Ultracorr Corrosion Monitoring System
Contents
1. 5 3 31 X 50 SLOT i See j 4 25 5 4 PLACES ah 4 00 A tie Y at j o o i l O20 Bod lla a e Ml DN J AR EZ tez Ez i Figure 5 3 Wall Mount Junction Box Ultracorr Corrosion Monitoring System 23 Ultracorr Corrosion Monitoring System 24 Chapter 6 Ultracorr Instrument Ultracorr utilizes high sensitivity ultrasonic technology to provide nonintrusive cost effective monitoring of corrosion and erosion The instrument can be used to provide periodic time and date stamped measurements of wall thickness and temperature of up to 50 transducers The thickness and temperature data can then be downloaded to a personal computer running CORRDATA Plus Corrosion Management Software for storage and trend analysis NOTE Each Ultracorr instrument is carefully tested inspected and packaged prior to shipment Before unpacking the instrument please inspect the packaged materials for shipping damage and retain all damaged packaged materials to support any claim against your freight carrier should this become necessary Unpacking Carefully remove the instrument from its package Included in the package you should find A Handheld Ultracorr instrument A CD ROM with Ultracorr Corrosion Monitoring System User Manual CORRDATA Plus Corrosion Management Software and User Manual A 6 AA batteries A Ultracorr to computer cable Lemo to2. Installation Toolkit Toolkits containing all the tools for uncoated and coated pipeline installations are available or tools may be ordered on an individual basis The toolkits contains such items as a cordless drill with a spare battery and charger tools for paint removal and surface preparation and the required epoxy to attach the transducer to the pipeline Please contact RCS for further details Ultracorr Corrosion Monitoring System 4 Chapter 2 Specifications System Thickness Measurement Range 0 1 to 2 0 inches up to 100 ft cable 0 2 to 2 0 inches up to 200 ft cable 0 4 to 1 25 inches up to 300 ft cable Resolution 0 0001 inch Accuracy 0 0002 inch at constant temperature 0 0005 inch from 0 C to 50 C Instrument 0 0003 inch from 0 C to 80 C Transducer Transducer Temperature Range 15 F to 185 F 10 C to 85 C Temperature Compensation 0 0002 inch inch C Temperature Differential Error 0 0001 inch inch C difference inside to outside of wall Temperature Measurement Range 0 to 80 C Resolution 0 1 C Accuracy 2 C Transducer 2 C Instrument Data Storage Memory Type Nonvolatile Probes 50 Readings Probes 256 Time and Date Stamped Interface Lemo to USB Ultracorr Corrosion Monitoring System Lemo to RS232 optional equipment Transducer Type Contact Transducer Cable RG 174 up RG 58 100 to 100 ft to 300 ft Ultracorr Ins
3. TEST STATIONS TRANSDUCER BURIED PIPE DA d lt q a Figure 3 1 Transducer Location Ultracorr Corrosion Monitoring System 9 Chapter 4 Transducer Mounting Correct installation of the Ultrasonic Transducers is a critical step in obtaining proper functionality of your Ultracorr System Careful steps must be made with installation to ensure the best reading possible in order to get an accurate thickness measurement A detailed step by step installation process follows to help make certain the transducers are properly installed A The first step in proper installation of the Ultracorr transducers involves finding the proper locations to monitor Locations that would most likely be ideal spots for Ultracorr monitoring would be low spots on the pipe line This is where water and other contaminants in the pipe line would settle and result in the highest corrosion rate Also the areas wishing to be monitored must fall in the operational temperature range of the transducer 185 F 85 C to 14 F 10 C A In order to obtain proper transmission of the ultrasonic sound waves through the pipe wall the transducer must be mounted to the bare metal of the pipe This means that all pipe insulation coating must be removed prior to insulation At the minimum a 4in x 4in 100mm x 100mm square of coating should be removed Figure 4 1 Coating Removal for Transducer Installation A If the pipe line is covere
4. Make sure the correct Interface is selected See Setting Ultracorr to PC Interface Connect probe to Ultracorr Ensure proper connection between Ultracorr and probe 52 Ultracorr Corrosion Monitoring System 53
