Polatrak ROV-II User manual

Deepwater Corrosion Services Inc. | 13813 FM 529 Rd, Houston, TX 77041 USA [phone] | Email: [email protected] | polatrak.com
Corrosion testing probes
SMB-009 ROV-II Manual Rev. 1
© 2016 Deepwater Corrosion Services Inc. Specications subject to change without notice
ROV-II™
CP probe
Operation manual
Twin reference
electrodes for
online calibration
Can be used with
ROVs or as a
diver-held probe
Works as either
a contact or
proximity probe
Use with Polatrak
Deep C Meter™
for subsea readout

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ROV-II operation manual
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Table of contents
1. ROV-II components 3
2. Reference documents 4
2.1 MSDS sheets 4
3. Health and safety 4
4. Installation procedure 4
4.1 Dive spread 4
4.2 ROV installation 5
4.3 Cautionary notes 5
5. Calibration 6
5.1 General 6
5.2 Using calibration for troubleshooting 6
5.3 Topside/bucket calibration 6
5.4 Subsea calibration 7
5.5 Proximity mode ground check 8
6. Operation 8
6.1 Wet check 8
6.2 Recording cathodic protection potentials 8
7. Taking cathodic protection potential readings 9
8. Data interpretation 9
9. Maintenance and repair 10
9.1 Tip replacement 10
9.2 Reference electrode element replacement 10
10. Troubleshooting 11
List of gures
Figure 1 Soft-splicing the whip onto the comms cable 4
Figure 2 SEA CON®RMG-3FS connector pin diagram 7
Figure 3 Identifying a failed reference electrode 8
Figure 4 Calibration vs. zinc coupon 12
Figure 5 Calibration cell-to-cell 13
Figure 6 Calibration vs. master Ag/AgCl electrode 14
Figure 7 Wiring schematic for diver-assisted platform survey 15
Figure 8 Wiring schematic for Deep C Meter™ readout 16
List of tables
Table 1 Normal cathodic protection ranges for bare carbon steel in seawater 9
Table 2 Troubleshooting quick guide 11

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ROV-II operation manual
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ROV-II™
Components
Housing
Nose cone
assembly
Hex screws
Tail assembly
Reference
electrode
element
An oshore case is
provided with the ROV-II.
The case can be lled
with seawater so that the
probe can be calibrated.
T-handle probe mounts
are available for use with
ROVs. There’s a stainless
steel version (above right)
with a shock absorber
to protect the probe
during stabbing, and
another made of Delrin
so inspection-class ROVs
can handle their weight.
Both are available with
sh-tail handles.
SEA CON®
RMG-3FS
connector
The Deep C Meter™ LED
readout can be used with
the ROV-II to record read-
ings without utilizing the
ROV’s umbilical.
Tip
Reference
electrode
element
Serial
number
Whip

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2. Reference documents
2.1 MSDS sheets
2.1.1 Dow Corning – 4 Electrical Insulating Compound MSDS – connector sealant
http://www.dowcorning.com/applications/search/products/details.aspx?prod=01903128&type=prod
PLEASE CONTACT YOUR POLATRAK REPRESENTATIVE FOR ANY QUESTIONS AND/OR ISSUES
REGARDING THIS MANUAL.
3. Health 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 leg-
islation. If required by the client, Deepwater personnel will attend any site safety induction courses
before carrying out work on-site.
4. Installation procedure
4.1 Dive spread
4.1.1 When used with diving operations, assemble a cable with a SEA CON®RMG-3FS connec-
tor at the subsea end. In our experience, the most suitable cable is the four (4) conductor armored
spiral comms cable used by most divers for diver communications; it has two twisted pairs and
is very rugged. A whip with this connector is provided with the probe and should be soft-spliced
onto the end of the comms cable (see Fig. 1). Ensure that the connection is taped back to the
armored wire to provide strain relief to the subsea connector.
Figure 1 - Soft-splicing the whip onto the comms cable
4.1.2 If required, Deepwater Corrosion can provide a complete assembly on a 500-foot-long
umbilical cable.
4.1.3 The appropriate length of cable should be married into the dive hose, leaving 4-6 feet (1.2m
– 2m) of slack at the subsea end and at least 50 feet (15m) at the topside end. Always install
the dummy plug on the connector when the probe is not attached.
4.1.4 The topside end of the cable will be run to the dive control area along with the platform
ground cable and any ground from pipeline risers. The connections can be made to a pair of dig-
ital multimeters (refer to g. 6, wiring schematic for diver-assisted platform survey.)
Comms cable
6’ Whip
To topside digital volt-
meters or LED readout
SEA CON®RMG-3FS
connector
Soft splice
ROV-IITail assembly

