Polatrak CP-Gun User manual

Deepwater Corrosion Services Inc. | 10851 Train Court, Houston, TX 77041 USA [phone] | Email: [e-mail] | polatrak.com
Corrosion testing probes
Document 352-MN01-ENG, Rev. D
© 2013 Deepwater Corrosion Services Inc. Specications subject to change without notice
Twin reference
electrodes verify
calibration during use
Ultra-bright LED
displays for limited
visibility conditions
On-off switch for
season-long
battery life
Interchangeable
freshwater/seawater
reference electrodes
CP-Gun™
Diver-held probe
Operation manual

www.polatrak.com | 10851 Train Court, Houston, TX 77041 USA | Telephone: [phone] | Email: [email protected]
© 2013 Deepwater Corrosion Services Inc. Specications subject to change without notice
CP Gun operation manual
2Document 352-MN01-ENG, Rev. D
Table of contents
1 Overview 5
2. Scope 5
3. Health and safety 5
4. Risk assessments 5
4.1. General hazards 5
4.2. Specic hazards 5
4.3. Environmental hazards 5
5. Reference documents 5
5.1. Drawings 5
5.2. Photos 5
5.3. MSDS documents 5
6. Components 6
6.1. Main body 6
6.2. Reference electrodes 6
6.3. Voltmeter 7
6.4. Bulkhead connector 7
6.5. Lens 7
6.6. Contact tips 7
6.7. On/off power switch 7
6.8. Spare parts and accessories 7
7. Calibration 7
7.1. Bucket calibration check 7
7.2. Underwater online calibration 8
7.3. Measuring potentials 8
7.4. Data interpretation 9
8. Maintenance 10
8.1. Overview 10
8.2. Tip replacement 10
8.3. Electrode element replacement 10
8.4. Battery replacement 11
9. Troubleshooting 12
9.1. Electrode element replacement 12
9.2. Battery replacement 12
10. Appendix 13

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CP Gun operation manual
3Document 352-MN01-ENG, Rev. D
List of tables
Table 1 - Normal cathodic protection ranges for bare carbon steel in seawater 10
Table 2 - Troubleshooting quick guide 13
Table 3 - CP Gun spare parts list 13
List of gures
Figure 1 - Kit components 4
Figure 2 - Probe components 4
Figure 3 - Calibration coupon attachment 8
Figure 4 - Bucket calibration readings 8
Figure 5 – Seacon RMG-3FS wiring diagram 11
Figure 6 – Calibration schematic 14

www.polatrak.com | 10851 Train Court, Houston, TX 77041 USA | Telephone: [phone] | Email: [email protected]
© 2013 Deepwater Corrosion Services Inc. Specications subject to change without notice
CP Gun operation manual
4Document 352-MN01-ENG, Rev. D
CP-Gun™
Figure 1
Kit components
Figure 2
Probe components
Pressure
housing
Reference
electrodes
O-rings
LED read-
out unit
Readout
lens
Readout
lens
retaining
screws
Contact
tip
Nose cone
assembly
Electrode
harness
Element
housing
On/o
switch
Handle
Calibration
coupon
Lens cover
Spare
reference
electrode
Tips
Replacement
O-rings
Batteries
Screws
Float
Lanyard
Transit
case
CP Gun
O-ring
lubricant
Insulating
compound
3/16”
Allen
key Spare parts
storage