5. Since it will often be advantageous to take a reading of the transducer from some remote point there are numerous cabling options to connect these two items For example cables may be run from numerous transducers into a single junction box at ground level where multiple readings may be taken very quickly Although there are many applications for the Ultracorr Corrosion Monitoring System there are three basic system applications Refer to chapter 3 4 and 5 for detailed installation procedures for various placement options 1 Above ground insulated pipelines or vessels 2 Above ground uninsulated pipelines or vessels 3 Below ground buried pipelines or vessels Ultracorr Corrosion Monitoring System 1 Figure 1 1 Ultracorr Instrument and Transducer Ultracorr Corrosion Monitoring System System Diagram Figure 1 2 illustrates a typical installation of the Ultracorr Corrosion Monitoring System The major components are described below CORRDATA Plus ES o C Figure 1 2 System Overview Ultracorr Transducer Signal Cabling Reading Point Ultracorr Instrument PC Running CORRDATA Plus Software moou gt Major Components Ultracorr Transducer The transducer probe is a small 1 inch diameter by 1 inch high sensor which is permanently mounted to the monitoring point This is accomplished using a special adhesive which also acts as an ultrasonic couplant The transducer has a magnetic base to aid in holding i
6. USB cable is provided as standard equipment Lemo to RS232 adapter is available for purchase as an option contact factory A Carry Case Battery Installation The Ultracorr is supplied with a set of six 1 5 Volt AA alkaline batteries To install these batteries remove the access panel on the back of the unit see below with the provided Allen Key and install the batteries with the polarities as indicated on the unit Replace the back cover when finished Ultracorr Corrosion Monitoring System 25 SANTA FE SPRIGG CA 90670 LISA Figure 6 1 Battery Cover of Ultracorr Instrument A secondary lithium battery mounted internally enables the non volatile storing of readings in the Ultracorr These batteries should provide 7 10 years of back up capacity Replacement of these batteries requires the unit to be returned to Rohrback Cosasco Systems or an authorized dealer Once the batteries are installed properly check the status of the batteries by pressing the ON button on the touch pad of the Ultracorr The following display should appear Rohrback Cosasco Systems Ver xx xx Please Wait Once the Ultracorr finishes its self test the display will change to show the battery status as shown below Ultracorr Corrosion Monitoring System 26 ROHRBACK COSASCO SYSTEMS Ver xx xx ER RB Bee F The number of
7. applications this same cable is available with a braided stainless steel armor jacket Figure 5 1 Weather Resistant Connector Ultracorr Corrosion Monitoring System 21 Local Mount Junction Box An alternative to leaving the connector exposed is to mount one or more connectors inside a NEMA 4X box There are several advantages to doing this including additional protection security and the ability to run multiple connections to a single point for rapid measurements Two standard box configurations are available RCS part number 744014 is designed to mount on a two inch pipe and has provisions for up to 5 transducer connectors see figure 5 2 This configuration is particularly suitable for buried pipeline applications as the cables can be run from the buried pipe through the 2 supporting pipe and into the box 5 00 5 Be PIPE Figure 5 2 Pole Mount Junction Box Ultracorr Corrosion Monitoring System 22 RCS part number 744017 is the same size box but is configured for the transducer connectors to mount on the bottom of the box Mounting ears are provided on the box for wall or pole mounting This box may be more suitable for above ground transducer applications see figure
