is included in accessory 

kit and not installed in the instrument), USB Cable, PC Software 

Hydrogen Patch Probe (sold separately) 

Hydrogen Patch Probe - HYY00330100 

Materials of 

Construction: 

Viton®, Polypropylene, Teflon®, Kalrez® 

Reference and 

Auxiliary Electrodes: Hastelloy C-276 

Working Electrode: 

Electrolyte: 

Temperature Range: 

Palladium foil (sold separately) 

96% H 2 

SO 4 

- cell volume 40 ml 

-10°F to +290°F 

Hydrogen Penetration Monitoring System and Hydrogen Patch Probe are trademarks of Metal Samples Corrosion Monitoring Systems. 

Teflon® is a registered trademark of Dupont. Viton® and Kalrez® are registered trademarks of DuPont Dow Elastomers. 







Introduction to High Pressure 


Access Fitting Bodies (HP & MH) 

Plug Assemblies (HP & MH) 

Protective Covers 

Ordering Chart 

Retrieval Tool and Service Valve 

Hot Tap Tool 



System Overview 

High Pressure Access Systems are specialized 

piping arrangements which permit internal 

access to production plant vessels and 

pipework operating under full process conditions. 

The corrosion monitoring industry 

standard for such access systems is based on a 

2-inch nominal bore design. 

When operated with a Retrieval Tool and 

Service Valve, high pressure access systems 

allow the installation and retrieval of corrosion 

monitoring coupon holders, probes, chemical 

injection equipment, and other devices to be 

carried out safely and without plant shutdown, at 

working pressures up to 3600 psi. 

High pressure access systems are used most frequently (although not exclusively) in oil and gas 

production operations. This is typical of high pressure operations in which users are not prepared 

to shut down and depressurize process systems in order to remove or install corrosion monitoring 

devices. 

High pressure access systems consist of five basic components: 

• an Access Fitting Body 

• a Plug Assembly 

• a Cover 

• a Service Valve 

• a Retrieval Tool 

The access fitting body is the specialized pipe fitting which is permanently attached to the process 

plant vessel or pipework. Access fitting bodies can be welded or flange-mounted. 

The plug assembly is the carrier for the installed device and, depending on the type of device 

being used, a solid plug assembly or a hollow plug assembly is selected. The plug assembly screws 

into the access fitting body and seals the bore of the fitting to contain line pressure. 

The access fitting body together with its plug assembly, and cover (designed to protect the external 

thread) is known as an access fitting assembly.

The retrieval tool and service valve are the components which are required to perform the online 

installation and retrieval of the plug assembly. With the plug assembly removed during the retrieval 

procedure, the service valve is used to contain line pressure. One service valve and one retrieval tool 

may be used to maintain a number of access fitting assemblies. 

A variety of different devices have been designed for use with high pressure access systems. The 

following equipment can typically be installed into process lines using standard access fitting 

assemblies: 

• Corrosion Coupons 

• Electrical Resistance Probes 

• Linear Polarization Probes 

• Hydrogen Probes 

• Biological Probes 

• Erosion Probes 

• Thermowells 

• Sacrificial and Impressed Current Anodes 

Using access fitting bodies which incorporate a side-tee, the following functions can be additionally 

undertaken: 

• Chemical Injection 

• Process Sampling 

• Sand Monitoring 

Metal Samples Corrosion Monitoring Systems offers two different styles of high pressure access 

systems; the HP System and the MH System. The HP System is the generic design and is widely 

used throughout the world. This system is compatible and interchangeable with access fitting equipment 

produced by other major manufacturers. 

The MH System is a proprietary design of Metal Samples Corrosion Monitoring Systems and incorporates 

a number of unique and patented features which are an improvement to the generic HP System 

design: 

• Acme style plug threads, reducing the risk of galling 

• Positive alignment grooves, allowing orientation of weight-loss coupons 

• A metal-to-metal back-up seal to prevent leakage 

Metal Samples Corrosion Monitoring Systems Retrieval Tool and Service Valve are compatible with 

both HP and MH Access Fitting Assemblies, but plug assemblies are not interchangeable between the 

two systems. 

Access Systems - 2

Retrieval Tool 

Used to install and retrieve 

Plug Assembly together with 

its attached monitoring 

/injection device while the 

system is operating at 

pressure. 

Covers 

Designed to protect the external 

threads of the access fitting body. 

Service Valve 

Used to control pressure in 

the Retrieval Tool and to 

contain line pressure during 

retrieval operation. 

Access Fitting Body 

Specialized pipe fitting 

permanently attached to the 

process vessel or pipework. 

Plug Assembly 

Retrievable carrier for monitoring / injection 

devices. Seals the bore of the access fitting body 

during normal operation. 

Figure 1. High Pressure Access System 

Access Systems - 3

Access Fitting Bodies 

High Pressure Access Fitting Bodies are available in styles that may be welded (Flareweld, Socketweld, 

and Buttweld), threaded (NPT), or flanged (API, ANSI RF, ANSI RJ) to the pipe or vessel wall. Basic 

body styles are shown in the HP and MH Access Fitting Bodies sections. 

Flareweld bodies are the most widely used. These bodies incorporate a reinforced welding neck and 

also have a radius machined into the base to accommodate the curvature of the pipe or vessel to which 

the body is welded. 

Access fittings are manufactured from materials which conform to NACE MR-0175 specifications for 

sour service. Choice of material for the access fitting body is based on minimum operating temperature 

as well as process stream corrosivity. “Standard” temperature materials are suitable for use above a 

minimum operating temperature of -20°F (-29°C). “Low Temperature” materials should be selected for 

minimum operating temperatures below this value. 

The Metal Samples Corrosion Monitoring Systems standard material specification for Flareweld 

Socketweld, Buttweld, and NPT bodies is AISI 1018 for standard temperature and ASTM A350LF2 

for low temperature. For flanged fittings, ASTM A105 is used for standard temperature and ASTM 

A350LF2 for low temperature. However, all access fitting components can be made to order in any 

customer-specified material; carbon or stainless steel, duplex materials, or other more exotic alloys. 

All access fitting bodies have an external 3-inch ACME thread, which is used to attach the service valve 

during retrieval operations. Access fitting bodies should always be fitted with a cover which is designed 

to protect both external thread and also the service valve sealing surfaces. 

Tee Type Access Fitting Bodies 

Tee type access fitting bodies are available for use in applications where inlet or outlet access to the 

process stream is required. 

A side-tee port is drilled and tapped in the access fitting’s extra thick body to provide an integral 

connection point for a nipple and shut-off valve arrangement. Fittings with 1/4", 1/2", 3/4", or 1" FNPT 

side-tee ports are available as standard items. 

Tee type access fitting bodies are used with Chemical Injection Systems, Sampling, and Sand Monitoring 

Systems. If required, the side-tee port may be sealed off with a pipe plug. This would allow devices 

normally used with the non-tee type access fittings to be used with the tee type access fittings. 

NOTE: The installation and removal of the pipe plug requires the process stream to be shut down and 

depressurized. 

The materials of construction of tee type access fitting bodies is the same as the non-tee type access 

fitting bodies. Flanged tee type access fittings are also available upon request. 

Access Systems - 4

Plug Assemblies 

The Plug Assembly is the retrievable carrier which holds corrosion monitoring, chemical injection, or 

various other devices which may be installed through the access fitting. There are two distinct types of 

plug assemblies - the Solid Plug and the Hollow Plug (see HP and MH Plug Assemblies sections). 

The plug assembly screws into the bore of the access fitting body and is designed to seal the fitting 

against line pressure. When tee type access fittings are being used, a pipe plug or nipple and shut-off 

valve is additionally required to seal the fitting. 

The standard material of construction for the plug assembly is 316 Stainless Steel. It should be noted 

that when stainless steel or duplex materials are specified for the access fitting body, the plug assembly 

should be specified to be Nitronic 60 to prevent thread galling. 

All plug assemblies are individually pressure tested at the factory and are rated for operation at 3600 

psi. The operating temperature range for standard plug assemblies is -50°F (-45°C) to 350°F (176°C), 

but this range can be extended by use of alternative sealing materials. 

MH plug assemblies incorporate the following innovative design features which distinguish them from 

HP plug assemblies and plug assemblies available from other major manufacturers. 

• A quick stab collet to facilitate easy attachment to the retrieval tool during removal and 

installation of the plug. 

• A coarse ACME plug thread to minimize the risk of galling or plug fouling. 

• A keyway feature (on solid plugs) to permit reproducible accurate orientation of installed 

hardware, coupon equipment, and injection nozzles. 

• A metal-to-metal back-up seal to minimize leakage, even if access fitting assembly is 

subjected to high temperatures. 

Solid Plugs 

Solid plugs carry coupon holders, injection/sampling systems, sand probes, and bioprobes 

A set screw arrangement is used with MH solid plugs to attach these devices for operation. With HP 

solid plugs, the solid plug nut is unscrewed from the base of the plug and replaced by the device being 

installed. A left-hand thread is used to ensure that installed devices do not become loose during the 

retrieval procedure. 

Hollow Plugs 

Hollow plugs are used with electrical resistance (E/R) probes, linear polarization resistance (LPR) 

probes, and hydrogen probes. 

To connect these devices with HP and MH hollow plugs, the hollow plug seal nut is removed and the 

monitoring device is screwed into the female thread in the base of the hollow plug. A left-hand thread is 

used. Access is allowed through the top of the hollow plug for electrical connections to be made directly 

to probes for the purpose of taking readings. 

Access Systems - 5


Protective covers are designed with internal threads which mate with the access fitting body and 

are recommended to prevent damage to the fitting’s exterior thread. In addition, they protect the 

surfaces against which the service valve seals during retrieval operations. 

Heavy Duty Pressure Rated Covers 

Heavy duty pressure rated covers are manufactured as standard in AISI 1018 and are supplied 

with a paint coat finish suitable for the most aggressive environments. Covers are individually 

pressure tested for a pressure rating of 4000 psi and are available with an optional bleed valve 

and/or pressure gauge. 

Covers are available with or without a center hole. Center holes are required when an external 

sensor connection is required to be permanently installed. Covers with an unthreaded 1 3/8" (3.5 

cm) diameter center hole are required for installations where mechanical Hydrogen Probes are 

installed. Covers with a 1/2" NPT center hole are required where continuous monitoring of electrical 

probes is required. Connection of an electrical probe to a permanent monitoring instrument 

requires the use of a probe adapter that extends through the 1/2" hole in the cover. The probe 

adaptor must be ordered separately. 

Heavy duty pressure rated cover with 1/2" NPT 

center hole and with 2 ea. 1/4" NPT holes for needle 

valve and pressure gauge 

Heavy duty pressure rated cover without center hole 

and with 2 ea. 1/4" NPT holes for needle valve 

and pressure gauge 

Non-pressure rated cover 

Non-Pressure Rated Covers 

More economical than heavy duty pressure rated covers, non-pressure rated covers are internally 

threaded to protect against mechanical damage to the external access fitting threads. Nonpressure 

rated covers are available in plastic or metal, with the plastic version having the added 

advantage of being lightweight and non-sparking. They can be ordered with or without a center 

hole. 






HP TM Access Fitting Bodies 

Non-Tee Types 

Model HP1000 

Flareweld 

Model HP2000 

Buttweld 

Model HP3000 

Socketweld 

Model HP4000 

NPT 

M odel 

H eight (in) 

Weight (lbs) 

HP1000 

Flareweld 

5.25 

5. 5 

HP2000 

Buttweld 

5.25 

4. 5 

HP3000 

Socketweld 

6.25 

4. 5 

HP4000 

NPT 

6.25 

4. 5 

Model HP5000 

ANSI Flange RJ 

Model HP6000 

ANSI Flange RF 

Model HP7000 

API Flange 

F lange Size 

H eight (in) 

Weight (lbs) 

150# 

5.25 

10.50 

300# 

5.25 

11.50 

4/600# 

6.25 

15.25 

9/1500# 

6.25 

30.75 

2500# 

6.25 

40.00 

Temperature Rating: -20° F (28.9° C) to +350° F (176.6° C) 

Pressure Rating: 6000 PSI or as Flange Size 






Tee Types 

Model HP1100 

Flareweld 

Model HP2100 

Buttweld 

Model HP3100 

Socketweld 

Model HP4100 

NPT 

Height 

(in) 

1/4" 

T 1/2" 

T 

3/4" 

T 

1" T 

Weight 

(lbs) 

Height 

(in) 

Weight 

(lbs) 

Height 

(in) 

Weight 

(lbs) 

Height 

(in) 

Weight 

(lbs) 

5.25 

4. 