www.polatrak.com | 10851 Train Court, Houston, TX 77041 USA | Telephone: [phone] | Email: [email protected]
© 2013 Deepwater Corrosion Services Inc. Specications subject to change without notice
CP Gun operation manual
5Document 352-MN01-ENG, Rev. D
1. Overview
The CP Gun is designed for situations where a few contact CP readings are required. This diver-held
probe can be stored easily on a tool belt when not needed by the diver. The CP Gun outperforms all
other bathycorrometer-type devices on the market in accuracy and convenience. Longer battery life,
interchangeable freshwater / seawater electrodes and ultra-bright LED displays (for limited visibility situ-
ations) make the CP Gun the most user-friendly diver-held CP probe available. The dual electrodes and
readouts allow verication of the reference electrodes even as the diver works.
2. Scope
The purpose of this document is to instruct the user how to use and maintain the CP Gun, including:
taking potential readings and replacing the elements and batteries.
3. Health and safety
3.1 General
It is the intention of Deepwater Corrosion that all test and inspection procedures are to be 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 on-site work.
3.2 MSDS
Where applicable, substances hazardous to health shall be listed and itemized in the form of a register.
Health and safety data sheets for all hazardous substances shall be kept in a le for reference. Site
personnel shall be issued copies of health and safety data sheets relevant to their work activities.
4. Risk assessments
4.1 General hazards
4.1.1 Site safety - There are various risks associated with working on any site; Regulations re-
quired by the site owner/operator should be observed.
4.1.2 Personal Protective Equipment (PPE) - Eye protection and disposable rubber gloves
should be worn as a minimum of personal protective equipment when maintaining the CP Gun, in
addition to any other equipment required by the site operator or deemed necessary by the task.
4.2. Specic hazards
4.2.1 Measuring potentials - The contact tip of the probe is very sharp and can cause serious
damage to the user if not handled with care. It should NEVER be used to remove marine growth or
coatings.
4.2.2 Impressed Current Cathodic Protection (ICCP) is present- Transformers should be
turned off BEFORE any person enters the water in that area.
4.3 Environmental hazards
The copper (II) sulphate, deionized gel solution contained within the Cu / CuSO4 reference elec-
trodes is potentially hazardous. Observe all federal, state and local regulations when disposing of this
substance. Please ensure that proper personal protective equipment (PPE) is worn during disposal.
For further information, please refer to the MSDS.
5. Reference documents
5.1 Drawings
5.1.1 Figure 4: Bucket calibration readings
5.1.2 Figure 5: SEA CON® RMG-3FS connector pin diagram
5.1.3 Figure 6: Bucket calibration check with Zn coupon

www.polatrak.com | 10851 Train Court, Houston, TX 77041 USA | Telephone: [phone] | Email: [email protected]
© 2013 Deepwater Corrosion Services Inc. Specications subject to change without notice
CP Gun operation manual
6Document 352-MN01-ENG, Rev. D
5.2 Photos
5.2.1 Figure 1: Kit components
5.2.2 Figure 2: Probe components
5.2.3 Figure 3: Calibration coupon attachment
5.3 MSDS documents
5.3.1 Parker Seals - Parker O Lube MSDS – O-ring lubricant
http://www.parker.com (search for: MSDS Super O-Lube)
5.3.2 Dow Corning – 4 Electrical Insulating Compound MSDS (Connector sealant)
http://www.dowcorning.com/applications/search/products/Details.
aspx?prod=01903128&type=PROD
5.3.3 McMiller – Leak Stop Gel – Copper (II) sulphate electrolyte MSDS
http://documents.mcmiller.com/msds.html
Please contact your Polatrak representative for any questions and/or
issues regarding this manual.
6. Components
The probe components are shown in Figure 2 along with a parts list in Table 3. The CP Gun with handle
weighs 6.3 lb (2.86 kg) in air and 1.5 lb (0.68 kg) in water. The following is a description of the major
components:
6.1 Main body
The rugged thermoplastic main body of the CP Gun comprises two sections: a water-tight pressure
housing which contains the LED readout unit, batteries and electronic circuitry, and a free-ooding
element housing, which contains the reference electrodes, contact tip and wiring harness. These two
halves are separated by unscrewing counterclockwise. This allows access to the probe contact tip
connection and the reference electrodes. The tip connector attaches to the electrode harness, and
once it’s unplugged, the entire electrode housing can be removed. The electrode elements and contact
tip can be replaced as necessary. Please see Table 3 for part numbers and ordering information.
6.2 Reference electrodes
The CP Gun uses two replaceable silver/silver chloride (Ag/AgCl) reference electrodes. Alternatively,
copper/copper sulfate (Cu/CuSO4) elements can be used for potential measurements taken in fresh
water. The electrodes are plugged into the electrode harness via pressure-resistant connectors. To
ensure proper function of the reference cells, several points should be observed:
6.2.1 Any time the elements are replaced, a thin layer of connector sealant should be applied to the
rubber shoulder of the male end, ensuring no sealant is applied to the copper pin. Please refer to the
MSDS before handling. All appropriate Personal Protective Equipment (PPE) shall be worn, including
safety glasses and disposable gloves as a minimum.
6.2.2 NEVER immerse the CP Gun with any of the connectors un-mated.
6.2.3 Take care when handling reference electrode elements — NEVER get oil or grease on them.
6.2.4 NEVER touch elements with your ngers. Do not use solvent cleaners on the electrode; use
only fresh water to clean.
6.2.5 After every use, soak the CP Gun in fresh water for at least 1 hour. This will extend the life of
the electrodes.