8. complete Data transfer complete Note Any transfer errors encountered will be shown by the CORRDATA Plus Corrosion Management Software program Ultracorr Corrosion Monitoring System 39 Ultracorr Corrosion Monitoring System 40 Chapter 9 Reading Ultracorr Probes Rohrback Cosasco Systems new generation UST transducers are referred to as smart transducers compared to the previous generation of UST transducers Procedure for configuring the two types of probes varies slightly Refer to the sections below for details Note The corrosion monitoring industry commonly uses the term probe to refer to the corrosion measurement sensor which could be an ultrasonic probe In the non destructive testing industry it is common to see the term ultrasonic transducer used For the purposes of this manual these terms are equivalent andmay be used interchangeably Reading a Smart UST Probe Reading probes with the Ultracorr is simple and fast To begin reading a probe press the Read F1 key from the Main display screen On the Connect to Probe screen press Read F1 shown below Connect to Probe Test Probe Exit All the new generation probes of Rohrback Cosasco Systems are smart probes These probes have the capability to retain its ID and Tag When an Ultracorr is connected to the probe Ultracorr will automatically identify the Probe ID and Tag if the probe was previously configured When reading a probe if the pr
9. solid boxes W will reduce with the depletion of the batteries If the batteries are low or in need of replacement a warning display will appear as follows WARNING LOW BATTERIES REPLACE NOW If batteries are good the instrument will proceed directly to the Main display shown below Ultracorr mmm dd yyyy hh mm ss Read Disp Dump Setup Ultracorr Corrosion Monitoring System 27 Ultracorr Corrosion Monitoring System 28 Chapter 7 Ultracorr Instrument Configuration and Setup Ultracorr Keypad The Ultracorr features a 34 key keypad with keys for the alphabet A through Z and numerals 0 through 9 The numerals are shared with letters F through P and S Switch between these letters and the numbers using the Alpha Numeric key There are also four soft keys F1 through F4 as shown below The soft keys are multi function keys used to make on screen selections A A A A Fi F2 F3 F4 Figure 7 1 Ultracorr Function Keys Setting the Date and Time on the Ultracorr The Ultracorr has its own clock so that individual transducer readings are automatically time and date stamped To set the internal clock from the Main display screen shown below press Setup F4 to go to the Ultracorr Configuration display Ultracorr Jan 01 2000 00 00 00 Read Disp Dump Setup Press Manual F2 on the Ultracorr Configuration screen display shown below Ultracorr Corrosion Monitoring System 29 Ultracorr Confi
10. spe ai ec aoe 6 Transducer Cable o o leo asian 6 Ultracorr Instrument sica a nena iris 6 Batt ry y Requirements cbc ota 6 Battery Lies 6 Operatine Temperature 6 AE Femperature nenne 6 Dimensions aana a cise O A ANS 6 A e 6 Supplied Willian ts 6 Chapter Data in 9 Location of Monitoring Points a ueu 8uu0sunnennnaniotungnesiannilnn 9 Chapter dr u REN DE o a iS ETa 10 Transdueer Mountine une nina 10 Chapter I ne II ES 10 Transducer Connection and Signal Cabling oooonncccnnncccnonoccnonancnoncnononanononanonnncnonnnano 21 Cable ee Nessie 21 Local Mount Junchon BOK ra ee 22 Chapter 6 ua il 25 Ultracort Instinto E GE 25 Unpacking ii 25 Battery Installation usa dio 25 Chaplin e elo EEE 29 Ultracorr Instrument Configuration and Setup coooccccnoccconoccnonnnnononcnononcnononanonanacinnnnnn 29 Ultracorr Keypad ads 29 Setting the Date and Time on the Ultracorr esesseeeseseeeeeseeeresereseesreseresresseserssee 29 Clearing Memory on Uliracorr jie eee ook ede tale Rena Que eiet 31 Setting Ultracorr to PC Interface ar 32 Checking the Firmware Version aan is 32 Testine a Proben rien e E ES 33 Chapter Siena 35 Confieuring a Proba bici 35 Manually Configure Probe and Save Setting to the Ultracorr eee eee 35 Use a PC to Configure Probe and Save Setting to the Ultracorr 37 ON 41 Readin a Ultracorr Probes tan een 41 Reading Smart UST POD rot Ote 41 Reading Previous Generati