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ROV-II operation manual
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4.2 ROV installation
4.2.1 The probe is best installed in or on a manipulator but may be attached directly to the ROV
frame if there is no manipulator available. (This should be done when only proximity readings are
required).
4.2.2 The recessed grooves in the probe body may be used to accommodate stainless steel
hose clamps for attachment. We recommend installing neoprene rubber pads between the probe
and the mounting surfaces and attaching a safety line to the probe. This will provide a better at-
tachment and some degree of compliance.
4.2.3 A male SEA CON®RMG-3FS connector on a 6’ (2m) whip is provided to facilitate splicing
into the ROV junction box.
4.2.4 Routing the two reference electrode wires in a shielded twisted pair in the ROV umbili-
cal is recommended. The tip wire can be connected to a coaxial cable or any other cable that is
straight-through to the control van with no breaks.
4.2.5 Topside, the system can be wired directly to a pair of digital multimeters (Fig. 7) or a Polat-
rak Deep C Meter (Fig. 8). It can also be wired directly into a video annotator with an input imped-
ance of at least 1 MΩ
4.3 Cautionary notes
Polatrak sintered silver / silver chloride reference electrode elements are designed to be rugged, but
they are consumables that have a given operational life. The life of these electrodes can be extended
to several seasons if the following care is taken:
4.3.1 Never allow the electrode elements to be directly shorted to ground or any other metallic
object when immersed in seawater.
4.3.2 Never use the electrode subsea with the underwater connector un-mated.
4.3.3 Never read the ROV-II probe with an analog voltmeter. Ensure that high-input impedance
digital equipment is used.
4.3.4 Never handle the bare reference electrode element (small gray pellet) with bare hands.
4.3.5 Do not use any type of solvent or detergent on the probe. Rinse only in fresh water after
every operation.
4.3.6 Never immerse the electrode in anything but fresh water or seawater.
4.3.7 Never allow a connector or bulkhead to be immersed unless it is mated or has a sealing
dummy plug inserted.
4.3.8 Never read the electrode on a multimeter scale other than DC Volts.
4.3.9 When not in use, store the probe in the provided container lled with seawater or tap
water. Probe can be stored dry between jobs but should be soaked in fresh water for at least one
hour before storage.
4.3.10 Do not attempt to eld-repair any wires on the probe or inside the probe and never attempt
to modify the probe tip in any way.

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5. Calibration
5.1 General
As with any subsea measurement device, it is important to calibrate the ROV-II probe to ensure that
the reference electrodes are working properly and that there is no damage to the probe. If the probe
is not calibrated, readings may be incorrect and the dive may have to be repeated.
Since the ROV-II probe uses two reference electrodes, the user always has two independent voltage
readings of the tip contact. This provides an advantage over probes that use a single reference elec-
trode because the cell-to-cell value can be checked at any time during operation to verify the probe
is calibrated and working properly. The cell-to-cell value is simply the dierence in voltage between
the two readings; this value should never exceed 5 mV topside and 10mV subsea. For example, if
both voltage readings are the same, the cell-to-cell value is 0 (zero) mV.
5.2 Using calibration for troubleshooting
Certain problems could cause the probe to be out of calibration. A common cause, particularly on
diver surveys, is damage to the cable insulation. This causes an oset in the voltage readings, which
would usually be interpreted as inadequate protection levels. Other causes include one or more
defective reference cell electrodes, wire damage within the probe or mud that has gotten inside the
probe. Calibration can be used to quickly diagnose a defective reference electrode or cable damage
and should be performed before, during, and after every use.
NOTE: Company calibration specications must be met, but we strongly advise also using the at-
tached procedures.
5.3 Topside/bucket calibration
There are two types of bucket calibrations that can be performed:
• Zinc coupon calibration
• Cell-to-cell calibration
Wiring schematics for these two bucket calibrations are shown in Figures 4-5.
CAUTION:
Never use a metallic container for storage or for performing calibrations.
5.3.1 Fill a non-metallic bucket or container approximately 18 in. (45 cm) deep with seawater or
simulated solution with a specic gravity between 1.021 and 1.028.
5.3.2 Place the probe in the bucket, allowing the body to ll with seawater. The entire probe,
including the tip, must be immersed.
CAUTION:
DO NOT immerse the Seacon RMG-3FS connector in water unless it is mated with the
dummy plug.
5.3.3 Wait 30 minutes for the electrode elements to reach equilibrium (rst time use only).
5.3.4 To perform a zinc coupon calibration:
• Immerse the zinc calibration coupon. Stab the probe tip rmly onto the zinc coupon.
• Using a digital voltmeter set on 2.00 V DC scale, contact pin socket #1 (the large socket; refer
to Figure 2) with the positive voltmeter lead. This pin socket measures the probe tip.
• At the same time, contact pin socket #2 (rst clockwise of the large pin socket) with the nega-

