Polatrak DEEP C METER 3000 User manual

CORROSION TESTING PROBE
Deepwater Corrosion Services Inc.
polatrak.com | [phone] |Email: [email protected]
©2016 Deepwater Corrosion Services Inc. Specications subject to change without notice
DEEP C METER 3000™
ROV-MOUNTED CP PROBE
OPERATION MANUAL
ROV-interfaced
cathodic protection
monitoring system
Rated for
depths up to
3,000 meters
Powered by
two nine-volt
batteries

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2SMB-006 Deep C Meter 3000 Manual Rev. 1
DEEP-C METER™ MANUAL
Table of contents
1 Overview 3
2 Documentation 4
3 Health and safety 4
4 Voltage readout unit components 4
4.1. Pressure housing 4
4.2. Articulated mount 5
5 Probe unit components 6
5.1. Main body 6
5.2. Nose cone 6
5.3. Main body section 6
5.4. Tail unit 7
5.5. Reference electrode element 7
5.6. ROV II probe T-handle mount 7
5.7. Flying lead 7
6 Spare parts and accessories 8
7 Calibration 8
7.1. Bucket calibration procedure 8
7.2. Underwater online calibration 9
8 Operation 9
9 Mounting on ROV 9
10 Taking CP potential readings 10
11 Data interpretation 11
12 Maintenance and repair 12
12.1. Overview 12
11.2. Tip replacement 12
11.3. Electrode element replacement 12
11.4. Battery replacement 13
12.0 Troubleshooting 15
12.1. General 15

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List of gures
Figure 1 - Voltmeter module 5
Figure 2 - Meter mount 6
Figure 3 - Exploded view of ROV II probe 7
Figure 4 - ROV-II probe 7
Figure 5 - Seacon RMG-3FS wiring diagram 12
List of tables
Table 1 - Normal cathodic protection ranges
for bare carbon steel in seawater 10
Table 2 - Troubleshooting quick guide 14
Table 3 - List of spare parts 15
1. Overview
The Deep-C-Meter 3000 is a complete ROV-interfaced cathodic
protection monitoring system. The system has three basic parts:
The readout unit, which is twin voltmeters housed in a stainless steel
pressure housing; The probe, a twin element, tip-contact CP probe
 (Polatrak®modelROV-II™)andtheyinglead,athree-meter-long
umbilical that connects the probe to the readout.
Flying lead
Voltage
readout
unit
ROV-II
contact
probe
Meter
mount
ROV-II probe
T-handle
mount
Figure 1: Deep C Meter 3000 components

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2. Documentation
2.1. The following documents are contained in the appendix:
2.1.1. ROV II operations manual
2.1.2. Parker Seals - Parker O Lube MSDS – O-Ring Lubricant
2.1.3. Dow Corning – 4 electrical insulating compound MSDS
connector sealant
PLEASE CONTACT YOUR DEEPWATER REPRESENTATIVE FOR
ANY QUESTIONS OR ISSUES REGARDING THIS MANUAL.
3Health and safety
It is the intention of Deepwater Corrosion that all test and inspection
procedures are carried out in a safe manner in accordance with the
Health and Safety At Work Act and any other relevant legislation. If
required by the client, Deepwater personnel will attend any site safety
induction courses before carrying out work on site.
4Voltage readout unit
components
The readout unit has two
major sub-assemblies: The
pressure housing and the
probe unit.
4.1 Pressure housing
4.1.1. Housing body - The
pressure housing is
made from a solid piece of 316 stainless
steel and is rated for 3,000 meters (10,000 feet) depth.
4.1.2. Lens - One end of the housing contains an acrylic
lens that seals with o-rings into the pressure housing. Four
stainless-steel screws keep the lens seated in the pressure
housing. Access to the inside of the pressure housing is
gained by pulling the lens. See maintenance and repair
Figure 2:
Deep C
Meter 3000
pressure
housing

