The Rouge Monitor provides accurate measurement of ultra-low corrosion (rouging) rates in pharmaceutical water systems. The Rouge Monitor is ideal for Biotechnology, Pharmaceutical, and other industries where monitoring corrosion in metallic piping is critical. Rouge can build up on internal surfaces of hot water and steam metallic piping systems, storage tanks, distribution systems, process vessels, and can be found on non-metallic surfaces including membranes, filters, and tubing. Particulate matter and sloughage from the build-up must be avoided to prevent contamination of downstream products. Monitoring the rouging (corrosion) rate of typical ions of ferric oxide, chromium oxide, and nickel oxides in the water assists the determination of derouging and passivation frequency. Typically, derouging and passivation frequency is subjectively determined by periodic inspection of the piping or a definitive time increment, without regard to rouge rate or rouge deposition thickness. The installation and use of a Rouge Monitor unit presents a scientific approach to derouging and passivation frequency with absolute measurements for rouge rate and rouge accumulation (thickness). Derouging and passivation frequency can be based on data rather than subjective opinions and prophylactic approaches. Read More...

Rouging is a description of corrosion deposits found in stainless steel systems. Rouge can vary in color from a light-red or orange color to a dark brick color. Dark purple or black colors are normally found in steam systems with varying colors due to hotter temperatures. Most often the light-red composite material of the deposits is primarily iron hydrated oxides. However, components of rouge can also include chromium, nickel, and molybdenum oxides. Tverberg and Ledden have identified three classes of rouge.

  • Class I Rouge — is deposited corrosion product, consisting of Iron oxides and hydroxides originating elsewhere in the system and deposited downstream. The underlying stainless steel surface beneath such deposits usually remains unaltered. This rouge deposit can usually be easily wiped away.
  • Class II Rouge — is an adherent corrosion product originating in-situ on unpassivated or improperly passivated stainless steel surfaces. By its formation the normally passive protective film on the stainless steel surface is altered.
  • Class III Rouge — is a blue or black, mostly Iron oxide corrosion product, commonly called magnetite which forms on surfaces in high temperature steam systems. On electropolished surfaces corrosion deposit may be glossy black, stable and adherent. On unpassivated mechanically polished surfaces the corrosion deposit may be powdery black, and may slough off.

Non-adherent rouge corrosion products may deposit in numerous locations in a high purity water system and are not limited to only stainless steel surfaces. Non-metallic surfaces of Teflon, ETFE, PTFE, and other derivatives seem to attract migrant rouge particulates. Some, non-metallic surfaces have an affinity for rouge deposition which may be due to physical electrostatic properties.

Rouge Monitor Technical Data Sheet

The Rouge Monitor comprises of three pieces; a probe that is inserted into the ultra-pure process stream, a local electrochemical transmitter, and a remote display, control and data-logging unit.

The probe has two stainless steel electrodes glass sealed into a stainless steel probe body and welded to a sanitary flange to allow mounting into the ultra-pure water system. The local transmitter is either mounted directly to the probe with a connecting adapter or connected with a short cable to the probe and mounted separately from the probe. The remote display control and data-logging unit can be mounted up to 4000 feet from the local transmitter.

Included with the Rouge Monitoring system is a calibration verification probe. The calibration verification probe is an electronic instrument which provides a known nm/month rouge rate. This probe is connected directly to the transmitter. Thus the probe assembly does not need to be deinstalled from the piping. A simple disconnect from the transmitter allows the entire probe assembly to remain installed. The calibration verification probe ensures the electrical signals and data interpretation of the probes current potential values are operational and within specification. The calibration verification probes performs similarly to a calibration verification probe of a conductivity meter.

To ensure that every Rouge Monitoring system is installed and operating correctly, RCS provides an IQ/OQ (installation Qualification/Operation Qualification) document with every system. An IQ/OQ (installation Qualification/Operation Qualification) document is formulated to commission and operate any piece of equipment in a GMP system. The document is structured to be individually customized and applicable to any site. The IQ/OQ documentation offers a step-by-step guidance in the commissioning and usage of a Rouge Monitoring system.

  • Hot Water Systems
  • High Temperature WFI Systems SS and Metallic Storage Tanks
  • SS and Metallic Equipment and Accessories
  • High Temperature Clean-in-Place systems
  • On-line determination of rouge deposition, rouge thickness without sampling, labor and laboratory testing is inexpensive, dynamic, and integrateble to existing computer and networking schemes.
  • Passivation and repassivation frequencies based on science and need. Not QC queasiness.
  • Rouge Monitoring Units are inexpensive: saving one passivation annually will pay for the unit many times over.
  • Cost savings: Tens of Thousands to Hundreds of Thousands of dollars per year per site.
  • Installation of units is based on number of loops with risk-based management and assessments.

The following documents are available for your reference. If you require any further product information, please Contact Us.

Rouge in Pharmaceutical and Water and Steam Systems

Rouge Monitor User Manual

The Rouge Monitor system consists of a highly-sensitive front end probe/transmitter assembly, a remote data display/controller, data logger, analog output, and a serial communication port for computer data uploads. The remote display unit provides both on screen and analog outputs of rouging rate in microns/month and rouge accumulation in microns. Measurement ranges from 0.001 - 10 µ. The unit can be easily configured for connection to a SCADA, BMS, data highway, or process control system. The data logger allows independent accumulation of all readings and measurement for direct transfer to a computer at the user's discretion. The display unit/controller provides power to the transmitter/probe assembly.