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CP Gun operation manual
7Document 352-MN01-ENG, Rev. D
6.3 LED readout unit
Each reference electrode is connected to its own voltmeter LED readout. Both voltmeters are con-
tained in a pressure housing facing the rear of the CP Gun. Power is supplied to these voltmeters by
two standard, replaceable PP3 9-volt alkaline batteries. To access, see Section 8, maintenance.
6.4 Bulkhead connector
The probe tip and reference cells are connected to the voltmeters via a Seacon 3-pin bulkhead con-
nector. Before use, ensure that the connector is properly tightened. A thin layer of connector sealant
should be applied to the rubber shoulder of the male end, ensuring no sealant is applied to the cop-
per pin. Please refer to the MSDS before handling. All appropriate Personal Protective Equipment
(PPE) shall be worn including safety glasses and disposable gloves as a minimum.
6.5 Lens
The lens is made from a clear, acrylic material. The only reason to remove the lens is to replace the
9-volt batteries which power the LED readout unit.
6.6 Contact tips
Tips should be replaced once a stable potential reading can no longer be obtained.
Tips should not be sharpened with a le or hammered into a point.
To replace, remove the existing tip with a 7/16” (or 10mm) wrench; ats are best. Ensure that the new tip
is tight, but do not overtighten (max torque 50 inch-lbs).
6.7 On/o power switch
The CP Gun is powered on with the red rotational magnetic switch. With the switch in the rear (off)
position, rotate the switch to the on (forward) position. If the meter does not power on, check the
batteries (Section 8, maintenance). When the CP Gun is not in use, switching it off will extend the life
of the batteries, enabling use of the CP Gun throughout an entire survey season without the need to
replace the batteries.
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.
6.8 Spare parts and accessories
The CP Gun is shipped in a waterproof transit case and includes the following spares and accesso-
ries. Please contact your Deepwater representative to order additional spares if required.
• Zinc calibration block (1) • Silicone connector lube (1)
• Contact tip (3) • Ag/AgCl electrode element (1)
• Lens retaining screw (4) • Lens back-up ring (2)
• O-Ring lube (1) • Lens O-ring (4)
7. Calibration test
(Please also refer to schematic in Fig. 6)
7.1 Bucket calibration check
7.1.1 Fill a clean, non-metallic bucket or container with enough seawater or simulated seawater to
completely submerge the probe unit. Ensure the bucket has been completely degreased and rinsed.
7.1.2 Place the probe in the bucket with the tip pointing up to ll body with seawater. The entire
probe, including the tip, must be immersed. Make sure there is no trapped air in the unit.
7.1.3 With a le or sandpaper, remove any layer of oxide from the zinc coupon before placing it in
the bucket.