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ROV-II operation manual
7SMB-009 ROV-II Manual Rev. 1
tive lead and note the reading. Then take the negative lead and contact pin socket #3; note the
reading.
• Figure 4 shows the correct wiring schematic and the expected results. The two readings
should not be more than 5 mV apart.
• Remove the probe tip from the zinc coupon. The reading should revert to a voltage within the
range of (-) 0.200 to (-) 0.400 V DC.
5.3.5 To perform a cell-to-cell calibration:
• Using a digital voltmeter set on 200 mV DC scale, contact pin socket #2 with the positive volt-
meter lead and pin socket #3 with the negative voltmeter lead. Note the reading.
• Figure 5 shows the correct wiring schematic and the expected results. The reading should be
between ±5 mV.
Figure 2 - SEA CON® RMG-3FS connector pin diagram
5.4 Subsea calibration
The cell-to-cell value can be checked at any time while the ROV-II probe is deployed subsea.
Subsea calibration should be performed with the entire cable immersed, as it will quickly detect
any cable damage. Diver surveys using the ROV-II probe should have two topside multimeters
connected to the dive cable. ROV-assisted surveys should have the Polatrak Deep C Meter along-
side the probe to provide a subsea LED readout of the voltages. Wiring schematics for these two
options can be seen in Figures 7-8.
CAUTION
NEVER submerge any unmated Seacon connectors.
5.4.1 While the probe is free-ying subsea without contacting any metal, the voltage readings
will vary depending on ROV/diver speed, time of immersion and whether the tip contact has
recently stabbed a structure or pipe. Normally, the voltage readings will be in the range of (-) 200
to (-) 400 mV.
5.4.2 Both voltage readings should never be more than 10 mV apart while the probe is subsea.
Remember, this dierence between voltage readings is the cell-to-cell value. If the cell-to-cell
value is greater than 10 mV, the cause may be:
• Lead wire is damaged, exposing copper to seawater.
• A connection is not properly mated or is leaking.
• One or more reference electrode elements has failed.
5.4.3 If it becomes apparent in the middle of an operation that one reference electrode element
has failed, it is possible to complete the dive. Follow these steps to isolate the bad reference
electrode:
Pin socket 1: Contact tip
Pin socket 2: Reference electrode #1 (R1)
Pin socket 3: Reference electrode #2 (R2)