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section for details on lens removal/replacement.
4.1.3. Bulkhead connector - The back end of the pressure housing is
sealed with a bulkhead connector. This connector threads into
the back of the pressure housing and also seals with an o-ring.
It should not be
necessary to
remove this
connector
during normal
maintenance.
A blank (dummy)
connector is
provided and
should be in place
whenever the
mating connector is removed.
4.1.4. Voltmeter module - The voltmeter module is located within the
pressure housing. The voltmeter module contains two
independent 3 ½ -digit LED voltmeters. Default factory range
is +/- 1999 mV DC on both
readouts. A 9V alkaline battery
powers each of the readouts.
On the face of the module is a
photocell that switches each
measurement circuit on when
exposed to light from the ROV.
4.2. Articulated mount
4.2.1. The articulated mount is
designed to secure the readout
to the ROV frame, and provides
angled adjustment to optimize
camera viewing of the displays.
The mount and all attaching
hardware is made of
316 stainless steel.
Figure 3: Volt-
meter module
showing battery
placement
Figure 4:
Articulated
meter mount

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5.0 Probe unit components
5.1. Main body
5.1.1. The Deep-C-Meter 3000 utilizes the popular Polatrak
ROV-II tip contact probe. This probe can be used
independently of the readout unit as a standard topside-wired
CP probe. For reference, the entire manual for this probe
is included herein or can be found separately under document
number 354-MN01-ENG.
5.1.2. The probe unit includes the nose cone that houses the contact
tip, the main body section, the tail unit (which houses the
reference electrode female plugs and the connection cable
with strain relief, the reference electrode elements, the
compliant tee handle mount for manipulator mounting and the
  yingleadconnectionbacktothereadoutunit.
5.2. Nose cone
5.2.1. The nose cone assembly is screwed into the main body
section. The cone houses the replaceable contact tip and
also has the female connector that attaches to the male pin
on the extension cable from the tail unit. Tips are made from
stainless steel plated with nickel; the nose cone is fabricated
from a rugged thermoplastic.
5.3. Main body section
5.3.1. The body section, made from a rugged thermoplastic,
protects the reference electrode elements and is designed to
  tthecompliantteehandlemountfor
convenient manipulator
mounting.
Figure 5:
ROV-II on
T-handle
mount

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  holesinthesideallowthebodytobecomefree-oodingand
  werespecicallyengineeredtoallowforaccuratepotential
measurements.
CAUTION
Do not cover or modify these or add additional holes in the body.
5.4. Tail unit
5.4.1. The tail unit attaches to the main body section with
two (2) stainless steel cap screws. The connection cable
passes through this unit and is strain-relieved with a spiral
  strain-relieftting.Thetailunitincludesonemaleconnector
for the contact tip and two female connectors for each of the
reference electrodes.
5.5. Reference electrode elements
5.5.1. Two plug-in sintered silver/silver chloride elements are
included; electrode elements are accurate to ± 5 mV. See the
operations and maintenance section for instructions on
electrode replacement.
CAUTION
Never handle electrode elements with bare hands or expose elements
to any liquid other than water; permanent damage may result.
5.6. ROV-II probe compliant T-handle mount
5.6.1. The T-handle mount allows easy interface with most
manipulator systems. The entire mount is made from 316
stainless steel; the compliant elements are neoprene rubber.
5.7. Flying lead
5.7.1.Thestandardyingleadis10ft(3m)long.Alonger
lead can be provided if it is necessary to use a rear-facing
camera to look at the readout. The lead has a polyethylene
abrasion-resistant sheath and has connectors on either end
that mate with the bulkhead connector on the readout and the
whip cable on the probe unit.