5 6.25 

5.75 

6.25 

6. 

5 7.25 

7 

Model HP5100 


Model HP6100 


Model HP7100 

API Flange 

Model 

Flange 

Size 

150# 

Height 

(in) 

5.25 

1/4 

" T 1/2" 

T 

3/4" 

T 

1" T 

Weight 

(lbs) 

9.50 

Height 

(in) 

7.25 

Weight 

(lbs) 

10.00 

Height 

(in) 

7.25 

Weight 

(lbs) 

10.00 

Height 

(in) 

7.25 

Weight 

(lbs) 

10.50 

HP5100 

ANSI 

Flange RJ 

300# 

4/600# 

9/1500# 

5.25 

6.25 

6.25 

11.50 

12.75 

25.75 

7.25 

7.25 

8.25 

11.75 

13.00 

26.00 

7.25 

7.25 

8.25 

12.00 

13.00 

26.25 

7.25 

7.25 

8.25 

12.00 

13.00 

26.50 

2500# 

150# 

6.25 

5.25 

40.20 

9.75 

8.25 

7.25 

40.50 

10.00 

8.25 

7.25 

40.40 

13.00 

8.25 

7.25 

40.75 

13.00 

HP6100 

ANSI 

Flange 

RF 

300# 

4/600# 

9/1500# 

5.25 

6.25 

6.25 

11.50 

12.75 

25.75 

7.25 

7.25 

8.25 

11.75 

13.00 

26.00 

7.25 

7.25 

8.25 

17.00 

18.00 

38.00 

7.25 

7.25 

8.25 

17.00 

18.00 

38.00 

HP7100 

API 

Flange 

2500# 

2000# 

3/5000# 

10000# 

6.25 

6.25 

6.25 

6.25 

40.10 

15.75 

31.00 

40.50 

8.25 

7.25 

8.25 

8.25 

40.50 

18.00 

38.00 

45.50 

8.25 

7.25 

8.25 

8.25 

45.50 

18.00 

38.00 

45.50 

8.25 

7.25 

8.25 

8.25 



45.50 

18.00 

38.00 

45.50

MH TM Access Fitting Bodies 

Non-Tee Types 

Model MH1000 

Flareweld 

Model MH2000 

Buttweld 

Model Height (in) Weight (lbs) 

MH1000 Flareweld 5.5 7 

MH2000 Buttweld 5.5 7 

Model MH5000 


Model MH6000 


Model MH7000 

API Flange 

Flange Size Height (in) Weight (lbs) 

150# 5.5 11 

300# 5.5 13 

4/600# 5.5 14 

9/1500# 5.5 27 

2500# 6.5 42 








Tee Types 

Model MH1100 

Flareweld 

Model MH2100 

Buttweld 

Model 

Height 

(in) 

1/4” T 1/2” T 3/4” T 1” T 

Weight 

(lbs) 

Height 

(in) 

Weight 

(lbs) 

Height 

(in) 

Weight 

(lbs) 

Height 

(in) 

MH1100 (Flareweld) 7.50 11 7.50 11 7.50 11 7.50 11 

MH2100 (Buttweld) 7.50 11 7.50 11 7.50 11 7.50 11 

Weight 

(lbs) 

Model MH5100 


Model MH6100 


Model MH7100 

API Flange 

Model 

MH5100 

ANSI 

Flange RJ 

MH6100 

ANSI 

Flange RF 

MH7100 

API 

Flange 

Flange 

Size 

Height 

(in) 

1/4” T 1/2” T 3/4” T 1” T 

Weight 

(lbs) 

Height 

(in) 

Weight 

(lbs) 

Height 

(in) 

Weight 

(lbs) 

Height 

(in) 

Weight 

(lbs) 

150# 7.50 15 7.50 15 7.50 15 7.50 15 

300# 7.50 17 7.50 17 7.50 17 7.50 17 

4/600# 7.50 18 7.50 18 7.50 18 7.50 18 

9/1500# 7.50 31 7.50 31 7.50 31 7.50 31 

2500# 7.50 46 7.50 46 7.50 46 7.50 46 

150# 7.50 15 7.50 15 7.50 15 7.50 15 

300# 7.50 17 7.50 17 7.50 17 7.50 17 

4/600# 7.50 18 7.50 18 7.50 18 7.50 18 

9/1500# 7.50 31 7.50 31 7.50 31 7.50 31 

2500# 7.50 46 7.50 46 7.50 46 7.50 46 

2000# 7.50 18 7.50 18 7.50 18 7.50 18 

3/5000# 7.50 31 7.50 31 7.50 31 7.50 31 

10000# 8.50 46 8.50 46 8.50 46 8.50 46 


Pressure Rating: 6000 PSI or as Flange Size

HP TM Plug Assemblies 


PIPE PLUG 

HOLLOW PLUG 

BODY 

PRIMARY PACKING 

HOLLOW PLUG NUT 

SET SCREWS 

PROBE PACKING 

D escription 

Part 

No. 

Pipe 

Plug 

HA700167 

Hollow Plug Body 

Anti-Gall Coating 

HA700300158 

Material 

Plastic 

316 SS 

Primary Packing H A700266785 

PTFE (25% G) 

Hollow Plug Nut 

HA700302158 

Set Screws 

2 required 

316 SS 

09158E1032ST0187 

316 SS 

Probe 

Packing 

H A700277785 

PTFE (25% G) 

Hollow Plug 

Sealing Nut 

Bore 

HP Hollow Plug Assembly 

HA700952158 

HA700311158 

316 SS 

BORE SEAL NUT 

PIPE PLUG 

SOLID PLUG BODY 

O-RING 

PRIMARY PACKING 

SOLID PLUG NUT 

SET SCREW 

HP Solid Plug Assembly 

HA700644158 

D escription 

Part 

No. 

Pipe 

Plug 

HA700697158 

Solid 

Plug Body 

HA700006158 

O-Ring 

HA700600834 

Material 

316 SS 

316 SS 

® 

V iton 

Primary Packing H A700266785 

PTFE (25% G) 

Solid 

Plug Nut 

HA700210158 

316 SS 

Set 

Screw 

09158E1032ST0187 

316 SS 






MH TM Plug Assemblies 


The MH plug assemblies incorporate the following innovative design features which distinguish 

them from the HP plug assemblies and plug assemblies available from other major manufacturers. 

• A quick stab collet to facilitate easy attachment to the retrieval tool during removal and 

installation of the plug. 

• A coarse ACME plug thread to minimize the risk of galling or plug fouling. 

• A keyway feature to permit reproducible accurate orientation of installed hardware, 

coupon equipment, and injection nozzles. 

• A metal-to-metal back-up seal to minimize leakage, even if the acccess fitting assembly is 

subjected to high temperatures. 

1 

2 

3 

4 

ACME Thread 

5 

Quick Stab Collet 

ACME Thread 

Metal to Metal 

Seal 

Item 

MH Hollow Plug Assembly 

HA700953158 

D escription 

Part 

No. 

Hollow Plug 

1 

Body 

2 -Ring 

High Pressure 

3 

Probe Packing 

HA700303158 

O PR6280834 

4 Set Screw 

HA700277785 

09158E1032- 

ST0187 

HA70031115 

5 Bore 

Seal Nut 

8 

Material 

316 SS 

® 

V iton 

25% GF 

® 

T eflon 

316 SS 

316 SS 

Quick Stab Collet 

ACME Thread 

Metal to Metal 

Seal 

ACME Thread 

8 

1 

2 

3 

7 

5 

6 

4 

Orientation Key 

Orientation 

Keyway 

Item 

MH Solid Plug Assembly 

HA700645158 

D escription 

Part 

No. 

Drive 

Scre HA700007159 

Retainer 

Pi PR6366159 

Thrust 

Washe PR6367783 

Wave 

Washe PR6370138 

1 w 

2 n 

3 r 

4 r 

5 Spirolox Pin 

PR6371138 

6 O-Ring 

PR6280834 

7 

Solid Plug HA700008159 

Mandrel 

8 Set Screw 

09158E3716- 

CP0750 

Material 

316 SS 

316 SS 

® 

T eflon 

SS 

SS 

® 

V iton 

316 SS 

316 SS



Non-Pressure 

Rated Cover 

Heavy Duty 

Pressure 

Rated Cover* 

Description Application Part No. Material Weight 

Non-pressure rated 

cover without hole 


cover w/ 1/2" NPT hole 


cover without hole 


cover w/ 1/2" NPT hole 

Heavy duty pressure 

rated cover w/o hole 


rated cover with 1/2" 

NPT hole 


rated cover and bleed 

valve 


rated cover, bleed valve 

& pressure gauge 


rated cover, bleed 

valve, pressure gauge 

and 1/2" NPT hole 


rated cover w/ bleed 

valve & 1/2" NPT hole 


rated cover, w/ pressure 

gauge & 1/2" NPT hole 

Intermittent monitoring - 

chemical injection 

* Fire safe covers certified to API 6FB are also available. 

HA700734413 Carbon steel 2.5 lbs. (1.6 kg) 

Continuous monitoring HA700732413 Carbon steel 2.0 lbs. (0.9 kg) 

Intermittent monitoring HA700436709 Nylon 0.5 lbs. (0.2 kg) 

Continuous monitoring HA700435709 Nylon 0.5 lbs. (0.2 kg) 

Intermittent monitoring 

(rated for 4,000 PSI) 

Continuous monitoring - 

provides a secondary seal 

and allows for probe adapter 

















HA700735413 Carbon steel 9 lbs. (4.1 kg) 

HA700731413 Carbon steel 9 lbs. (4.1 kg) 

HA700480413 

HA700481413 

HA700482413 

HA700483413 

HA700484413 


Carbon steel 

(cover), 316 SS 

(bleed valve) 

Carbon steel 


(bleed valve & 

gauge) 

Carbon steel 


(bleed valve & 

gauge) 

Carbon steel 


(bleed valve) 

Carbon steel 


(gauge) 




Houston Office: 6327 Teal Mist Lane, Fulshear, TX 77441 Phone: (832) 451-6825 

9 lbs. (4.1 kg) 

10 lbs. (4.5 kg) 

9 lbs. (4.1 kg) 

9 lbs. (4.1 kg) 

9 lbs. (4.1 kg)

HP TM and MH TM Ordering Chart 

Access Fitting Body Options 

MOUNTING OPTIONS 

BODY STYLE 

PIPELINE SIZE 

BODY MATERIAL 

1 - Flare Weld 

2 - Butt Weld 

3 - Socket Weld 

4 - NPT 

5 - 2" ANSI Flange RJ 

6 - 2" ANSI Flange RF 

7 - 2" API Flange RJ 

0 - Non-Tee 

1 - 1/4" Tee 

2 - 1/2" Tee 

3 - 3/4" Tee 

4 - 1" Tee 

5 - 1/2" 150# RF 

6 - 1/2" 300# RF 

7 - 1/2" 4/600# RF 

8 - 1/2" 9/1500# RF 

9 - 1/2" 2500# RF 

A - 1/2" 150# RJ 

B - 1/2" 300# RJ 

C - 1/2" 4/600# RJ 

D - 1/2" 9/1500# RJ 

E - 1/2" 2500# RJ 

F - 1" 9/1500# RJ 

G - 1" 2500# RJ 

H - 3/4" 9/1500# RJ 

J - 1" 150# RF 

Y - Tee 1/2" & 3/4" 

(for blank) 

Z - Misc. 

