Electrical Resistance (ER)

General Information

INTRODUCTION ADVANTAGES
One of the most common electronic methods of Caproco ER probes allow readings to be taken at
monitoring corrosion is using the electrical resistance any time with external connections to a Caproco ER
technique. This technique involves measuring the Instrument or Data Logger, thereby eliminating the
change in electrical resistance of a conducting need to remove the probe from the line or interrupt
element, and using this rate of change to calculate operations. Continuous monitoring in a control room
the corrosion rate. ER monitoring has been used in can be achieved via hardwiring or remote telemetry,
industry applications for over forty years and is a thereby providing instantaneous feedback on process
proven on-line measurement technique in wet and dry changes.
conditions.
ER probes are the most flexible of the electronic
ELECTRICAL RESISTANCE THEORY probes in terms of their possible applications.
Because the technique is not dependant on an
Electrical Resistance probes operate on a
electrochemical reaction, a current-carrying
straightforward concept. As a conductive metal
electrolyte is not necessary. ER monitoring can be
element is exposed to a corrosive environment, its
used to measure virtually all environments, such as
surface area will be reduced, thereby lowering its
solids, non-aqueous liquids, gases and vapors; all of
conductivity and increasing its electrical resistance.
which can be of high or low conductivity.
Readings from the sensing element are relative to a
non-corroding reference element sealed within the By complementing probe readings with corrosion
body of the probe. Small changes in resistance can coupons exposed over the same time interval, the two
be detected by a sensitive measuring instrument. measurement techniques will verify the quantitative
results. ER probes can rapidly indicate changes in
The electrical resistance of any conductor is given by:
corrosion rates, and will show when the changes took
place, which is helpful in evaluating process
ρL decisions.
R=
A PROBE TYPES
Caproco produces a variety of ER probes, each of
Where ρ = Resistivity which have different characteristics and applications.
L = Element length The lifespan of all probes is inversely proportional to
A = Cross sectional area of the element their sensitivity. A probe becomes more sensitive as
the element thickness is reduced, and therefore the
A separate reference element allows testing of the time interval in which it can measure a change in
internal integrity of the probe. Through careful resistance is decreased, providing faster response.
design, the reference element also serves in However in a highly corrosive environment, a thinner
eliminating thermal variations. Since temperature element will degrade faster, thereby reducing the life
variations can have an effect on resistance, the of the probe. A clear understanding of the
reference element is subjected to the same environment being monitored and the urgency in
temperature as the exposed element, which ensures which information is needed will help in selecting a
consistent measurements. probe that will optimize the lifespan/response time
Probe elements are made of a material similar to decision. Consult the selection guide on the following
that of the pipe or vessel in which it is placed, in order page for information on different element types.
to simulate as closely as possible the corrosive Caproco ER probes come in three main designs:
environment. By taking periodic readings over a fixed Retrievable, Retractable and Fixed.
time interval, the rate of metal removal can be
determined and a corrosion rate in mils/year can be
calculated.
Retrievable Fixed
Retrievable probes can operate in systems Fixed probes are usually mounted on line through
pressurized up to 6,000 psi. The probe is mounted on flanged or NPT bullplug-style bodies. The actual
a hollow plug, through a high pressure access fitting. probe body maintains line pressure, so they cannot
By using a Caproco retriever and service valve, the be removed until the system is shut down, however
probe can be changed / inspected with no interruption readings can be taken at any time without system
to the system. Readings can be taken any time by interruption. Certain models are rated for operating
connecting a data logger or probe signal transmitter pressures up to 10,000 psi. Fixed probes provide an
to the probe's standard 6 pin electrical connector. economical and easy-to-use option for electronic
monitoring.
Retractable
Instrument
Retractable probes are intended for lower
pressure systems, and are rated up to 1,500 psi. The A critical component to measuring corrosion rates
probe is inserted through a low pressure access electronically is the instrument used to interpret the
fitting, and is held in place by a safety clamp. It can data. Caproco has designed a high quality,
be removed under pressure either manually or by field-proven ER Analyzer instrument that can take an
using a Caproco Sidewinder Retractor, and readings instantaneous corrosion rate measurement, or act as
can be taken at any time with no system interruption. a data logger, storing information for later analysis.

CAPROCO ER PROBE SELECTION GUIDE

Probe Most Suitable Less Suitable Element Element

-Areas of low
Most -Greatest sensitivity
corrosion
Sensitive -Wide selection of -Fluids which attack
-Situations that call 4 mil TL4
Loop element materials Tube Loop glass and ceramics
for rapid detection 8 mil TL8
-Glass sealed (e.g. Fluorides)
of changes in
element
corrosion rate

-Second most
sensitive -Locations
-Areas of general 40 mil W40
-Element constructed Wire Loop susceptible to pitting
corrosion 80 mil W80
of single length of or heavy deposits
solid wire

-Measuring
-Not affected by edge conditions at wall -Extremely high
10 mil F10
Flush corrosion or high Flush surface temperature
20 mil F20
velocity -Locations that locations
require pigging

-Specialized
-Not affected by edge -Extremely high 8 mil S8
underground,
corrosion or high Flush Strip temperature 20 mil S20
concrete and
velocity locations 40 mil S40
underwater probes

-Highly corrosive
environments
-Most rugged element
prone to deposit
design
buildups, pitting
-High integrity seal 10 mil T10
Most -Situations that -Suitable for virtually
Cylindrical -Element welded Tubular 20 mil T20
Robust require more exotic all applications
directly to probe body 50 mil T50
alloys
-Less susceptible to
-High temperature
bridging
or high velocity
settings