Coupon Holder for Corrosion Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for measuring corrosion, erosion, and material build-up in processing equipment are disruptive, inaccurate, and prone to errors due to the need for equipment shutdown, destructive testing, and potential chemical reactions, especially when using coupons that can be damaged or incorrectly placed.
Innovation Solution
A device with a coupon that can be selectively inserted and removed through an opening in the equipment, featuring a fluid contacting surface flush with the equipment's interior and a fastener outside the equipment, minimizing fluid dynamics impact, and using ultrasonic transducers for precise measurements, ensuring accurate and repeatable data collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a coupon is placed directly into the path of fluid flow for testing, then the coupon can be easily positioned and removed, but the measurement accuracy is compromised due to altered fluid dynamics and exaggerated wear rates
Solution Approach 1:
The patent introduces a coupon holder as an intermediary device that positions the coupon in a recess within the piping system. This holder acts as a mediator between the coupon and the fluid flow, allowing the coupon to be easily installed and removed while maintaining accurate representation of actual wear conditions by preventing direct interference with fluid dynamics
Solution Approach 2:
The coupon is nested within a recess in the piping system, with the coupon holder providing a nested structure that accommodates the coupon. This nesting arrangement allows the coupon to be positioned without protruding into the fluid flow path, thereby maintaining measurement accuracy while enabling easy operation
2Ease of operation
If the coupon is removed from the equipment for inspection, then the coupon can be examined without interfering with equipment operation, but the coupon is exposed to air and temperature changes that affect measurement accuracy
Solution Approach 1:
The patent provides preliminary protection by designing the coupon holder with a sealed environment that maintains the coupon's exposure conditions until inspection is required. The coupon can be removed and inspected without prolonged exposure to air and temperature changes, as the holder design minimizes the time and extent of exposure during removal and inspection processes
3Measurement precision
If equipment is shut down for visual inspection or thickness measurement, then accurate measurements can be obtained, but manufacturing productivity is reduced due to process disruption
Solution Approach 1:
The patent implements self-service measurement capabilities by equipping the coupon holder with integrated sensors and measurement devices. The coupon holder can perform thickness measurements and material loss assessments autonomously while the equipment remains operational, eliminating the need for shutdowns and maintaining manufacturing productivity
Solution Approach 2:
The patent enables continuous measurement and monitoring capabilities through the coupon holder design that allows inspections to be performed without interrupting the fluid flow or equipment operation. This maintains continuous useful action in both manufacturing processes and measurement activities
4Reliability
If a coupon is used to measure material deterioration, then corrosion and erosion can be detected, but the coupon may be damaged by unintended removal of material such as scale, oxides, or coatings
Solution Approach 1:
The patent applies local quality by designing the coupon with differentiated surface treatments or material compositions in specific zones. The coupon holder positions the coupon to expose only specific areas to the fluid flow, allowing selective measurement of corrosion and erosion while protecting other areas from unintended material removal
Solution Approach 2:
The coupon holder serves as an intermediary that protects the coupon from unintended damage during installation and removal operations. The holder design includes protective features that prevent mechanical damage to the coupon and its surface coatings, ensuring that only the intended corrosion and erosion effects are measured
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device provides accurate and precise measurements of material deterioration, reducing the risk of equipment failure and processing disruptions while minimizing exposure to air and temperature changes, allowing for faster and more reliable data collection.
Implementation Method 1
The concurrent enhancements in accuracy, precision, and in a reliably repeating coupon placement location can also yield faster measurements of high fidelity data resulting in lower risk of catastrophic loss of equipment integrity
Data Source
AI summary
A device for improving the accuracy and precision of measuring equipment changes due to corrosion, erosion, build-up of material, and combinations thereof. Increased control over the placement and removal of a coupon within the equipment is provided. Embodiments of the coupon provide multiple approaches for such measurements such as e.g., weight changes, thickness changes, inspection and analysis of the contacting surface of the coupon, and combination. Improved measurements with coupons using probes such as e.g., ultrasonic transducers is also described.