11. the term ultrasonic transducer used For the purposes of this manual these terms are equivalent andmay be used interchangeably To enter the Test Mode from the Main display screen press Read F1 to go to the Connect to Probe display shown below Connect to Probe Test Probe Exit Ultracorr Corrosion Monitoring System 33 Press Test Probe F3 on the Connect to Probe screen to enter the Test Mode display Test Mode SW Read Rev Probe Press Read Probe F2 to begin The Ultracorr will show continuously updated readings with a screen refresh rate of about one second The measured Thickness Material Temperature and Signal will be displayed To stop readings and return to the Test Mode press the Stop F4 See below Thickness x xxxx in Mat Temp xxx x C Signal xx x db Hold down F4 to Exit Ultracorr Corrosion Monitoring System 34 Chapter 8 Configuring a Probe There are two ways to configure a probe with the Ultracorr handheld instrument 1 Configure manually 2 Configure using a PC running CORRDATA Plus Corrosion Management Software Note Ultracorr reads probes and stores data according to the ID of the probe If two probes in different locations are set with the same ID and read with the same Ultracorr it will not know to differentiate and will store data values in the same ID Example Location A with Probe ID 1 and Location B with Probe ID 1 is seen as the same ID if read by the same Ultr
12. Data screen shown below Data Display by by Curr ID Tag Probe Exit A location may be selected by pressing either by ID F1 or by TAG F2 If Curr Probe F3 is selected Ultracorr will display the information for the last probe location the Ultracorr was used with If by ID F1 is selected following will display on the Ultracorr Enter Probe ID ID gt lt 1 50 Enter Cir Bksp Exit If by Tag F2 is selected following will display on the Ultracorr Enter Probe Tag gt lt Enter Cir Bksp Exit Ultracorr Corrosion Monitoring System 45 Enter the ID or Tag accordingly and press Enter F1 If the provided ID or Tag is invalid usually this happens if the ID is not configured or if the Tag does not exist following screen will appear with the option to manually configure the probe Warning ID or Tag not found Config Exit Press Config F1 at this time to manually configure a probe if desired Follow the instructions on Manually Configure Probe and Save Setting to the Ultracorr If the entered data is valid the last reading for that probe will be displayed as shown below Probe ID XX Tag XXXXXXXXXXXX Thickness x xxxx in More Exit Press More F2 see below to view the Material Temperature Alloy and Signal information Pressing Back F2 will return the display to the above screen Mat Temp XXX X C Alloy XXXXXX Signal XX X db Back Ultracorr Corrosion Monitoring Syste
13. Ultracorr Corrosion Monitoring System User Manual Rohrback Cosasco Systems Inc P N 725050 MANUAL Rev A 11841 East Smith Ave Santa Fe Springs CA 90670 Tel 1 562 949 0123 Fax 1 562 949 3065 E mail sales rohrbackcosasco com Web Site www rohrbackcosasco com 11 O 2006 Rohrback Cosasco Systems Inc All rights reserved Ultracorr and CORRDATA Plus are trademarks of Rohrback Cosasco Systems Inc Windows is a trademark of Microsoft Corporation No part of this manual may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying and recording for any purpose without the express written permission of Rohrback Cosasco Systems Inc 111 1v Table of Contents Capi A et ea A A a A 1 AAC ts a de e e edi ls o anes 1 System OyeryieW or eienaar ie aee ii 1 Major Components iii neck olen eeahen ares 3 Ultracorr TransdUcCer osito iii saa eu R e adios 3 SA CA kn 4 A E lee 4 Ultracore Instrument a se 4 Personal Comp tet senna nna ane a a a a a te eens 4 CORRDATA PS Sollwale nen 4 Installation Toolkit sey dd AS 4 A 2 2 2 en ER RN 5 PELI CAMAS ds 5 DV SUS ENN EES TE E RE T E A EE 5 Thickn ss Measurement unicidad a iai 5 Kransdueer Temperaturen ia Dein 5 Temperature Compensation uuu u eesasisele labels 5 Temperature Differential Error sses iieii oeiee ns Dias 5 Temperature Measurement estacion idad ici 5 Data SOTA es 5 Interface es 5 Transd cer
