Polatrak DEEP C METER 3000 User manual
CORROSION TESTING PROBE
Deepwater Corrosion Services Inc.
©2016 Deepwater Corrosion Services Inc. Specications 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®modelROV-II™)andtheyinglead,athree-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
yingleadconnectionbacktothereadoutunit.
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
tthecompliantteehandlemountfor
convenient manipulator
mounting.
Figure 5:
ROV-II on
T-handle
mount
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holesinthesideallowthebodytobecomefree-oodingand
werespecicallyengineeredtoallowforaccuratepotential
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-relieftting.Thetailunitincludesonemaleconnector
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.Thestandardyingleadis10ft(3m)long.Alonger
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
thebodyllswithseawater.Theentireprobemustbe
immersed, including the tip.
7.1.3.Cleanthezinccouponwithaleorsandpaperto
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.Stabthezinccouponrmlyontotheprobetip.
(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.Whilefree-ying,bothvoltmeterdisplaysarereading
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
maximizeefciency.Thelensontheunitmustbecamera-
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.Routetheyingleadinsuchawaythatitwillnotbe
stressed, entangled or pinched during manipulator operation.
8.1.6. Apply a small amount of the provided connector
sealanttotheshoulderoftheyingleadconnector,ensuring
thatnosealantisappliedtothecopperpin.Connecttheying
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-
CORDTHESENUMBERS.Continuetostabuntilreadingsareinspecica-
tion. See troubleshooting section if problems persist.
• NEVER operate the system with any of the connectors un-mated unless
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Table 1 - Normal cathodic protection ranges for bare carbon
steel in seawater
Range (mV) Interpretation Action
-500 or more
positive Error (unless unprotected) Remake contact & verify
Measure two other points
around the component
-501 to -649 Isolated from cathodic
protection Remake contact & verify
Record data
-650 to -799 Not cathodically protected
-800 to -849 Marginal cathodic
protection
-850 to -1049 Cathodically protected Record data
-1050 to -1149 Anode potential
-1150 or more
negative Error Remake contact & verify
Measure two other points
around the component
10.2. Removal from ROV
10.2.1. When equipment is removed from the ROV, wash
thoroughly with fresh water and allow to dry. Soak the ROV II
probe unit in fresh water for at least one hour. Replace lens
cover on Deep C Meter and return to storage case provided.
Note: For brackish or fresh water, please consult Peterson’s Nomogram.
the blanking plugs are installed.
10.0 Data interpretation
10.1. For carbon steel structures in seawater, the readings obtained
should be within the ranges in Table 1. Exceptions may occur if the
probe is stabbed onto an isolated section of a corrosion-resistant
alloy (stainless steel, copper, nickel etc.). In these cases readings
less negative than the indicated range may be noted. If this is the
case, ensure that the readings are steady and within the ±5 mV
allowable range.
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11.0 Maintenance and repair
11.1. Overview
11.1.1. This section covers general operational maintenance.
Do not attempt any tasks not described in this section as it
may damage the system.
11.1.2. Please contact your Polatrak representative if you
have any questions.
11.2. Tip replacement
11.2.1. Tips should be replaced once a reading can no longer
beobtained.Removetheoldtipwitha7/16”wrench(atsare
best). Ensure that the new tip is tight.
CAUTION
The contact tip has been machined to a very sharp point to enable
easier readings through coatings. This point can also easily cut or
poke through human skin. Please handle with care.
11.3. Electrode element replacement
11.3.1. Remove the probe unit from the ROV and un-mate the
connector. Install the blank plug provided onto the exposed
yingleadconnector.Next,determinewhichelementisbad.
11.3.2. Perform a bucket calibration described in section 7.1.
11.3.3. Using a digital voltmeter set on 2.00 VDC range, stab
thelargepinwiththepositivevoltmeterlead,andpin1(rst
clockwise of large pin) with the negative lead (note reading).
Then repeat, stabbing pin 2 with the negative lead, noting the
reading. The faulty electrode will be the one that gives the
lowest (least negative) reading.
Pin socket 1: Contact tip
Pin socket 2: Reference electrode #1 (R1)
Pin socket 3: Reference electrode #2 (R2)
Figure 6: SEACON RMG-3FS wiring diagram
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11.3.4. Ensure that the probe is drained of seawater.
11.3.5. Take the probe unit to a clean area.
11.3.6. DO NOT handle the electrode pellet with bare hands.
11.3.7. Remove the two screws securing the tail unit and
gently pull out the tail unit, exposing the electrode elements.
Try to avoid un-mating the tip connector.
11.3.8. Visually inspect to ensure that the wire or element is
not damaged and the connector is properly mated.
11.3.9. Remove the bad electrode and discard according to
appropriate local environmental procedures.
11.3.10. Take the new electrode and carefully place a small
amount of connector sealant on the shoulder being careful not
to cover the copper pin. Please refer to the MSDS in
appendix before handling sealant. All appropriate Personal
Protective Equipment (PPE) shall be worn including safety
glasses and gloves as a minimum.