FLARE WELD 

0 - (Blank) 

1 - 2" 

2 - 3" 

3 - 4" 

4 - 6" 

5 - 8" - 10" 

6 - 12" - 18" 

7 - 20" - 36" 

8 - Flat 

9 - 38" - 48" 

ANSI 

FLANGE SIZE 

0 - N/A 

1 - 150# 

2 - 300# 

3 - 4/600# 

4 - 9/1500# 

5 - 2500# 

API 

FLANGE SIZE 

0 - N/A 

1 - 2000# 

2 - 3/5000# 

3 - 10,000# 

1 - AISI 1018 Carbon Steel 

2 - ASTM A105 Carbon Steel 

3 - ASTM A350 LF2 Carbon Steel 

4 - AISI 316SS 

5 - Duplex SS 

6 - ASTM A694 

7 - 321 SS 

8 - C276 

HP 

MH 

X X X X - X X X - X 

0 - Not Req'd 

1 - Solid 

2 - Hollow 

TYPE 

0 - Not Req'd 

1 - 316 

2 - 316L 

3 - C276 

4 - NIT60 

5 - CS 

ALLOY 

Plug Assembly Options 

0 - Not Required 

1 - Viton ® O-Ring Teflon ® Primary Packing 

2 - Ethylene Propylene O-Ring Vespel Primary Packing 

3 - Kalrez ® O-Ring Vespel Primary Packing 

4 - No O-Ring NIT60 Packing 

5 - Hydrin O-Ring Teflon ® Packing 

6 - Nitrile O-Ring Teflon ® Packing 

PACKING 

0 - Not Required 

1 - Heavy Prot. Cover w/o Hole (non-pressure rated) 

2 - Heavy Prot. Cover w/Hole (non-pressure rated) 

3 - Polycarbonate Cover w/o Hole 

4 - Polycarbonate Cover w/Hole 

5 - 4000 PSI Rated Cover w/Bleed Valve 

6 - 4000 PSI Rated Cover w/Bleed Valve & 


7 - 4000 PSI Rated Cover w/ 1/2" NPT Hole, 

Bleed Valve & Pressure Gauge 

8 - 4000 PSI Rated Cover w/o Hole 

9 - 4000 PSI Rated Cover w/ 1/2" NPT Hole 

A - 4000 PSI Rated Cover w/Pressure Gauge 

B - C.S. MH Cover - Fire Safe 

C - 4000 PSI Rated Cover w/ 1/2" NPT Hole 

& Pressure Gauge 

D - 4000 PSI Rated Cover w/ 1/2" NPT Hole 

& Bleed Valve 

Cover Options 

Ordering Instructions 

1. To order an access fitting body only, use the first four characters on the chart. Example: If a 1/4" Tee 4/600# ANSI Flange RJ fitting 

made of Duplex SS is required, order part # HP5135. 

2. To order a body with a plug assembly, use the first seven characters on the chart. Example: If a 3/4" Tee 4" Flareweld made of ASTM 

A105 Carbon Steel is required with a solid CS hydrin O-ring Teflon ® packing plug, order part # HP1332155. 

3. To order a body with a plug assembly and a cover, use all eight characters on the chart. Example: If a Non-Tee 9/1500# ANSI Flange 

RF fitting made of AISI 316 SS with a hollow no O-ring NIT60 packing 316 plug and polycarbonate cover with no hole is required, 

order part # HP60442143.

Retrieval Tool and Service Valve 


The Metal Samples Corrosion Monitoring Systems retrieval tool and 

service valve can be used to insert or retrieve sensors from process 

systems operating under full pressure (up to 3600 psi). An HP adapter 

supplied with a retrieval tool can be interchanged for an MH adapter, 

and vice versa, so that the tool can be used with both HP and MH 

high pressure access system. (Each tool is supplied with one adapter. 

The alternate adapter must be purchased separately). The tool also 

works with other conventional 2" access systems. 

The retrieval tool and service valve system incorporates the following 

unique features: 

• Side-wheel manipulation to allow safe operation. 

• No telescoping parts. 

• Positive indication of full insertion or retrieval of 

plug/sensor assembly to avoid operation errors. 

• Compact design to allow retrieval in minimum 

clearance areas. 

• Lightweight construction for single person operation. 

• Full compatibility with systems manufactured by 

other suppliers. 

• Quick-stab collet latch mechanism (MH system) for 

rapid operation. 

Figure 1. Retrieval 

Tool / Service Valve 

Dimensional Schematic 

Stroke required = 9.5" + Length of Plug + Attachment Length 

solid plug = 2.5" 

hollow plug = 3.75" 

Letter 

A 

Description 

Retrieval Tool Overall Length - 

Inches 

Retrieval Tool and Service 

B 

Valve Overall Length to Pipe 

OD (includes non-tee access 

54 

62 

70 

78 

86 

94 

106 

118 

126 

fitting) - Inches 

C Stroke 

Available - Inche s 18. 

5 22. 

5 26. 

5 30. 

5 34. 

5 38. 

5 44. 

5 50. 

5 54. 5 

Retrieval 

Tool Weight - lbs. 47 

52 

57 

62 

67 

72 

83 

92 

97 

Case 

/ Tool Kit Weight - lbs. 37 

37 

40 

40 

43 

43 

48 

48 

53 

Total 

Weight - lbs. 

84 

89 

97 

102 

110 

115 

131 

140 

150 

3 

Total 

Cubage - ft 

2. 

4 2. 

4 2. 

9 2. 

9 3. 

5 3. 

5 4. 

3 4. 

3 4. 8 

Table 1. Dimensions from Schematic 

All retrieval tools have a body material of 316 SS and a working pressure of 3600 psi. 

MH is a trademark of Metal Samples Corrosion Monitoring Systems 

Maximum Pipeline Size 

4 " 8 " 12" 

16" 

20" 

24" 

30" 

36" 

40" 

39 

47 

55 

63 

71 

79 

91 

103 

111

Retrieval Tool 

The exploded view of the retrieval tool shown in Figure 3 illustrates some of the exclusive safety 

and convenience features available only from Metal Samples Corrosion Monitoring Systems. The 

retrieval tool is constructed to comply with NACE MR-0175(90) and is pressure tested at the factory 

to 6000 psi for a working pressure of 3600 psi. The standard tool is suitable for operation between 

0°F and 450°F (-18°C and 232°C). For operation below this temperature range, a low temperature 

version is available on request. The retrieval tool is normally 

supplied as a kit complete with field service case, assembly 

accessories and one O-ring seal kit. 

Tool size, or stroke, is determined by the combined maximum 

pipeline size and the maximum height of any access 

fitting assembly with which the tool will be used. The stroke 

is defined as the distance that the plug/sensor assembly must 

travel to permit the service valve to close. 

Metal Samples Corrosion Monitoring Systems retrieval tool 

part numbers for various pipeline sizes are given below. If 

the required pipeline size falls between two size ranges, the 

larger tool should be selected. 

Retrieval Tool Part Numbers 

Part # Pipeline Size 

HA10004X 4" 

HA10008X 8" 

HA10012X 12" 

HA10016X 16" 

HA10020X 20" 

HA10024X 24" 

HA10030X 30" 

HA10036X 36" 

HA10040X 40" 

Figure 2. Retrieval Tool and Service Valve 

X = 0 (HP adapter), 1 (MH adapter), 2 (HP adapter for low temperature) 

Retrieval Tool - 2

A2 

A6 

A5 

1A 

1B 

B2 

B6 

A3 

B3 

B4 

A4 

B3 

A3 

B5 

A1 

B1 

ITEM 

A 

1 

2 

3 

4 

5 

6 

B 

1 

2 

3 

4 

5 

6 

QTY 

D ESCRIPTION 

PART 

# 

M 

TM 

Adapter 

Assy 

PS5554158 

Collet 

Latc 

PR6297110 

M 

TM 

Spanne 

r 

PR6296158 

Spirol 

Rin 

PR6243158 

Adapter 

Guid 

PR6244158 

Set 

Scre 

9141E2520CP1000 

Spirol 

Pi 

PR6247141 

H 

TM 

Adapter 

Assy 

PS5552158 

Landing 

Scre 

PR6242159 

H 

TM 

Adapter 

Body 

PR6246158 

Spirol 

Rin 

PR6243158 

Adapter 

Guid 

PR6244158 

Sprin 

R6245599 

Spirol 

Pi 

PR6247141 

Hammer 

Unio 

R6290C25 

F ront Tub 

PR6264158XX* 

Spirol 

Rin 

PR6265138 

Bleed 

Valv 

PR6359158 

Pressure 

Gag 

PR7020158 

Set 

Scre 

9141E3716CP0375 

Gear 

Box Ass 

PS5551 

Hand 

Wheel Nu 9141E7510JN0000 

Lock 

Pi 

PR6291139 

Handwheel 

Bod 

PR6289338 

Shaft 

Retaine 

R6267707 

O-Rin 

PR6268834 

Gear 

Shaf 

PR6269110 

1 1 H 

A 1 h 

A 1 H 

A 2 g 

A 1 e 

A 1 w 

A 1 n 

1 1 P 

B 1 w 

B 1 P 

B 2 g 

B 1 e 

B 1 g 

B 2 n 

2 1 n 

3 1 e 

4 1 g 

5 2 e 

6 1 e 

7 5 w 

8 1 y 

9 1 t 

10 

1 n 

11 

1 y 

12 

1 r 

13 

1 g 

14 

1 t 

Table 2. Retrieval Tool Parts 

Figure 3. Retrieval Tool Exploded View 

MATERIA 

L 

s Listed 

ITEM 

* XX is 10" greater than the Retrieval Tool length; i.e. XX = 26 if Retrieval Tool length is 16". 

** XX is 11" greater than the Retrieval Tool length; i.e. XX = 15 if Retrieval Tool length is 4". 

*** XXXX is 18.56" greater than the Retrieval Tool length; i.e. XXXX = 3456 if Retrieval Tool length is 16". 

If replacement parts are required, use the part numbers listed above and specify length where neccessary. Viton ® is the 

standard O-ring material, however other materials are available. Consult your Metal Samples Corrosion Monitoring 

Systems representative for the options available with non-standard materials. 

Viton ® is a registered trademark of DuPont Dow Elastomers. 