14. acorr without clearing memory Manually Configure Probe and Save Setting to the Ultracorr From the Main display screen press Setup F4 to go to the Ultracorr Configuration display Ultracorr Configuration from Inter PC Manual face Exit Choose Manual F2 to go the Manual Configuration screen Manual Configuration Set Clear Probe Time Mem Exit Ultracorr Corrosion Monitoring System 35 Press Probe F1 to begin configuring the probe Following display will appear on the Ultracorr Enter Probe ID ID gt lt 1 50 Enter Cir Bksp Exit Enter an ID number for the probe ID numbers are restricted to be from 1 to 50 A If the ID entered already exists Ultracorr will display this information as follows ID XX Tag XXXXXXXXXXXX Alloy XXXXXX Save Change Exit A Selecting Save F1 will enable the user to keep the existing settings and continue to program the probe Select Change F2 to enter new Tag information on the Enter Probe Tag screen If the probe being configured is a previous generation probe Save F1 is disabled and the user must select the Change F2 button If a valid never before configured ID was entered the Ultracorr will proceed to the following Enter Probe Tag screen Enter Probe Tag gt lt Enter Cir Bksp Exit Enter the desired probe tag Press the Enter F1 to proceed to the Select Alloy screen shown below Select Alloy gt Enter Up Down Exit Ultracorr Corr
15. ase Wait ID XXXXXXXXXXXX Hold down F4 to Exit Note Exit F4 is disabled when data is being transferred Any transfer errors encountered will be shown by the CORRDATA Plus Corrosion Management Software program If CORRDATA Plus Corrosion Management Software prompts the user with the following error see below verify that the cable is properly connected between the PC and Ultracorr and the correct COM port is checked It is also possible to receive this error if the Ultracorr has no saved data Ultracorr Corrosion Monitoring System 48 Corrdata Plus A UltraCorr No Data Received Check Communications A successful transmission of data will yield the following display Data transfer complete Ultracorr Corrosion Monitoring System 49 Ultracorr Corrosion Monitoring System 50 Chapter 12 Troubleshooting Failure to get proper readings from the Ultracorr system is normally attributed to one of three causes the instrument the cabling connections or the transducer The instrument is simple to check if a spare transducer is available Use water or other suitable couplant and read the instrument in TEST mode The only maintenance required on the instrument is battery replacement If good batteries are in the instrument and the unit still does not function properly contact the factory Cabling and connections is the most common cause of problems Ensure proper cable connection with genuine Rohrback Cosasco Syst
16. cerin Not Supplied First clean the sanded pipe surface with the supplied alcohol wipes to remove any debris left from sanding Then clean the transducer face as it may have residual debris on it Connect the transducer cable to the Ultracorr handheld unit and turn on The Ultracorr will load up and then display the main menu From the main menu navigate through the following screens Main Menu Screen Push the Ultracorr Read key mmm dd yyyy hh mm ss Read Disp Dump Setup Connect to Probe Screen Push the Test Connect to Probe Probe key Test Read Probe Exit Read Probe Screen Push the Read Test Mode Probe key SW Read Rev Probe Exit Continuous Read Screen Thickness x xxxx in Mat Temp xxx x C Signal xx x db Hold down F4 to Exit Ultracorr Corrosion Monitoring System 12 4 READ gt TEST PROBE gt READ PROBE When you access this screen the Ultracorr is in continuous read mode The Ultracorr unit will display thickness temperature and decibel readings every second A Glycerin should now be applied to the face of the transducer and placed on the prepared surface of the pipe Enough glycerin should be used to cover the entire face if the transducer The transducer has a magnet installed in it and should hold itself sufficiently onto the pipe Do not press the back of the transducer as this will result in a false reading and can possible damage the piezoelectric element The magnet provides a suffi