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CP Gun operation manual
8Document 352-MN01-ENG, Rev. D
7.1.4 Wait 30 minutes for the
electrode elements to reach equi-
librium.
7.1.5 Unscrew the contact tip us-
ing a 7/16” (or 10mm) wrench (ats
are best) from the nose cone and
attach the zinc calibration block’s
ring terminal over the contact tip
threads. Reattach the contact tip
as shown. (Alternatively, the zinc
block can be stabbed directly with
the contact tip.)
7.1.6 Quickly ip the CP Gun over
so the nose points down. Rotate
the red switch forward to turn on
the LED readouts.
7.1.7 Read the two display lines on
the LED readout. The two voltages
should be between (-) 1030 and (-)
1070 mV and should match each
other to within 5 mV. See Fig 4.
7.1.8 If the readings are not within
this range, please see the trouble-
shooting section.
7.1.9 Note: If the probe has not
been used in a while, it may take
another 15 – 30 minutes for the
electrode elements to reach equi-
librium.
7.1.10 Remove the zinc calibration block if attached, and using a 7/16” (or 10mm) wrench (ats
are best), ensure that the contact tip is tightly reattached on the nose cone.
7.1.11 Ensure that the tip is sharp.
7.2. Underwater online calibration check
7.2.1 The CP Gun reference calibration can be checked while underwater by stabbing a reference
piece of zinc and ensuring the potential is between -1,030 and -1,070 V, and that the measure-
ments are within 5mV of each other. If the readings are not within 5 mV of one another, the probe
unit is out of calibration. The survey can continue, provided the diver records both readings until
the CP Gun can be brought back to the surface to recalibrate against the zinc block.
7.3 Measuring potentials
To obtain accurate CP readings from the CP Gun, follow these steps:
7.3.1 When underwater, switch the unit on by moving the red switch forward.
Figure 4:
Bucket
calibration
readings
Readings
should be
between
(-)1030 mV and
(-)1070 mV and
within 5 mV of
one another
Figure 3:
Calibration
coupon
attachment

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CP Gun operation manual
9Document 352-MN01-ENG, Rev. D
7.3.2 Ensure the instrument calibration is valid (Sections 7.1 and 7.2).
7.3.3 Stab the tip contact probe onto the structure where the reading is required. Ideally, this
should be bare steel or a designated CP test point.
7.3.4 When a good contact is made, the reading will be steady. It may take some effort to stab
and break through coatings or marine growth. If marine growth is thick and hard, it will need to be
properly removed before a measurement can be taken.
7.3.5 Do NOT use the CP Gun to remove marine growth.
7.3.6 The two readouts should give a steady result and should be within 5 mV of each other.
7.3.7 If the readings are not within 5 mV of one another, the CP Gun is out of calibration.
CAUTIONS
• The contact tip has been machined to a very sharp point to enable easier readings through coat-
ings. This point can also easily cut or poke through human skin. Please handle with care.
• The CP Gun should be attached to the diver’s belt with the tip facing downward when not in use.
• Avoid stabbing painted or coated surfaces. Whenever possible, try to take readings on bare steel
or on spots specially designated for CP measurement.
• Avoid trying to stab through heavy, hard marine growth.
• If the readings are not steady or don’t match the criteria in the table below, it’s probably due to a
high-resistance contact (a bad stab). DO NOT RECORD THESE NUMBERS; continue to stab until
readings are in specication. See Section 9, troubleshooting, if problems persist.
• Take care not to shove the CP Gun nose into mud, as this may contaminate a reference electrode
and shorten its life. If this does occur, rinse with fresh water. Verify the instrument calibration accord-
ing to the bucket calibration procedure in section 7.
• When a job is complete, turn off the CP Gun and soak in fresh water for at least 1 hour. Let dry,
replace the lens cover and stow in case.
7.4. Data interpretation
7.4.1 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 such as stainless steel, copper or nickel. 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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CP Gun operation manual
10 Document 352-MN01-ENG, Rev. D
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 for Al or Zn
-1150 or more negative Error (unless Mg anode)
Remake contact & verify.
Measure two other points around the
component
Abort & refer to troubleshooting section
8. Maintenance
8.1 Overview
8.1.1 This section covers general operational maintenance; do not attempt any tasks not de-
scribed in this section, as it may damage the system.
8.1.2 Please contact your Deepwater representative if you have any questions.
8.2 Tip replacement
8.2.1 Tips should be replaced once a stable reading can no longer be obtained. Remove the
old tip with a 7/16” (or 10mm) wrench (ats are best). Replace with the provided spare. Additional
spare parts may be obtained from Polatrak as needed (see table 3). Ensure that the new tip is
tight, but do not overtighten (max torque 50 in-lb).
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.
8.3 Electrode element replacement
8.3.1 Take the CP Gun to a clean area.
8.3.2 Unscrew and gently remove the element housing (Figure 2) of the CP Gun to expose the
electrode elements. Try to avoid un-mating the tip connector.
8.3.3 Visually inspect to ensure that the connector is properly mated and that the wire or element
is not damaged.
8.3.4 Disconnect the electrode harness from the bulkhead connector by unscrewing counter-
clockwise.