Retrieval Tool - 3 

QTY 

A 15 

4 r 

17-4PH 

16 

4 g 

316 

SS 

17 

1 g 

316 

SS 

18 

1 l 

316 

SS 

19 

1 g 

0 SS 

20 

1 e 

SS 

21 

1 g 

As 

Listed 

22 

1 p 

316 

SS 

23 

1 g 

316 

SS 

24 

1 g 

316 

SS 

25 

2 w 

316 

SS 

26 

2 y 

P IN 600 

27 

1 g 

SS 

28 

2 e 

P A350 

LF2 

29 

1 e 

316 

SS 

30 

1 g 

SS 

31 

1 p 

316 

SS 

32 

1 k 

316 

SS 

33 

1 w 

0 SS 

34 

1 p 

Cast 

316L SS 

35 

1 g 

0 304 

SS 

36 

2 g 

SS 

37 

1 g 

Aluminu 

m 38 

1 g 

P NIT6 

0 

39 

1 e 

® 

V iton 

17-4PH 

D ESCRIPTION 

PART 

# 

Thrust 

Washe 

PR6270158 

O-Rin 

PR6271834 

O-Rin 

PR6263834 

Omnisea 

PR6251 

Flange 

Bearin 

PR6239 

Drive 

Tub 

PR6272159 

Thrust 

Bearin 

R6273207 

Bearing 

Ca 

PR6274159 

Sleeve 

Bearin 

PR6275 

O-Rin 

PR6293834 

Set 

Scre 

9141E3716CP0500 

Ke 

R6276377 

Drive 

Rin 

PR6277158 

Handl 

PR6278158 

B ack Tub 

PR6279158XX* 

* 

O-Rin 

PR6280834 

End 

Ca 

PR6281158 

S pline Rac PR6282110XXXX** 

* 

Flat 

Head Scre 9141E3716FH0500 

End 

Sto 

PR6283158 

O-Rin 

PR6284834 

Grease 

Fittin 

PR6427139 

O-Rin 

PR6285834 

O-Rin 

PR6286834 

Handwheel 

Handl PR6288338 

MATERIA L 

316 SS 

® 

V iton 

® 

V iton 

Fluorocarbo n 

P/M Bronze 

316 SS 

AISI 5210 

316 SS 

P/M Bronze 

® 

V iton 

S 

AISI 101 

316 SS 

316 SS 

316 SS 

® 

V iton 

316 SS 

17-4PH 

S 

316 SS 

® 

V iton 

303 SS 

® 

V iton 

® 

V iton 

Aluminu m 

P 0 

0 S 

P 8 

0 S

Service Valve 

Three ball-type service valves are available for use with Metal Samples 

Corrosion Monitoring Systems retrieval tools: standard, low and high 

temperature. The female threads on this valve are industry-standard 

ACME threads and may be used with any Metal Samples Corrosion 

Monitoring Systems high pressure access fitting as well as any other 2" 

access fitting. The valves have a bleed valve located on the non-process 

side of the ball. This bleed valve may be used to drain the retrieval tool, 

sample process, or be used as a path for back-pressuring. All valves are 

NACE MR-0175 compliant for use in sour service, factory pressure 

tested for a working pressure of 3600 psi* W.O.G., and meet API6FA 

and API607 fire safe requirements. 

The service valve is a portable valve that is used in conjunction with a 

retrieval tool. The service valve is threaded onto an access fitting in 

preparation for retrieving a plug. Next, the retrieval tool is attached to the 

service valve. System pressure is then equalized in the retrieval tool by Figure 4. Service Valve 

unseating the plug. Occasionally deposit buildup in access fitting bodies 

does not allow for pressure equalization through the plug. If this occurs, the retrieval tool can be back 

pressured by use of a back-pressure kit (P/N - HA104000). Once pressure equalization has occurred, the 

plug is removed and the valve is shut. Finally, the retrieval tool is removed from the valve allowing access 

to the plug and its accessory. A Blanking Cap/Plug Assembly (P/N - PS5612) may be installed on the 

valve as an additional safety measure, if required. 

Service valves are supplied with a durable lightweight field service case, extension bar, tool kit, and one 

O-ring seal kit. Additional accessory items are listed below. 

Model 

HA101250 (Standard Temperature Valve) 

HA101251 (Low Temperature Valve) 

HA101252 (High Temperature Valve) 

200°F to 0°F (93°C to -18°C) 

200°F to -50°F (93°C to -46°C) 

450°F to 0°F (232°C to -18°C) 

Physical Data 

Valve Weight: 45 lbs. Case Weight: 25 lbs. Total Weight: 70 lbs. 

Case Dimensions: 12 3/4" x 13 3/4" x 20 1/4" 

Service Valve Tool Kit 


PR6961 Socket 19mm 12 Point 

1/2" Drive Deep Wall 

PR6962 8mm Allen Wrench 

PR6963 10 mm Allen Wrench 


• Complies with API6FA and API607 as a fire-safe unit 

• NACE MR0175 

• Pressure rating - 3600 PSI 

• Seal options available for temperature ratings up to 450°F 



KR1009834 Standard Temperature Seal Kit 

KR1010 Standard Temperature Repair Kit 

PR6303834 Standard Temperature Male End O-Ring 

HA700604834 Standard Temperature Female End O-Ring 

PS5612 Blanking Cap/Plug Assembly 

PR6358 Brass Hammer 

(supplied in each retrieval tool kit) 

* A 6000 psi model is also available. Contact our sales department for details. 

Retrieval Tool - 4

Handle 

Stem 

Hammer 

Union 

Lower Flange 

6 

5 

9 

8 

Bonnet 

7 

10 

1 

2 

11 4 

Body 

3 

Figure 5. Service Valve Parts 

Low Temp Standard High Temp Low Temp Standard High Temp 

Item Part No. Part No. Part No. Description Material Material Material Qty 

1* HA700604370 HA700604834 HA700604834 Viton O-Ring Buna-N Viton 70 Viton 70 1 

2* --- --- --- Viton O-Ring Buna-N Viton Viton 1 

3* PR6303370 PR6303834 PR6303834 Viton O-Ring Buna-N Viton 70 Viton 70 1 

4* --- --- PR6720A50 Seat SealCelcon Celcon PEEK 2 

5* --- --- --- Viton O-Ring Buna-N Viton Viton 1 

6* --- --- --- “L” Seal Buna-N Viton Viton 2 

7** --- --- --- Carrier 4130 4130 4130 2 

8* --- --- --- Stem Seal Polymyte/ Polymyte/ Polymyte/ 1 

Buna-N Viton Viton 

9* --- --- --- Ring, Back-Up Teflon Teflon Teflon 1 

10 --- PR6359158 --- 316 6000 PSI 316 316 316 1 

Bleed Valve 

11** --- --- --- Ball 17-4 PH SS 17-4 PH SS 17-4 PH SS 1 

Table 3. Descriptions of Service Valve Parts 

* Parts included in Seal Kit / Repair Kit. 

** Parts included in Repair Kit. 

1. Seal Kit - P/N KR1009834 (Standard Temp) 

2. Repair Kit - P/N KR1010 (Standard Temp)

Hot Tap Tool 

for High Pressure (HP and MH) Access Systems 

The Metal Samples Corrosion Monitoring Systems hot tap tool 

provides a safe and reliable method of hot tapping high pressure 

access fittings on pressurized pipelines or vessels. 

Operation 

A special cutter assembly is installed in the access fitting, 

previously welded onto the pipe. To tap a hole through the pipe 

wall, a service valve is installed on the fitting. This allows the cutter 

fitting to be isolated, if necessary. The hot tap tool is mounted 

on the service valve and mated to the cutter. The drive screw on the 

hot tap tool puts pressure on the cutter as the tool shaft is rotated to 

cut through the pipe wall. 

After the hole is cut through the pipe wall, the tool is removed 

from the valve and the retrieval tool is then used to pull the cutter 

assembly and pipe plug from the fitting. Shavings and cuttings are removed using swabs or brushes. 

The hot tap procedure may be expedited by use of an air operated drill motor to turn the cutter shaft. 

Safety is enhanced in the Metal Samples Corrosion Monitoring Systems assembly because the 

cutter is isolated from the atmosphere by a service valve. At any time in the procedure, the cutter 

drive shaft may be retracted and the fitting and its contents isolated from the atmosphere by closing 

the service valve. 

The hot tap tool is adaptable to either the MH access fitting system or the HP access fitting 

system, which is compatible with other major manufacturers’ access fitting systems. 

MH and HP are trademarks of Metal Samples Corrosion Monitoring Systems. 






Hot Tap Tool (HA102102) 

for HP High Pressure Access Systems 

Hot Tap Tool (HA102101) 

for MH High Pressure Access Systems 

Description Part # 

Bore Reamer Assembly HA102004 

HP Thread Chaser w/ Adapter HA102016 

Seat Reaming Assembly HA102018 

Weld and Seal Test Asy HA102017 

Cutter Assembly - HP 5 1/4" 

Nipple 

HA102015 

HP Cutter Test Assembly HA102020 

Bushing Insertion Tool PR6483 

Hot Tap and Extraction 

Tool Test Assembly HA102013 

Hot Tap Turning Handle Asy HA102007 

Over Shot for Cutter HA102014 

Adapter for Tools 

HA102001158 

Magnetic Swab Assembly HA102003 

3/16" Allen Wrench PR6352 

Spanner Wrench 

PR6356 

1 3/8" Hex Socket PR6433 

Snap Ring Pliers (Internal) PR6479 

Seal Insertion Ring 

PR6480 

Brass Hammer 

PR6358 


Snap Ring Pliers (External) PR6484 

Quick Coupling (Female) PR6477 

1/2" Drive, Socket "T" Handle PR6357 

Case 

PS5604A69 

Seal Repair Kit 

KR1007 

Description Part # 

Bore Reamer Assembly HA102004 

MH Thread Chaser Asy HA102009 

Seat Reaming Assembly HA102008 

Weld and Seal Test Asy HA102019 

Cutter Assembly - MH 5 1/2" 

Nipple or as specified HA102010 

MH Cutter Test Assembly HA102012 

Bushing Insertion Tool PR6483 

Hot Tap and Extraction 

Tool Test Assembly HA102013 

Hot Tap Turning Handle HA102007 

Over Shot for Cutter HA102014 

Adapter for Tools 

HA102001158 

Magnetic Swab Assembly HA102003 


Spanner Wrench 

PR6356 

1 3/8" Hex Socket PR6433 

Snap Ring Pliers (Internal) PR6479 

Seal Insertion Ring 

PR6480 

Brass Hammer 

PR6358 


Snap Ring Pliers (External) PR6484 

Quick Coupling (Female) PR6477 

1/2" Drive, Socket "T" Handle PR6357 

Case 

PS5604A69 

Seal Repair Kit 

KR1007 

The above tools are furnished as standard 

equipment with each complete Hot Tap Tool Kit. 

In addition, a 3/16" punch, large crescent wrench, 

large screw driver, etc., are necessary. 

The above tools are furnished as standard 

equipment with each complete Hot Tap Tool Kit. 

In addition, a 3/16" punch, large crescent wrench, 

large screw driver, etc., are necessary.

Injection and Sampling Systems 

IP2000 - Fixed Length w/ NPT Pipe Plug 

IP3000 - Adjustable Length 

IP4000 - Retractable 

IP6000 - Fixed Length with Flange 

Injection and Sampling System 



Model IP2000 

Injection & Sampling System 

Fixed Length with NPT Pipe Plug 

Raised Quill 

Standard 

Quill 

Insertion Rod 

3/4" NPT 

Pipe Plug 

Customer-specified 

connection 

Open 

Cap & core 

I.L. 

Std. Length 

1" min. 

.20" 

NPT with 

Nozzle 

Model IP2000 Injection & Sampling System is a fixed-length, 3/4" NPT pipe plug-mounted unit 

commonly used in field and plant applications. Process shutdown or process isolation is required 

for installation and inspection. The unit assembly consists of an insertion rod, a welded pipe plug, 

and an injection/sampling tip. The injection tip, which is threaded, welded, or machined to the end 

of the rod, can be either a quill, open, cap & core, or nozzle assembly type. Insertion length (I.L.) is 

calculated to the end of the rod and is based on a customer specified length. For standard injection 

systems, the maximum insertion length is given in the chart below. The standard pipe plug for the 

IP2000 is the 3/4" NPT pipe plug, although other options are available. 







6" 3.8" 

8" 5.8" 

12" 9.8" 

18" 15.8" 

24" 21.8" 






IP2000 Ordering Information 


* Nozzles must be ordered separately.

Model IP3000 


Adjustable Length with NPT Pipe Plug 

Raised Quill 

Standard 

Quill 

Insertion Rod 

3/4" NPT 

Compression Fitting 


connection 

Open 

Cap & core 

I.L. 

Std. Length 

2" 

.20" 

NPT with 

Nozzle 

Model IP3000 is an adjustable, 3/4" NPT pipe plug mounted injection & sampling system 

commonly used in field and plant applications. The adjustable pipe plug allows the injection/ 

sampling system to be inserted into the process to the required length. Process shutdown or process 

isolation and a threaded pipe fitting is required for installation and inspection. The unit assembly 

consists of an insertion rod, a compression fitting, and an injection/sampling tip. The injection tip, 

which is threaded, welded, or machined to the end of the rod, can be either a quill, open, cap & core, 

or nozzle assembly type. For standard injection systems, the maximum insertion length is given in 

the chart below. The standard adjustable pipe plug for the IP3000 is the 3/4" NPT compression fitting, 

although other options are available. 