11.3.11. Plug the new electrode into the connector.
11.3.12. Check that all connectors are fully mated, then
carefully put the electrodes back into the housing and
re-attach the tail unit and nose cone.
11.3.13. Repeat bucket calibration as described in section 7.1.
(Note: Anew dry reference electrode may take an additional
30 minutes to reach equilibrium)
11.3.14. NEVER immerse an electrode in water with the
connector pin exposed.
11.4. Battery replacement
11.4.1. Batteries will need replacing after approximately 48-60
hours of operation or when the displays begin to fade. To
replace batteries, the readout must be removed from the
vehicle and taken to a clean, dry location. This is best done
in a workshop.
11.4.2. Remove four (4) 10-24 stainless steel retaining screws.
11.4.3. Rotate the lens approximately 10 degrees in either
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direction. This will prevent damage to the housing threads.
11.4.4. Next, screw in the four (4) ¼” – 20 stainless steel Allen
screws evenly to draw lens out.
11.4.5. Carefully pull lens out by the four Allen screws.
11.4.6. Remove the four (4) ¼” – 20 stainless steel Allen
screws from the lens.
11.4.7. Carefully remove the voltmeter module from the
housing; there is enough slack cable to allow this. Remove
and replace the two (2) PP3 9 volt batteries.
11.4.8. Carefully re-insert the voltmeter module and illuminate
the photo cells to ensure that the displays light up.
11.4.9. The lens has two grooves: the outer groove (closest
to the external, convex surface of the lens), and the inner
groove (closest to the internal surface of the lens). The inner
groove is designed for one round O-ring to be seated next to
one backup ring (square cross-section). The outer groove
contains a single round O-ring.
11.4.10. Replace all O-rings and backup rings.
NEVER REUSE O-RINGS.
11.4.11. Make sure new O-rings are properly installed and
seated;conrmthatthebackupringisnottwisted.
11.4.12. Apply a small amount of O-Ring lubricant to the lens
and the inside wall of the pressure housing, smoothing it out
into a thin layer. Do not apply lubricant to the internal or
external face of the lens. Please refer to the MSDS in the
appendix before handling. All appropriate Personal
Protective Equipment (PPE) shall be worn with eye protection
and gloves as a minimum.
11.4.13. Gently push the lens in until the second ring is just
above the rim of the pressure housing.
11.4.14. Use the four (4) 10-24 stainless steel retaining
screws to tighten the lens down until it is properly seated
against the pressure housing.
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Table 2 - Troubleshooting the Deep C Meter™
Symptom Cause Action
Instrument will
not calibrate
One electrode is bad See section 11.3
Zinc coupon is passive (more
positive than (-)1000 mV) Removezincandcleanwithle
or sandpaper
Readings still more positive
than (-) 1000 mV Inspect the tip wire for damage.
Electrodes are dry Soak for 30 minutes and retry
Both electrodes
reading low Tip wire damaged
Remove probe tail unit, unplug
tip wire, remove nose cone,
inspect tip wire and repair with
ScotchKote® as a temporary
measure. Order replacement
nose cone.
Readings are
not steady and
continue to
change
Batteries are low Replace batteries
Poor structure contact Re-stab to ensure contact
One reading
suddenly goes
less negative
Connectorisooded Check connectors
Leadwire(yinglead)
is nicked Inspect and repair / replace as
necessary
Displays are
blank
Not enough light
to photocell Increase light intensity and re-
direct to center of lens.
Batteries are dead Replace batteries
12.0 Troubleshooting
12.1. General
12.1.1. If the displays are not within ± 5 mV, check these:
• Repeat the bucket calibration (section 7.1). The electrode
with the more positive reading is probably in error.
• Remove the reference electrode elements and replace with
spares, being careful not to touch the silver/ silver chloride
pellet with bare or greasy hands. See section 11.3 for details.
12.1.2. If the tip wire is damaged, a temporary soft-splice
repair can be made using ScotchKote® sealant (not included)
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and splicing tape. However, prolonged operation in this
manner is not recommended. Order a new nose cone
assembly as soon as possible.
12.1.3. After any replacement or repair, recalibrate the
probe by performing a bucket test as described in section 7.1.
Part no. Description Required Spares
DCM0003-3000 Pressure housing 1 0
DCM0001 Meter mount 1 0
MLT0014 Lens 1 0
GSK0009 Lens O-Ring 2 4
GSK0008 Lens backup ring 1 2
FAS0104 Lens retaining screw 4 1
MFR0015 Lens cover 1 0
UWC0003 Bulkhead connector 1 0
UWC0019 Bulkhead dummy plug 1 0
ROV0016 ROV II probe nose assembly 1 0
ROV0004 Contact tip 1 3
DCM0008 Main connector 1 0
MLT0045 Replaceable Silver / Silver chloride element 2 1
MLT0010 Voltmeter module 1 0
ROV0014 ROV II probe T-handle mount 1 0
GSK0006 Tube O-Ring lubricant 1 0
EOR0015 Tube connector sealant silicon grease 1 0
ROV0018 Zinc calibration block 1 0
SMB-004 Instruction manual 1 0
Table 3: List of spare parts
Table of contents
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