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• Stab the probe onto the structure and determine which reading displays the most positive
voltage; this is normally the failed reference electrode. The good reference electrode will have the
most negative reading.
For example, (-) 900 mV is more negative than (-) 800 mV. (-) 900 mV would indicate the good
reference electrode; (-) 800 mV would indicate the failed reference electrode.
• Record the cell-to-cell value.
• Only use the voltage readings from the good reference cell for the rest of that dive.
Figure 3 - Identifying a failed reference electrode
5.5 Proximity mode ground check
When the probe is being used in proximity mode, the user needs to verify that the platform ground
wire and probe tip will yield the same reading at any point on the main structure.
• Stab the steel structure with the probe and record the voltage reading.
• Take the reading again using the platform reference ground wire instead of the probe tip. The
readings should be identical.
If the readings vary by more than 3 mV, check the platform ground wire connection.
6. Operation
Most companies have their own survey procedures to follow. The following guidelines are given as
guidance only.
6.1 Wet check
6.1.1 When interfaced to an ROV, it’s important to perform a wet check before every dive. Sig-
nal errors caused by umbilical power cable interference could introduce reading errors.
6.1.2 With the probe wired to the ROV, immerse the system to a depth of at least –30 feet (–10
m), and with the vehicle still in its Tether Management System (TMS), bring up one electrical sys-
tem at a time and note the potential of the tip. (It will vary some depending on immersion time).
If there is a problem, the potential will change rapidly or will spike when the circuit is powered.
Repeat for all electrical and hydraulic systems. If a problem is detected, it should be xed. Usu-
ally, the cause is a poor ground connection or a faulty leaking underwater connector. The system
at fault can be switched o if it will not hinder operation.
6.2 Recording cathodic protection potentials
If wired correctly, the cathodic protection potentials should have a negative polarity. Accurate read-
ings will be steady as long as the probe is not moving. If readings are erratic, this is a sign of a con-
nection problem and the cause should be isolated and xed.
Most negative reading:
Indicates good electrode
Most positive reading:
Indicates failed electrode

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7. Taking cathodic protection potential readings
Stab the tip-contact probe onto the point on the structure where the reading is required. When a
good contact is made, 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 cathodic protection measurement.
• If necessary, anodes can be stabbed. However, it is best to stab the anode band if possible.
• Avoid trying to stab through heavy, hard marine growth.
• The probe unit should be kept out of the mud, which will contaminate the electrodes.
• If the readings are not steady or do not match the criteria in Table 1, the cause is prob-
ably due to a high-resistance contact. DO NOT RECORD THESE NUMBERS. Continue to
stab until readings are within the range specied in Table 1. See troubleshooting section if
problems persist.
• NEVER operate the system with any of the connectors un-mated unless the dummy
plugs are installed.
8. Data interpretation
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 such as stainless steel, copper or nickel. In these cases, readings less negative than the indi-
cated range may be noted. If so, ensure that the readings are steady and within the ±5 mV allowable
tolerance.
Table 1 - Normal cathodic protection ranges for bare carbon steel in seawater
Range (mV) Interpretation Action
-500 or more positive Error
Remake contact & verify
Measure two other points around the
component
Abort & refer to troubleshooting section
-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
Abort & refer to troubleshooting section

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9. Maintenance and repair
This section covers general operational maintenance. Do not attempt any task not described in this
section, as it may damage the system.
9.1 Tip replacement
From time to time it will be necessary to replace tips. Remove the old tip with a 7/16 in. wrench (ats
are best). Avoid using an adjustable wrench if possible. Ensure that the new tip is tight.
CAUTION: The contact tip has been machined to a very sharp point to enable easier read-
ings through coatings. This point can also easily cut or poke through human skin. Please
handle with care.
9.2 Reference electrode element replacement
Spare plug-in electrode elements are available for the ROV-II probe. These elements will also work in
the Polatrak CP Gun. If one element or more needs to be changed, follow this procedure:
9.2.1 Remove the probe from the ROV and un-mate the connector. Install the provided
dummy plug onto the exposed ying lead connector.
9.2.2 Perform a zinc coupon bucket calibration as described in section 5.3.4. The faulty elec-
trode will be the one that gives the more positive reading.
9.2.3 Ensure that the probe is drained of seawater.
9.2.4 Take the probe unit to a clean area.
9.2.5 DO NOT handle the small electrode pellet with bare hands.
9.2.6 Remove the two screws securing the tail unit and gently pull out the tail unit to expose
the electrode elements. Try to avoid un-mating the tip connector.
9.2.7 Visually inspect to ensure that the wire is not damaged and the connector is properly
mated.
9.2.8 Remove the bad electrode and discard according to appropriate local environmental
procedures.
9.2.9 Take the new electrode and carefully place a small amount of insulating compound on
the sealing section of the electrode connector. Please refer to the MSDS in appendix before
handling sealant. All appropriate Personal Protective Equipment (PPE) shall be worn, including
safety glasses, as a minimum.
9.2.10 Plug in the new electrode.
9.2.11 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.
9.2.12 Repeat calibration as described above. (Note that a new dry element may take up to 30
minutes to reach equilibrium)
Caution: NEVER immerse an electrode element in water with the connector pin ex-
posed.