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6.0 Spare parts and accessories
6.1.The Deep-C Meter is shipped in a waterproof transit case and
contains the following spares and accessories. Please contact
your Polatrak representative to order additional spares
if required.
6.1.1. Zinc calibration block (1)
6.1.2. Contact tips
6.1.3. Lens retaining screws (4)
6.1.4. O-ring lube (1)
6.1.5. Silicone connector lube (1)
6.1.6. Bulkhead connector dummy plug (1)
6.1.7. Ag/AgCl electrode element
6.1.8. Lens back-up ring (2)
6.1.9. Lens O-ring (4)
7.0 Calibration
7.1. Bucket calibration procedure
7.1.1. Fill a non-metallic bucket or container with enough
seawater or simulated seawater to completely submerge
the probe unit.
7.1.2. Place the probe in the bucket with the tip pointing up so
  thebodyllswithseawater.Theentireprobemustbe
immersed, including the tip.
7.1.3.Cleanthezinccouponwithaleorsandpaperto
remove any oxide layer and place it into the bucket.
7.1.4. Wait thirty minutes for the electrode elements to
reach equilibrium.
7.1.5.Stabthezinccouponrmlyontotheprobetip.
(alternatively, the contact tip can be removed and the cable
can be attached directly to the nose cone as indicated below)
7.1.6. The upper displays on the readout unit should read
between (-) 1000 & (-) 1100 mV (negative symbol does not
display on the MKII and prior). Both displays should read

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within ± 5 mV (the decimal point is not displayed).
7.1.7. If the readings are not within this range, please see the
troubleshooting section.
7.1.8. Note: If the probe has not been used in a while, it may
take another 15 – 30 minutes for the electrode elements to
reach equilibrium.
7.2. Underwater online calibration
7.2.1.Whilefree-ying,bothvoltmeterdisplaysarereading
the potential of the tip contact. This number will vary
depending on ROV speed, time of immersion and whether a
protected structure has been recently stabbed. Normally, the
reading will be in the (-) 200 to (-) 400 mV range, and both
displays should be within ± 5 mV.
7.2.2. If the readings are not within ± 10 mV, the probe unit is
out of calibration. The survey can continue until the ROV can
be brought back to the surface if both readings are recorded.
8.0 Operation
8.1. Mounting on ROV
8.1.1. Find a good location on the vehicle to mount the display
unit and attach the articulated mount. Typically, the display
unit should be in view at the same time as the probe unit to
  maximizeefciency.Thelensontheunitmustbecamera-
visible and have a light source directed at it to activate the
displays. Ensure that all fasteners are tight and that all
locknuts and washers are in place. Leave the lens cover in
place while the unit is on deck (unless calibrating) since the
displays are light-activated and battery life will be reduced.
8.1.2. Insert the probe unit into the compliant tee-handle
probe mount and position in a manipulator or tool basket that
is manipulator accessible.
8.1.3. We recommend tying a safety lanyard to the probe’s
mounting U-bolts.
8.1.4. Ensure fasteners are tight and lock nuts are in place.

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8.1.5.Routetheyingleadinsuchawaythatitwillnotbe
stressed, entangled or pinched during manipulator operation.
8.1.6. Apply a small amount of the provided connector
  sealanttotheshoulderoftheyingleadconnector,ensuring
  thatnosealantisappliedtothecopperpin.Connecttheying
lead to the probe lead and tighten the connector lock ring.
Please refer to the MSDS in the appendix before handling
the sealant. All appropriate Personal Protective Equipment
(PPE) shall be worn, including safety glasses and gloves as
a minimum.
8.1.7. Perform bucket calibration (see section 7.1)
8.1.8. Using a 7/16” wrench, ensure that the contact tip is tight
on the nose cone.
8.1.9. Ensure that the tip is sharp.
8.1.10. Remove the lens cover from the instrument.
9.0 Taking CP potential readings
9.1. Stab the tip contact probe onto the point on the structure
where the reading is required, when a good contact is made
the reading on the displays will show a steady reading.
CAUTIONS
Avoid stabbing painted or coated surfaces whenever possible. Try to
take readings on bare steel or on spots specially designated for CP
measurement.
• If necessary, anodes can be stabbed. However, if possible, it is best to
stab the anode band which is grounded to the structure.
• Avoid trying to stab through heavy, hard marine growth if possible.
• The probe unit should be kept out of the mud, as this may contaminate
the electrodes.
• If the readings are not steady or don’t match the criteria in the table in the
next section, it’s probably due to a high resistance contact. DO NOT RE-
CORDTHESENUMBERS.Continuetostabuntilreadingsareinspecica-
tion. See troubleshooting section if problems persist.
• NEVER operate the system with any of the connectors un-mated unless