Model IP4000 



Raised Quill 

Standard 

Quill 

Open 

Std. Length 


connection 

Cap & core 

NPT with 

Nozzle 

Std. Length 

This configuration is required if an 

Easy Tool is necessary for insertion. 

Easy Tool 

adapter 

(5 1/2") 

Model IP4000 Injection & Sampling System is a retractable unit commonly used in field and plant 

applications. A specially designed packing gland is used with the unit for insertion into or retraction 

from a pressurized system without a process shutdown. The unit is designed to mount onto a 1" piping 

system, but can easily be adapted to fit your specific requirements. The unit assembly consists of 

a packing gland and an insertion rod with an injection/sampling fitting. The fitting, which is threaded 

or welded to the end of the rod, can be either a quill, open, cap & core, or nozzle assembly type. A 

safety chain is also provided to prevent blowout. In systems with pressure over 150 psi, an adaptor 

for the Easy Tool may be added to the unit. Standard packing material in the packing gland is 

Teflon ® , however, grafoil packing can be provided for high temperature applications. Model IP4000 

units are available in different lengths and materials. 




850°F / 454°C - Grafoil 




24" 16" 

30" 22" 

36" 28" 

42" 34" 









Model 

IP45 

IP75 

IPB7 

IP00 

Injection & Sampling System 1" NPT Female Thread, Packing Gland with Teflon® 

Injection & Sampling System 1" NPT Female Thread, Packing Gland with Grafoil 

Injection & Sampling System 1-1/2 " NPT Male Swage Nipple (used with Head, Cap, Core) 

Injection & Sampling System Replacement Insertion Rod 

Mounting Material (Packing Gland & Rod) 

22 

44 

316 

C276 

Injection Tip Option 

000 

010 

020 

030 

040 

050 

060 

070 

090 

N/A 

Quill (straight) 

Quill (raised) 

Open 

1/4" NPT (female) with nozzle* 

Head with cap and core (9/16")* -- Must use Swage Nipple. 

1/4" NPT (male) with nozzle* 

3/8" NPT (male) with nozzle* 

1/2" NPT (female) with nozzle* 

Tube Size 

1 

2 

3 

3/8" 

1/2" 

5/8" 

Length 

24 

30 

36 

42 

16” max. insertion length 




Dry End Mount Options 

01 

02 

03 

Blanked Off 

1/2" NPT 

3/4" NPT 

IP45 22 010 2 24 02 Example of Probe Ordering # 



Model IP6000 


Fixed Length with Flange 

Raised Quill 

Flange 

Standard 

Quill 


connection 

Open 

Cap & core 

NPT with 

Nozzle 

I.L. 

Std. Length 

1" min. 

Model IP6000 Injection & Sampling System is a fixed-length, flange-mounted unit commonly used 

in field and plant applications. The unit is ideally suited for use in high pressure and/or hazardous 

applications where threaded fittings are not available or not recommended. Process shutdown or 

process isolation is required for installation and inspection. The unit assembly consists of a flange 

and an insertion rod with an injection/sampling tip. The injection tip, which is threaded, welded, 

or machined to the end of the rod, can be either a quill, open, cap & core, or nozzle assembly type. 

Insertion length (I.L.) is calculated to the end of the rod and, in this case, is based on a 1" total flange 

thickness. Customers can specify any length required. For standard injection systems, the maximum 

insertion length is given in the chart below. Several standard injection tips and flanges are available 

to meet your specific needs. Model IP6000 units are available in different lengths and materials. 






Std. Length I.L. (Max) 

12" 10" 

18" 16" 

24" 22" 

30" 28" 

36" 34" 

42" 40" 







Modelo 

IP6 

Injection & Sampling System Fixed Length with Flange 

Flange Size 

1 

2 

3 

4 

6 

1" Flange 

1 1/2" Flange 

2" Flange 

3" Flange 

1/2" Flange 

Insertion Rod Material 

2 

4 

316 

C276 

Mounting Material (Flange) 

2 316 

4 C276 

Injection Tip Options 

01 Quill (Straight) 

02 Quill (Raised) 

03 Open 

04 

05 

06 

1/4" NPT (Female) with Nozzle * 

Head with Cap & Core (9/16”) 

1/4" NPT (Male) with Nozzle * 


1 150 # 

2 300 # 

3 

5 

6 

600 # 

1500 # 

900 # 

Tube Size 

1 

2 

3 

3/8" 

1/2" 

5/8" 

Length 

12 

18 

24 

30 

36 

42 







Dry End Mount Options 

01 

02 

03 

09 

Blanked Off 

1/2" NPT 

3/4" NPT 

1" - 150 # RF Flange 

IP6 2 2 2 02 3 3 24 02 Example of Probe Ordering # 



Injection and Sampling Systems 


Protective Cover 

Solid Plug 


Nipple 

Injection Nut 

To Feed Pump 

or Sampling 

Cylinder 

Shutoff Valve 

Quill Open NPT w/ Nozzle Head w/ Cap & Core 

Figure 1 

Injection and Sampling systems are fundamental to corrosion control and process control programs. 

They are applicable to a large variety of processes in the petroleum, chemical, and water treatment 

industries. Injection systems are used to inject a wide range of chemicals into processes. Such 

chemicals include biocides, demulsifiers, corrosion inhibitors, oxygen scavengers, glycol and monoethylene 

glycol, dewaxers, methanol, odorizers, and product additives. 

Injection systems may be as simple as using an open-ended tube that allows for even distribution of 

the injected chemical or as complex as using a head with a cap and core to obtain precise atomization 

of the chemical. 

Sampling systems are used to take samples of the process fluid or medium. Such samples are then 

analyzed in the laboratory for inhibitor concentration levels, the presence of metal ions, oxygen levels, 

scale forming compounds, and a wide range of process parameters.

Injection Systems 

The art of chemical injection is a complex 

technology. Irrespective of the type of injection 

or injected fluid, several factors relative to the 

process system and the injection system must be 

considered. Principal factors are: 

Pressure Differential 

This is the difference between the injection 

pump pressure and the process line or vessel 

pressure. Ideally the pressure differential should 

be 100 PSI (6.8 Bar). However, varied injection 

rates can be achieved by changing the pressure 

differential. 

Temperature 

Temperature directly affects viscosity. Ideally the 

temperature of both the injected chemical and 

the line product should be about 70° F (21° C). 

Viscosity 

This is the measure of a fluid's resistance to flow. 

The more viscous the fluid the smaller the spray 

angle. 

Spray Angle 

Spray angle is affected by viscosity, spray distance, 

and pressure differential. 

Spray Coverage 

This is the theoretical coverage area. 

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 

This is the amount of chemical to be injected 

within a specified time and is defined as Gallons 

Per Hour (GPH), Liters Per Day (LPD), etc. Injection 

Systems are available for injection rates 

varying from 0.1 GPH (0.38 liters/hr) to 65.7 

GPH (250 liters/hr). 

Injection - 2 

Injection Point 

The maximum fluid velocity is usually at the 

center of the line. Therefore, the most effective 

position for injection is generally at the center of 

the pipe in the direction of the product flow. If 

the line is to be pigged, the injection point may 

be flush with the pipe wall. This eliminates the 

need to remove the injection probe before pigging 

operations begin. On pipelines this means 

that injection is perpendicular to the product 

flow. Top of the line may be used if the injection 

is required to be oblique or horizontal to the 

product flow. 

A typical Two-Inch System Injection Assembly 

is shown in Figure 1. A Sampling system uses 

the same components. The various components 

of the assembly are: 

1. An Access Fitting body with a side Tee 

through which the fluid transfer takes place. 

The Tee may be threaded or welded. Welded 

Tees are either flanged or buttweld nipples. 

Threaded Tees are based on an NPT tapped 

hole in the fitting body. The Tee size is rated 

according to the injection rate and viscosity 

of the injected chemical. 

2. A Solid Plug Assembly inside the fitting 

body is used to carry an injection nut that has 

the injection tube/nozzle assembly screwed 

into its base. 

3. An Injection/Sampling Nut is a multiple 

use device that replaces the nut on the end of 

the solid plug. It is used to direct the injected 

product to the injection tube or atomization 

device. An Injection Nut sizing chart is 

shown in Table 1. 

4. The Injection/Sampling Tube or Nozzle. 

a. Quill is an open-ended tube cut at a 45° 

angle with a slot. It utilizes the turbulence 

created by its unique design to achieve 

distribution of the injected chemical into

the product flow. Injection Tube Quills 

are clog proof and give extremely good 

dispersion of the inhibitor if the product 

flow is 15 ft. per second or greater. As 

with the Open Tube, injection rate must 

be controlled at the injection pump or 

shut-off valve. 

b. Open is an open tube. The natural turbulence 

within the pipeline is used to insure 

even distribution. There is essentially no 

pressure differential experienced at the 

orifice, so it is necessary to control the 

injection rate at the injection pump or the 

shut-off valve. 

c. NPT is similar to the Open Tube but is 

threaded at the dispersion end, thus allowing 

attachment of female nozzle assemblies. 

Injection may be perpendicular to 

the flow with the use of a straight nozzle 

or parallel to the flow with the use of a 

right angle nozzle. 

d. Head with Caps, Cores, and Strainers 

are the various devices that, when attached 

to the dispersion end of the Injection 

Tube, permit atomization of the fluid as it 

is injected into the product line or vessel. 

The assemblies can be provided in complete 

units that contain caps, cores, and 

strainers. The head has female threads 

to match threads on the caps, cores, and 

strainers, so that these attachments can 

easily be replaced. 

5. Nipples are used with threaded Tee Access 

Fitting bodies and are the means of connecting 

the shut-off valve to the Access Fitting 

body. 

6. Shut-Off Valves are required to cut off the 

injection flow and maintain pressure integrity 

through the Tee when the Solid Plug Assembly 

is being removed or replaced. They are 

also used to control the injection flow rate. 

A Nipple and Shut-Off Valve sizing chart is 

given in Table 3. 

7. Check Valves are optional items that may be 

fitted either within the Injection Tube or in 

the inlet line to the Access Fitting Body Tee. 

8. The Injection or Feed Pump must be 

capable of generating sufficient injection 

line pressure to overcome the line operating 

pressure and thus create the required pressure 

differential across the atomizing nozzle or 

injection tube. 

Materials of Construction 

All components are manufactured from 316 SS 

as standard with the exception of seals and 

packing. These materials comply with the 

requirements of NACE Standard MR-0175 

Recommended Materials for sulfide stress 

cracking environments. 

Injection Tube Sizing 

(Lengths are rounded down to the nearest 1/8".) 

Center of Line Non-Flange Fitting 

Open/Quill: (FH + PD/2) - (2.04 + N) = L 

Head: (FH + PD/2) - (2.04 + N) = L 

*NPT: (FH + PD/2) - (3.353 + N) = L 

Center of Line Flange Fitting 

Open/Quill: (FH + PD/2 + MF) - (2.04 + N) = L 

Head: (FH + PD/2 + MF) - (2.04 + N) = L 

*NPT: (FH + PD/2 + MF) - (3.353 + N) = L 

Flush Non-Flange Access Fitting 

Open/Quill: (FH + PW) - (2.04 + N) = L 

Head: (FH + PW) - (2.04 + N) = L 

*NPT: (FH + PW) - (3.353 + N) = L 

Flush Flange Access Fitting 

Open/Quill: (FH + PW + MF) - (2.04 + N) = L 

Head: (FH + PW + MF) - (2.04 + N) = L 

*NPT: (FH + PW + MF) - (3.353 + N) = L 

FH = Access Fitting Height 

PW = Pipe Wall Thickness 

N = Injection Nut Length 

L = Injection Tube Length 

MF = Mating Flange Height 

PD = Pipe Outer Diameter 

IL = Insertion Length into Pipe or Vessel 

* Length of tube is based on nozzle length of 1.313". 