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10. Troubleshooting
10.1 The cell-to-cell value is greater than 5 mV topside or 10 mV subsea
The problem could be one of the following:
• One reference electrode has failed.
Repeat the bucket calibration (section 5.3). The electrode with the more positive reading is prob-
ably in error. Replace the reference electrode element (section 9.2).
• There is damage to the tail assembly cable or umbilical cable.
When recovering the ROV-II Probe from the dive, any cable damage can be quickly located and
repaired. Monitor the cell-to-cell value as the cable comes out of the water. If the problem is cable
damage, the cell-to-cell value will revert to the acceptable range (10 mV or less) as soon as the
damaged area of cable clears the water.
10.2 Both displays reading low (more positive) voltages
If both electrodes read low during a stab (more positive than (–)500 mV), the problem is probably
with the contact tip wire attached to the nose cone assembly. If the tip wire is damaged, a temporary
soft-splice repair can be made using ScotchKote® sealant (not included) and splicing tape. How-
ever, prolonged operation in this manner is not recommended. Order a new nose cone assembly as
soon as possible.
10.3 Recalibration
After any replacement or repair, recalibrate the instrument by performing a bucket calibration as
described in section 5.3.
Table 2 - Troubleshooting quick guide
Symptom Possible problem Action
Instrument will not calibrate
One electrode is bad
Zinc coupon is passivated
Electrodes are dry
See section 9.2
Remove zinc and clean with rasp
Soak in seawater 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 temporary
measure. Order replacement nose cone.
Readings are not steady and
continue to change.
Voltmeter batteries are low
Poor structure contact
Replace voltmeter batteries
Re-stab to ensure contact.
One reading suddenly goes
less negative
Connector is ooded
Lead wire (ying lead) is nicked.
Check connectors
Inspect and repair / replace as necessary
Deep C Meter LED readouts
are blank
Not enough light to photo-cell
Batteries are dead
Pressure housing is ooded
Increase light intensity and re-direct to
center of lens.
Replace batteries
Go to backup; return unit to Polatrak.
10.5 If a problem persists or is not listed, please call our hotline at [phone] and ask for PolaT-
rak technical support.

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Figure 4
Cell to Zn coupon
ROV-II calibration wiring schematic
Calibration
voltmeter display
at 2 Volts DC setting
Seawater solution
Non-metallic bucket
Step +VE —VE DC scale Expected result
01 Tip / Pin 1 Reference electrode 2 / Pin 3 2 V –1.030 to –1.070
02 Tip / Pin 1 Reference electrode 1 / Pin 2 2 V –1.030 to –1.070
Zn calibration coupon
(Readings should
be within ±0.005V
of each other)

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Figure 5
Cell to cell
ROV-II calibration wiring schematic
Calibration
voltmeter display
at 200 mV DC setting
Seawater solution
Non-metallic bucket
Step +VE —VE DC scale Expected result
01 Pin 3 Reference electrode 1 / Pin 2 200 mV ±5.0 mV
02 Pin 2 Reference electrode 2 / Pin 3 200 mV ±5.0 mV

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Figure 6
Cell to Ag/AgCI master
ROV-II calibration wiring schematic
Calibration
voltmeter display
at 200 mV DC setting
Seawater solution
Non-metallic bucket
Step +VE —VE DC scale Expected result
01 Master Reference electrode 1 / Pin 2 200 mV 0 mV ± 5.0 mV
02 Master Reference electrode 2 / Pin 3 200 mV ±5.0 mV
03 Master Tip / Pin 1 2 V -3 V ± 0.1 V
Ag/AgCI master
electrode
Note:
This calibration
procedure is
only performed
by qualied
Polatrak
technicians
before
shipment or
during repair.

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Figure 7
Wiring for diver-assisted platform survey
ROV-II wiring schematic
Survey
voltmeter display
at 2 Volts DC setting

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ROV-II operation manual
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Figure 8
Wiring for Deep C Meter™readout
ROV-II wiring schematic
SEA CON®
connector
Pin 1:
Contact tip
Pin 2:
Reference electrode #1 (R1)
Pin 3:
Reference electrode #2 (R2)