17. cient amount of force to hold the transducer to the pipe Figure 4 4 Glycerin on the Transducer A With the transducer on the pipe gently move it around the prepared surface while monitoring the db signal strength on the Ultracorr unit The db signal strength is actually the amplification of the echoed ultrasonic sound wave needed to measure the wall thickness The higher the db signal the weaker the echo received in the transducer Therefore the ideal mounting location would be where the db signal is at its lowest When looking for a mounting spot on the prepared pipe surface a sufficient db reading would be in the 40 db and lower range for pipes 4 or less in thickness 43 db for 4 to 7 and 45 db for 7 and up If you are not able to achieve a db reading this low you must sand the pipe surface further and retest until the reading becomes acceptable A high db reading is unacceptable and will result in inaccurate thickness measurements Ultracorr Corrosion Monitoring System 13 Figure 4 5 Finding the Location of Lowest db Reading A After a location with an acceptable db reading has been found it should be noted Hold down F4 on the Ultracorr unit to stop the continuous read function Lift the transducer off of the pipe and thoroughly clean its face with the supplied alcohol wipes Also thoroughly clean the pipe surface with the supplied alcohol wipes It is important that all glycerin be removed from transduce
18. confusion with any previously collected data To clear the memory proceed as follows From the Main display screen press Setup F4 to go to the Ultracorr Configuration display Press Manual F2 on the Ultracorr Configuration screen to go to the Manual Configuration display Ultracorr Configuration from Inter PC Manual face Exit Manual Configuration display shown below Manual Configuration Set Clear Probe Time Mem Exit Press Clr Mem F3 to proceed to the next screen shown below Warning This will erase all data Clear Press Clear F1 to clear the memory or Exit F4 to return to the Main display screen Note This will clear readings stored in internal memory All configuration information will be lost Ultracorr Corrosion Monitoring System 31 Setting Ultracorr to PC Interface Ultracorr may be connected to the PC by using a Lemo to USB cable or Lemo to RS232 cable Lemo to USB cable is provided as standard equipment Lemo to RS232 is available as an option consult factory for details Before data transfer can begin between the PC and Ultracorr proper cabling must be specified on the Ultracorr To setup the interface from the Main display screen press Setup F4 to go to the Ultracorr Configuration display Press Interface F3 on the Ultracorr Configuration screen shown below Ultracorr Configuration from Inter PC Manual face Exit Selected Interface will be shown To change the sele
19. ction either press RS232 F1 or USB F2 on the display shown below Interface USB RS232 USB Exit When Exit F4 is pressed the settings will be saved and the Ultracorr will advance to the Ultracorr Configuration screen Press Exit F4 again to return to the Main screen Checking the Firmware Version Firmware version is displayed on the first screen at startup of the Ultracorr An alternate way of accessing the Ultracorr firmware version is by pressing Read F1 from the Main display and selecting Test Probe F3 from the Connect to Probe display screen shown below Connect to Probe Test Read Probe Exit Ultracorr Corrosion Monitoring System 32 Press SW Rev F1 to view the firmware version of the Ultracorr below Test Mode SW Read Rev Probe Firmware version will be displayed as shown below Ultracorr Ver XX XX Testing a Probe Any probe may be read in test mode This mode does not require the location to be preprogrammed into the instrument Test mode is a helpful function to select an ideal mounting location for the probe see Transducer Mounting chapter for more details on mounting transducers lt also helps to verify probe functionality without programming it into the instrument Note The corrosion monitoring industry commonly uses the term probe to refer to the corrosion measurement sensor which could be an ultrasonic probe In the non destructive testing industry it is common to see
20. d by paint or other hard type coating it must be sanded off to expose the bare metal underneath Ultracorr Corrosion Monitoring System Figure 4 2 Painted Pipeline with Paint Removed A After all insulation coating is removed the pipe surface must be properly prepared for mounting 80 to 120 grit aluminum oxide flexible sanding discs that can be mounted in a cordless drill are recommended Often the same sanding disc can be used to remove pipe coating and prepare the pipe surface for mounting Figure 4 3 Sanding the Pipe Surface The area that is sanded should be larger then the face of the transducer You want to sand the surface flat and smooth Some pipes have