Nozzle is sold separately. 

Injection - 3

How to Order 

A) Access Fitting Body height and Tee size may be determined from the Access Fitting literature. 

B) The Injection Nut size may be determined from Table 1. 

Model Length (Fitting type / Height) Probe End Thread Seal Material Alloy Code 

IQN --- ---- X ---- ---- X ---- ---- X ---- ---- XXX 

1 - 1.75" (HP / 5.25") 

2 - 2.75" (HP / 6.25") 

3 - 3.75" (HP / 7.25") 

4 - 4.75" 

5 - 5.50" (HP / 8.25") 

6 - 3.50" (MH / all heights) 

0 - N/A 

1 - 1/8" - 27 NPT 

2 - 1/4" - 18 NPT 

3 - 3/8" - 18 NPT 

4 - 1/2" - 14 NPT 

5 - 3/4" - 14 NPT 

6 - 3/8" - 24 UNF - 2B 

7 - 7/16" - 20 UNF - 2B 

8 - 1/2" - 20 UNF - 2B 

9 - 9/16" - 18 UNF - 2B 

A - 5/8" - 18 UNF - 2B 

0 - N/A 

1 - Viton® o-ring / 


2 - Ethylene propylene / 


3 - Kalrez o-ring / 


4 - Hydrin o-ring / 


5 - Nitrile o-ring / 


6 - Teflon® o-ring / 


158 - 316 SS 

A12 - C276 

Table 1 

C) Determine Injection Tube Thread size required. Determine the Type. Calculate the Injection 

Tube Length using the sizing formulas. Use this information to determine the Part # from Table 2. 

Model Thread Size Type Alloy Length Designation 

IQ --- ---- X ---- ---- XX ---- ---- XXX ---- ---- XXXX 

1 - 1/8" NPT 

2 - 1/4" NPT 

3 - 1/2" NPT 

4 - 3/4" NPT 

5 - 1" NPT 

01 - Quill 

02 - Open 

03 - NPT for a Nozzle 

04 - Head w/ Cap & Core 

158 - 316 SS 

A12 - C276 

Length in inches, 

stated in 2 decimal 

place format 

(Ex: 6 1/8" = 0612) 

Table 2 

D) A Nipple & Shut-Off Valve to match the Tee of the Access Fitting Body may be selected from Table 3. 


Tee Size 

1/4" 

1/2" 

3/4" 

1" 

Valve 

316 SS 

Part No. 

HA700022158 

HA700023158 

HA700027158 

HA700029158 

Table 3 

Nipple, 4 in (100 mm) 

316 SS Sch. 80 

Part No. 

HA700018158 

HA700019158 

HA700020158 

HA700021158 

E) If applicable, select a suitable Nozzle Type or Cap & Core Assembly from Table 4. 

Nozzle Type / Part Number 

1/4" FNPT Noz. 1/4" MNPT Noz. Cap & Core Assem. (9/16") 

Orifice 

Size 

Expected Flow Rate 

in GPH @ 100 PSI 

PR626213903 

PR626213904 

PR626213906 

PR609713903 

PR609713904 

PR609713906 

.006 

.012 

.016 

.48 

.64 

.96 

PR617613903 

PR617613904 

PR617613906 

Table 4 






Accessories 


Probe Extension Cable Assemblies 

Probe Adapters 

Length Calculation & Accessories (Retractable Probes & Coupon Holders) 


Model SR2159 


The Easy Tool Retracting System is 

designed for the safe insertion or retraction 

of the Metal Samples Corrosion Monitoring 

Systems series 4000 systems, including 

electrical resistance probes (E/R), linear 

polarization probes (LP), coupon insertion 

systems (RT), and chemical injection 

systems (IP). Metal Samples Corrosion 

Monitoring Systems requires that an Easy 

Tool be used when working on systems 

with pressures over 150 psi. 

The Easy Tool can insert/retrieve standard 

electrical resistance probes and coupon 

insertion systems up to 42". 

With a weight of under 15 pounds and a 

overall length of 44", the Easy Tool is one 

of the lightest and shortest retracting tools 

available on the market. 

The Easy Tool can be used with most 

standard packing glands. 

Ordering Part #: 

SR2159ER24 - Insertion length of 24" 

SR2159ER36 - Insertion length of 36" 

Split Shaft 

Upper Plate 

Lower Plate 

Spinner Nut 

Middle Plate 

Swing Arm 






Probe Extension Cable Assemblies 

5-Pin Probe Extension Cable Assembly 

6-Conductor Cable 20#AWG 

2X Telescoping Boot 

5-Pin Male 

Connector 

"L" 

5-Pin Female 

Connector 


where XXX = Length ("L") in feet (Ex: 020 = 20 feet) 

6-Pin Probe Extension Cable Assembly 

6-Conductor Cable 20# AWG 

2X Telescoping Boot 

6-Pin Male Connector 

"L" 

6-Pin Female 

Connector 


where XXX = Length ("L") in feet (Ex: 020 = 20 feet) 






Probe Adapters 

Probe to Instrument Connection 

Adjustable 6-Pin Male to 6-Pin Female (Standard) 

6-Pin Receptacle 

1/2" NPT 

Rod Assembly 

8" 

(Small) 

Blowout Preventer 

(w/Blowout) 

1.25" 

Rubber 

6-Pin 

Adapter 

Adjustable 5-Pin Male to 3-Pin Female (Small w/Blowout) 


1/2" NPT 

Rod Assembly 


8" 

1.25" 

Rubber 

3-Pin 

Adapter 

5-Pin Adapter 

3-Pin Adapter 






Adjustable 5-Pin Male to 6-Pin Female (Small w/Blowout) 


1/2" NPT 

Rod Assembly 


8" 

1.25" 

Rubber 

6-Pin 

Adapter 

Probe Adapter Ordering Information

Length Calculation and Accessories 

for Retractable Probes & Coupon Holders 

2" 

Safety Clamp 

(optional) 

6" 

Safety Chain 

L 

L1 

Nipple 

Bleed Valve 

(optional) 

3.6" 

1" Full Port Valve 

L2 

L3 

Velocity Shield 

Safety Nut 

4.4 L4 

1.25 1 

2 

5.25 

4 

Figure 1. Retractable Probe / Coupon Holder Assembly 

The length of a retractable probe or coupon holder assembly is calculated by adding the required 

lengths of its various accessories. 

Electrical resistance probes, two electrode linear polarization probes, and coupon holder assemblies 

require a 1" (minimum) full port valve and nipple for mounting. Three electrode linear polarization 

probes require a 1½” (minimum) full port valve and nipple for mounting. 

The insertion rod extends 2" above the packing gland when fully inserted. 

A packing gland is used with the probe for insertion or retraction from a system without process 

shutdown. Standard length of the packing gland is 6". 

Note: Installation of a probe with a packing gland requires a certified fitter.

When removed from the process environment, the end of the insertion rod retracts into the 

nipple. This allows the full port valve to be closed. Standard nipple length (L1) is 4", but may vary 

depending on the length of accessories attached to probes or the length and number of coupons 

attached to coupon holder assemblies. 

The bleed valve (optional) is used to release pressure and drain any process fluid/gas that accumulates 

within the nipple after the probe is retracted from the process and the port valve is closed. 

The length from the top of the valve to the process environment (L2) is determined by the customer. 

The portion of the probe or coupon holder assembly that enters the process will vary in length depending 

on the type of element, electrode, or coupon being used. Figure 1 shows some of the 

various types and their lengths. 

A velocity shield may be added to fit over the element at the end of an electrical resistance probe. 

The shield reduces fluid velocity around the element and protects the element from floating debris. If 

a shield (which is longer than the element it covers) is used, the nipple will need to be longer to 

allow for the total retraction of the probe from the process environment. The shield also provides 

protection against accidental blowout. If the safety chain is not hooked in place or if the chain fails, 

the packing gland will catch on the velocity shield preventing blowout. To ensure that this added 

safety feature is provided to customers who do not order shields, Metal Samples provides a safety 

nut with all probes which can be attached to the end of the probes in place of shields. 

A coupon adaptor may be attached to the threads on the end of the safety shield, allowing for the 

addition of coupons. The nipple length would then need to be longer to compensate for the length of 

the added adaptor and coupons. Example: If an adaptor with a coupon extended 2" beyond the 5" 

safety shield to which it was attached, the required nipple length would be 7". Figure 2 shows two 

coupon adaptors attached to safety shields. 

Figure 2. Coupon Adaptors attached to Safety Shields 

A safety chain is provided with every retractable probe to prevent accidental blowout of the insertion 

rod. Optional safety clamps may be ordered to provide additional protection against blowout. 

The clamps are put in place after the probe has been inserted to the required depth. 

A six-pin connector is mounted to the top of electrical resistance and linear polarization probes. 

Coupon holding probes are capped with either a mushroom knob or an Easy Tool adaptor head. 

The Easy Tool is required for probe insertion in systems with pressure over 150 pounds.

Materials Evaluation 


Mechanical Test Specimens 

Test Apparatus 

Reference Assortment Kits 

Electrodes 

Return to Main menu

Mechanical Test Specimens 

Mechanical test specimens are used to evaluate the physical characteristics of materials. Assessing the strength, 

ductility, and hardness of an alloy gives the engineer valuable information in determining the best materials for 

use in industrial applications. Metal Samples machines tensile and fracture mechanics test specimens to ASTM 

specifications or to your requirements. Specimens in a wide variety of sizes and materials are available. 

Flat Tensile Specimens 

Tensile Specimens 

Round Tensile Specimens 

Charpy 

Fracture Mechanics Specimens 

Wedge Open Load 

Compact Tension 

P/N IS2700 

P/N IS2701 

Double Cantilevered Beam 

P/N IS2702 

P/N IS2703

Test Apparatus 

ASTM Engine Coolant Test Apparatus 

P/N TF4000 P/N TF4006 P/N TF4009 

ASTM D1384 corrosion test bundle for 

testing engine coolants in glassware. 

ASTM D2570 simulated service corrosion 

test bundle for testing engine coolants. 

ASTM D2847 method for evaluation of 

engine coolants in actual vehicle service. 

Engine Coolant Testing Parts 

P/N Description P/N Description 

TF4000 D1384 Test Bundle CO1464273504100* Solder Coupon (30/70) 

TF4006 D2570 Test Bundle CO1464270504100 Brass Coupon (CDA260) 

TF4009 D2847 Test Bundle CO1463780504100 Steel Coupon (C1020) 

TF4000A Brass Leg CO337B930504100 Grey Cast Iron Coupon (CL3500) 

TF4000C Insulating Sleeve (TFE) CO3373130504100 Cast Aluminum Coupon (AL319) 

TF4000D Steel Spacer ST1253783 1/16" Insulating Spacer (TFE) 

TF4000E Brass Spacer 09369E1024HN0000 10-24 Brass Nut 

TF4000F 3/16" Insulating Spacer (TFE) 09369E1024PH2000 2" x 10-24 Brass Pan Head Screw 

CO1464190504100 Copper Coupon (CDA110) 09369E1024PH2500 2 1/2" x 10-24 Brass Pan Head Screw 

* Solder Coupon (30/70) is solder coated brass. Please specify if you require pure solder. 

P/N TF2424 (Ford Test) 

P/N TF4005 

AL319 Cast Aluminum Specimen 

with two holes for thermocouple leads 

and a 600 grit finish on one side. Used 

in conjunction with P/N TF2424 in 

heat transfer corrosion testing. Other 

materials are available at your request. 

P/N TF4012 

ASTM G32 Vibratory 

Cavitation Erosion Test 

Buttons. These buttons are 

available in AL319 cast 

aluminum and grey cast 

iron. 

ASTM D4340 Heat Transfer Corrosion 

Assembly for evaluating the effectiveness of 

engine coolants in combating corrosion of 

aluminum casting alloys under heat transfer conditions. 

Available in 120V 60Hz or 240V 50Hz. 

Note: Metal Samples manufactures test apparatus in accordance with 

ASTM standards. Metal Samples does not conduct test procedures 

and therefore does not attempt to address testing considerations. 

Please consult ASTM standards for safety guidelines and additional 

information regarding testing procedures.

ASTM F-3 Test Apparatus 

P/N TF2436 

P/N TF2401 

ASTM F36 Test Cell for compressibility and recovery 

of gasket materials. Fixture shipped partially assembled. 

P/N TF2425 

ASTM F36 Test Cell with Test Panel. This is the 

complete assembly for the ASTM F36 test method. 

Assembly is ready for attachment to pressure supply. 

P/N TF2402 

ASTM F37 (Method A) Test Cell is used to evaluate 

the fluid sealing properties of gasket materials. 

P/N TF2421 

ASTM F37 (Method A) Test Cell with Test Panel. 

This is the complete assembly for the ASTM F37 (A) 

test method. Assembly is ready for attachment to 

pressure supply. 

P/N TF2403 

ASTM F37 (Method B) Test Cell is used to evaluate 

the gas sealability of gasket materials. This test cell 

can also be used for evaluating liquid sealability. 

ASTM F37 (Method B) Test Cell with Test Panel. 

This is the complete assembly for the ASTM F37 (B) 

test method. Assembly is ready for attachment to 

pressure supply.

P/N TF2406 

ASTM F38 Method B Test Apparatus includes 

all equipment necessary for Creep Relaxation testing. 

Yokes for the ASTM F607 Test apparatus are also 

available. 

Included with 

P/N Description 

P/N TF406 

FP5700 Upper Yoke 

FP5701 Lower Yoke 

FP5702 Dial Indicator • 

FP5703 Dowell Pins 

FP5704 Dial Indicator Adapter • 

FP5705 4140 Nut* 

FP5706 4140 Washer* 

FP5707 4140 Bolt* 

FP5708 4140 Platen (2)* • (5 pair) 

FP5713 Mounting Plate • 

FP5714 Custom Wrench • 

FP5760 Preconditioned & Calibrated • (5 sets) 

Bolt, Nut, and Washer* 

* High temperature INCONEL Alloy 718 available. 

ASTM G49 Test Apparatus 

The ASTM G49 test fixture is used to 

evaluate stress on a 1/8" round tensile 

specimen. The fixture is comprised of 

two assemblies, the loading fixture 

(P/N TF5201) and the stress frame 

(P/N TF2430). The stress frame is purchased 

separately. The test specimen is not included. 

P/N TF5201 

P/N TF2430 

Immersion Test Assembly 

The TF2443 immersion test assembly (120V 60Hz) is used to determine the corrosivity of aqueous and nonaqueous 

liquid waste. The asssembly is made in accordance with NACE TM-01-69 and EPA 11-10 of SW846 

specifications. Metal Samples can supply the complete assembly as well as test specimens and replacement 

parts. 

P/N TF2443 

Fluid Sealing Pressure Gasket Assembly 

P/N TF2408 

This flanged, carbon steel, pressure 

gasket test fixture (TF2408) is used 

for evaluating fluid sealing properties. 

The fixture meets the Fluid Sealing 

Association’s FSA-NMG-2040 

specifications. A stainless steel 

version of this fixture is also available.

Reference Assortment Kits 

Reference Kit No. KR5100 

Metal Samples has selected some commonly used 

metals for non-destructive testing. Reference 

Assortment Kits can be very useful in performing 

the Chemical Spot Test. This test method is based on 

electrographic extraction of metal atoms from 

a surface and can be verified by testing on a known 

alloy. An additional use of these kits is to check the 

element content of an alloy by examining the color 

intensity of a chemical spot in comparison to a 

standard. The reagent chemicals can be tested on a 

metal standard to ensure the shelf life of the chemical 

has not been exceeded. 

Another non-destructive evaluation that utilizes metal 

standards is the Thermoelectric Alloy Separators 

Test. This test measures the “EMF” generated by a 

heat junction of dissimilar metals. The magnitude of 

the “EMF” is a function of the metal’s chemistry and 

physical characteristics. 

Reference Kit No. KR5100 contains 44 different 

alloys and Reference Kit No. KR5101 contains 54 

different alloys. Additional slots are provided with 

the kit to expand the selection of alloys to meet your 

specific requirements. The chemical analysis of each 

alloy in the kit has been tabulated from mill test 

reports and certified chemical analyses. These test 

results are recorded on an analysis sheet that accompanies 

the assortment. Alloy specimen sizes can be 

either 1" x 2" x 1/16" or 1" x 2" x 1/8". 

Contents: 

Al1100 800H 321 

Al2024 825 347 

Al3003 400 410 

Al5052 20Cb3 416 

Al5086 G3 420 

Al6061 HC-276 430 

CDA 110 HB-3 440C 

CDA 260 Haynes 25 Ti Gr 2 

CDA 360 17-4PH F255 

CDA 464 303 C1010 

CDA 510 304 C4140 

CDA 706 304L C4340 

CDA 715 316 Mg 

600 316L Zinc 

625 317L 

Reference Kit No. KR5101 

Contents: 

Al1100 800H 317L 

Al2024 825 321 

Al3003 400 347 

Al5086 20Cb3 410 

Al6061 G3 430 

Al7075 HC-276 904L 

CDA 110 HB-3 F255 

CDA 122 HX Ti Gr 2 

CDA 260 Haynes 25 Ti Gr 7 

CDA 360 Al-6X Ti Gr 12 

CDA 443 E26-1 C1010 

CDA 464 Al29-4C C1020 

CDA 706 304 1 1/4Cr 1/2Mo 

CDA 715 304L 2 1/4Cr 1Mo 

200 309 5Cr 1/2Mo 

600 310 9Cr 1Mo 

625 316 C4140 

X750 316L C4340

Electrodes 

Metal Samples provides electrodes compatible with our 

various probes and instruments, as well as those of most 

other major manufacturers. Other electrodes not shown 

here are also available. Electrodes are made from a variety 

of materials (see Alloys list). 

P/N EL400 


1.250 

O .188 

P/N EL405 

Lapped Surface 

8-10 RMS 

one side only 

R .094 

4-40 UNC-2B Threads 

Surface Finish: Approx. 8 - 16 RMS Surface area: .736 in 2 

P/N EL410 

3-48 Tap 

P/N EL412 

1/16” 

O 5/8” 

or 1/8” 



L 

(± .005) 

O ± .005 

Tap 5-40 NC 2B 

1/2” 

O 3/8” 

Centerless Grind O.D. Surface area: .700 in 2 


Gaskets Commonly used with Electro-Chemical Apparatus 

P/N MI2616 

Teflon ® gasket for use with EG&G 

O 5/8” disc holder 

P/N MI2604 

Teflon ® compression spacer for electrochemical 


P/N MI2605 

Teflon ® compression gasket for electrochemical 


O 1/8” thru 

1/4” 

O 1/8” thru 

3/4” 

1/4” 

O 3/8” 

O 3/8” 

1/4” 

O 3/16”

Precision Machining 

Precision Machining Services 

Complete List of Capabilities 

Photo Tour of Our Company 

Return to Main menu

Precision Machining Services 

Metal Samples uses a wide variety of CNC 

and conventional machining equipment to 

offer you a one stop source for all of your 

manufacturing needs. 

We have gained extensive experience in 

machining materials of all kinds, including 

exotic and difficult alloys such as Titanium, 

Nickel, Zirconium, Uranium, Molybdenum, 

and Rhenium. 

Our machining services include: 

• Laser cutting and welding 

• Press brake services 

• EDM services 

• CNC milling, Lathing 

• Punching, Forming 

• Laser cladding 

• CNC screw machining 

• Tube cutting and bending 

• Waterjet cutting 

• Precision plasma cutting 

• Robotic welding 

• Grinding, Drilling 

• Powder coating 

• Electropolishing 

• Heat-treating, Anodizing 

• Prototype fabrication 

Screw Machining Services 

Our CNC Swiss-type screw machines 

allow turning of long length to diameter 

ratios. These bar-fed machines allow 

complete automatic manufacturing of 

turned components with multiple features 

in a single operation, eliminating the need 

for many secondary operations. 

Capabilities include milling, slotting, cross drilling and tapping, knurling, 

and threading. 

Milling Services 

Our vertical 4-axis CNC milling centers, coupled with a Pro-Engineer 

offline programming system, are able to machine with ball end tooling, 

using four axes simultaneously to produce very complex contours in 

a variety of materials. These machines are also capable of performing 

standard milling functions such as drilling, tapping, slotting, etc. 

EDM Services 

Our electrical discharge machining (EDM) department features the latest in technologically 

advanced equipment, including auto threading, 4-axis cutting, submerged 

machining, anti-electrolysis power supply, and small wire capabilities. Our sinker 

machines can EDM parts spherically and helically 

at the same time. 

These machines are used to hold exceptionally 

tight tolerances on exotic and other difficult-tomachine 

materials. They can cut material thicknesses 

up to 20 inches and produce finishes of 

12-15 RMS on steel and 8-9 RMS on carbide.

Laser Cladding - Cutting - Welding - Marking 

Through our sister company, Alabama Laser, we offer a full range of laser 

cladding, cutting, welding, marking/etching, and heat treating services. 

Laser cladding is emerging as a strategic technique for repairing damaged 

components and improving surface protection properties for better wear or 

corrosion resistance. 

For more information on our laser services, visit www.alabamalaser.com. 

Grinding Services 

We provide complete precision grinding services with a variety of surface 

conditions, ranging from mill finishes to mirror-like finishes of 1 to 2 RMS. 

Capabilities include surface, double-disc vertical and horizontal, centerless, 

and thread grinding. Forms and profiles in single-run or large quantity orders 

can be ground cost effectively. 

Punching & Press Brake Services 

Our punch press department houses several machines, 

including automated CNC presses with sheet loaders. 

Our press brakes enable accurate bending and forming 

on materials. One of our press brakes is a robotic 

system that allows for greater repeatability than could 

be obtained with a conventional hand-fed machine. 

Robotic & Conventional Welding Services 

Our welding department uses robotic welding systems which provide precise gas 

metal arc welds (GMAW) in repetitive motion applications. These systems are 

ideal for the automated run of repeat, large quantity parts. 

We also have conventional welding stations (MIG & TIG) with a skilled team of 

welders dedicated to meet your welding needs. 

Material Inventory 

Metal Samples stocks the largest 

variety of materials in the world. 

Exotic and conventional alloys 

are stocked in a number of forms, 

including bar, pipe, plate, rod, sheet, 

wire, and castings. Storing these 

materials in-house helps us expedite 

customer orders more effectively.

Machining 

Capabilities 

Laser Services 

30 laser systems including: 

CO2 lasers -- Nd:YAG lasers -- Fiber lasers -- Direct diode lasers -- Fiber-delivered, direct diode lasers 

• Laser Sheet Cutting -- 10 systems - sheets up to 6’ x 11’ - cut up to 3/4” on CS, 3/8” on SS & aluminum 

• 5-Axis Laser -- 3-D capabilities 

• Laser Tube Cutting -- 3 systems -- 14” diameter on round tubing, 12” side diameter on square tubing 

• Laser Welding 

• Laser Cladding / Metal Deposition 

• Laser Etching / Marking 

• Laser Heat Treating / Hardening 

Services — Systems — Research — Process Development 

Electronic Discharge Machining (EDM) 

• Wire EDM - 5 machines 

• RAM/Sinker EDM - 2 machines 

Tolerances: ± .0002 (wire EDM) -- Up to 20” thickness -- Intricate shapes and sizes 

Press Brakes / Metal Folders 

• Press Brakes - 6 machines (capacity up to 240 tons and lengths up to 14 feet) 

• Robotic Press Brake - parts formed completely automated 

• Metal Folders - 3 systems 

Tube Machining Capabilities 

• Tube Cutting 

• Tube Swaging 

• Tube Bending 

• Tube Polishing 

Welding - Robotic & Conventional 

• Robotic Welding - 4 systems 

• Multiple Conventional Welding Stations (MIG & TIG) 

Water Jet / Precision Plasma Cutting System 

• Water Jet Cutting - thicknesses up to 6” 

• Precision Plasma Cutting - thicknesses up to 3” 

(Handles material up to 6’ wide by 12’ long)

Punch Presses 

• CNC Punch Presses - punch up to 5/16” on mild steels (4 systems) 

• Automated Punch Press 

• Laserpress - Laser & Punch Press Combination 

• Automatic Sheet Loading Tower - automated material handling for punch presses 

CNC Milling 

Horizontal & Vertical Mills 

• 4-Axis CNC Mills - 7 machines -- including 30” horizontal milling center 

• 3-Axis CNC Mills - 5 machines 

CNC Lathes 

• 10 CNC Lathes 

• Additional manual lathes 

CNC Screw Machines 

• Swiss Screw Machines - 4 machines with automatic bar feeders 

Grinding 

• Disc Grinders 

• Surface Grinders 

• Thread Grinders 

Hones - Drills - Saws 

• Honing Machines 

• Gundrilling Machine 

• Spindle Drills 

• Cylindrical Grinders 

• Centerless Grinders 

• Vertical & Horizontal Band Saws 

• High-Speed Abrasive Band Saw 

• Automatic Downfeed Cold Saws 

Powder Coating / Painting 

• Powder Coating Line - automated transfer line thru washing booth, spray booth, and drying chamber 

• Painting Booths - multiple booths, including large automotive-style booth 

Finishing Machines 

• Vibro Deburr Systems 

• Flat Deburring Machines -- wide-belt -- can also be used to put polish or grain finishes on material 

• Blast Finishing Tumbler

Other Miscellaneous 

• Parts Straightener 

• Multi-Center for Stamping/Forming 

• Shearing 

• Stenciling 

Engineering / Design / Research 

• Engineering Staff (Metallurgical, Electrical, Mechanical, Aeronautical) 

• CAD / Design Department 

• Metallurgical Laboratory -- failure analysis, micro structural analysis and hardness measurement 

Metallurgical Microscope, Micro Hardness Testing Machine 

• Research Labs 

Quality Assurance Inspection Equipment 

• Zeiss Precision Inspection Systems 

• Nikon Vision System (54 to 250X mag power) 

• Portable Coordinate Measuring Arm 

• Fabrivision - flat dimensional inspection 

- reverse engineering capabilities 

• CNC 3-axis Coordinate Measurement Machine 

• “Pocket-Surf” Profilometers 

• Optical Comparator - CNC 30" 

• Bore Gages 

• Micrometers, surface plates, etc. 

Alabama Specialty Products, Inc. 

152 Metal Samples Rd., Munford, AL 36268 

Phone: (256) 358-4202 Fax: (256) 358-4515 

E-mail: msc@alspi.com Internet: www.alspi.com 

ISO9001:2008 • HUBZone • Service Disabled Veteran Owned Small Business

One of our Machining Facilities 

Return to Menu 

Next

Screw Machining Services 

Back 

Next

Parts machined on Screw Machine 

Back 

Next

EDM Services 

Back 

Next

Milling Services 

Back 

Next

Milling Services (continued) 

Back 

Next

Grinding Services 

Back 

Next

Punch Press Services 

Back 

Next

Press Brake Services (Robotic & Manual ) 

Back 

Next

Automated Production Tooling Center 

(for production stamping, forming, welding, and assembly) 

Back 

Next

Parts made on Automated Production Center 

Back 

Next

Conventional Welding Services 

Back 

Next

Robotic Welding Services 

Back 

Next

Water Jet & Precision Plasma Cutting Services 

Back 

Next

Powder Coating / Painting Services 

Back 

Next

Materials Inventory Facility 

Back 

Next

One of our Laser Machining Facilities 

Back 

Next

Laser Cutting Services 

Back 

Next

5-Axis Laser for 3-D cutting & welding 

Back 

Next

Laser Tube Cutting 

Back 

Next

Tube Bending 

Back 

Next

Laser Welding Services 

Back 

Next

Laser Cladding / Metal Deposition 

Back 

Next

Laser Etching / Marking Services 

Back 

Next

Laser Research 

Back 

Next

Quality Assurance (ISO Certified) 

Back 

Main Menu 

See additional services at www.metalsamples.com

New Products & Services 


Remote Corrosion Monitoring Telemetry System 



Laser Cladding Services 

Return to Main menu



New! 


The MS4500E is a hand-held, batterypowered, 

corrosion meter capable of 

measuring and storing data from all 

types of electrical resistance (ER) 

corrosion probes. The instrument is 

light weight, microprocessor-based, 

and features a simple, menu-driven 

interface using a keypad and a backlit 

graphical LCD display. 

Corrosion rate measurements are made 

using the electrical resistance method. 

Essentially, the instrument measures the 

resistance of the probe element which 

changes over time, as metal loss occurs. 

The rate of change is directly proportional 



to corrosion rate. This method finds a wide variety of applications since it can be used in conductive 

and nonconductive environments such as petroleum, chemical, water, soil, or even atmosphere. The new 

high-resolution measurement of the MS4500E detects smaller increments of metal loss, providing faster 

response than traditional ER instruments. 

After taking a reading, the instrument displays metal loss in mils and corrosion rate in mils per year 

(mpy). The reading can then be stored to memory or discarded. All stored readings are automatically 

time and date stamped. Readings are stored to non-volatile Flash memory which retains data without the 

need for a battery backup. 

On-screen charting 

Transfer data directly to USB Flash drive 

The MS4500E can store 16,000 readings per probe on up to 250 different probes (4 million total). Stored 

data can be downloaded to a PC via the USB cable or downloaded directly to a USB Flash (“jump”) 

drive. Data can be opened and charted using the provided CDMS software, or can be imported into any 

standard data analysis (spreadsheet) program such as Microsoft Excel. Data can also be reviewed and 

charted on the instrument’s LCD display for quick reference.

Model 

MS4500E - Handheld ER Corrosion Data Logger 


Physical Data 

Instrument Weight (w/ boot): 

Instrument Weight (w/o boot): 



Instrument Dimensions (w/ boot): 

Instrument Dimensions (w/o boot): 






Range - Standard: 

Range - High: 

Resolution - Standard: 

Resolution - High: 

Repeatability: 

1.00 lb. (0.45 kg) 

1.45 lb. (0.66 kg) 

6.70 lb. (3.04 kg) 




-4° to 130°F (-20° to 54°C) 

-4° to 158°F (-20° to 70°C) 

ER measurement using any standard ER probe types 

(Wire Loop, Tube Loop, Cylindrical, Flush, Strip, etc.) 





± 0.1% of Full Scale 



Four AA Batteries 

Maximum Probe Cable Distance: 200 ft (61 m) 

Download Method: 

To PC via USB cable or directly to USB Flash drive 

Intrinsic Safety Certification 

US, CSA, ATEX 


• High resolution ER measurement for rapid response 

• Data storage capacity of 16,000 readings per probe on 250 different probes (4 million total) 

• Backlit graphical LCD display (320 x 240 pixel resolution) 

• On-screen charting 

• Non-volatile Flash memory 

• Multilingual menu (English, Spanish, Portuguese, French) 

• Portable 


Carrying Case, Probe Cable (1' coiled - 6' extended), USB Cable, Meter Prover, Operation Manual, 

Corrosion Data Management Software 








Remote Corrosion Monitoring 

Telemetry System 

Metal Samples’ remote telemetry system obtains 

real-time corrosion monitoring data via the Internet 

from anywhere in the world. The system features 

communications via Inmarsat IsatM2M satellite to a 

secure Web Monitor data server. With this powerful 

web-based back end, you can bring the data to your 

desk no matter where the site is located. 

System Benefits Include: 

• Eliminating costly travel to remote sites 

• Gathering important corrosion data at a low cost 

A small optional solar panel (4.5” x 6”) easily connects 

to the Base Station for use where no power is available. 

Using its internal ‘gel cell’ and charge control circuit, the 

unit functions in the ‘Monitor & Sleep’ mode. 

Remote corrosion monitoring 

telemetry system with solar panel 

Once the telemetry system is in place, just log in to the provided website to view your data. 

Above: Sample data as viewed on the Internet from a corrosion probe connected to the telemetry system.

Graphs of corrosion data can be viewed from 

the web site or can be copied into Excel for 

more detailed analysis. 


Base Station 

Power: 

Enclosure: 

115 / 230 VAC, 50-60 Hz or 8 - 30 volts DC or AC for ‘Always On’ Operation 

Optional 4.5” x 6” solar panel for autonomous ‘Monitor and Sleep’ Operation 

NEMA 4X case 

System Operating Environment 

Temperature: -20° to +70° C 

Humidity: 0 - 100% non-condensing 

System Features 

• Configurable from the website - no laptop necessary in the field 

• Worldwide communications 

• Easy-to-use web interface 

• Low monthly messaging costs 

Communications Via 

Skyware Inmarset ISatM2M 

Available Configurations 

Electrical Resistance Corrosion Monitor (single channel) 

Linear Polarization Resistance Corrosion Monitor (single channel) 

Sand (Erosion) Probe (4-channel) 

Call for special applications or configurations. 


























12 to 35 VDC 


600' to 1000' 3.09inUsing 


Wireless 

Receiver 



Output to 

DCS/SCADA 

12-30VDC 

Supply 

Probe 
































Input: 



Output: 

Resolution: 

Mounting: 

POWER SUPPLY 

Voltage: 

Current: 

SIGNAL 

Input: 

Voltage: 


One probe 

10,000 feet 



+/- 0.1 mpy or 0.01 mil 


100 - 240 V AC, 1 phase, 50/60 Hz 

< 2 Amps 


24V DC 

250 Ohms 



Weight: 

Size: 

Panel cutout: 

4 lbs. (1.9 kg) 

8.25” x 10” x 6” (20.95 cm x 25.40 cm x 15.24 cm) 

8.25” x 10” (20.95 cm x 25.40 cm) 

NETWORK 








Metal Samples (in association with our sister company 

Alabama Laser) provides laser cladding services, systems, 

and process development using lasers to deposit a layer of 

material onto a substrate. 

This process enhances the properties of a surface and, with 

the right material choice, provides good wear and corrosion 

resistance. 

• Services 

• Process Development 

Laser cladding produces minimal dilution and a small heat affected zone when compared to conventional welding. 

Unlike a thermal spray process where the bond is mechanical, laser cladding provides a metallurgical bond between the 

base material and the substrate. 

Materials that we Clad include: 

Stainless Steel 

IN625 

Tool Steel 

Stellite® 

Nickel based super alloys 

Tungsten Carbide 

Cladding/metal deposition is emerging as a strategic technique for repairing 

damaged components and improving the properties of base materials for surface 

protection.

Laser Cladding Services 

Hot Wire Laser Cladding 

Hot Wire Laser Cladding combines a 

solid-state laser with a wire heated by 

a gas metal arc welding power source. 

After grinding 

Before grinding 

Cylinder clad with Tungsten Carbide 

Our track systems allows us to clad cylinders more than 

60 ft. long. Cylinders with diameters from 1" up to 48" 

can be clad. 

Visit www.alabamlaser.com for our laser cladding articles in: 

• LIA Today (Laser Institute of America) - Dec. 2006 

• Welding Journal - Feb. 2008 

• The Fabricator - Feb. 2010 

Alabama Laser 

55 Laser Blvd. • P.O. Box 55 Munford, AL 36268 

Phone: (256) 358-9055 Fax (256) 358-4515 

E-Mail: als@alspi.com Web: www.alabamalaser.com

Metal Samples catalog

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?