an uneven surface finish with small dimples similar to an orange peel This should be sanded down so that it is a near polished surface A good tip that is used when sanding is to sand the pipe with the sanding disk at a slight angle so that the outer area of the disc is in contact with the pipe This will help control the cordless drill better While sanding try to slightly flatten the curvature of the pipe at the mounting location This will help to transmit the ultrasonic sound waves better when Ultracorr Corrosion Monitoring System 11 mounting the transducer After the pipe surface has been sufficiently sanded and prepared the next step is to test the transmission of the ultrasonic wave through the pipe This is done using an ultrasonic couplant such as gly
21. de monitoring locations are available Ultracorr Instrument The Ultracorr instrument is the heart of the Ultracorr Corrosion Monitoring System A single Ultracorr instrument may be used to periodically take individual time and date stamped wall thickness and temperature readings of up to 50 sensors It will store up to 256 readings for each of these sensors Refer to chapters on Ultracorr for more information Personal Computer The last readings from the Ultracorr instrument may be displayed on its LCD For optimal data analysis the Ultracorr instrument can download all of its data to a personal computer Use the CORRDATA Plus Corrosion Management Software package for trend analysis data analysis and storage CORRDATA Plus Software The CORRDATA Plus Corrosion Management Software controls the transfer of data from the Ultracorr instrument into a personal computer It can display and print the data in tabular format It can also convert the data to a CSV comma separated value format for export into any spreadsheet program The CORRDATA Plus software is a powerful application that can perform the above functions and much more For example it allows the graphical display of data along with integration of data with other process parameters such as readings from CORROSOMETER and CORRATER instruments Refer to Transfer Readings from Ultracorr to the CORRDATA Plus section for more information on transferring and analyzing data on a personal computer
22. displays will appear Enter Probe ID ID gt lt 1 50 Enter Cir Bksp Exit Enter Probe Tag gt lt Enter Cir Bksp Exit Enter the ID or Tag accordingly and press Enter F1 Following will appear at this point Probe ID XX Tag XXXXXXXXXXXX Read Exit Note Ifthe probe has never been configured Ultracorr will detect this and provide the user with the option to manually setup the probe at this time refer to Manually Configuring a Probe section Ultracorr Corrosion Monitoring System 43 Select Read F1 to start reading the probe Once the reading is taken the Ultracorr will display the following screen Probe ID XX Tag XXXXXXXXXXXX Thickness X XXXX in Read More Save Exit Pressing the Read F1 will reread the probe To save the reading to the internal non volatile memory press Save F3 Press More F2 to see additional information below Pressing Back F2 will return the display to the above screen Thickness x xxxx in Mat Temp xxx x C Signal xx x db Back Ultracorr Corrosion Monitoring System 44 Chapter 10 Displaying Data on the Ultracorr Displaying the Last Reading The last probe data reading taken at each location may be viewed on the Ultracorr by choosing the current probe probe ID 1 50 or the probe Tag The data includes the ID Number Tag ID Thickness Material Temperature Alloy and the Signal From the Main screen press Disp F2 to go to the Display
23. edence over existing configured Probe IDs This will erase any previously stored data and settings in the selected IDs in the Ultracorr Press Setup F4 on the Ultracorr from the Main screen to advance to the following display Ultracorr Configuration from PC Manual Exit Ultracorr Corrosion Monitoring System 37 Press PC Conf F1 following screen will appear Connect to PC Run Corrdata Plus Press Configure Device Start Exit Click the Configure Device command button on the CORRDATA Plus software program Following dialogue box will appear Corrdata Plus Device Configuration 1 Configuring an UltraCorr This will erase any previously stored data in the selected IDs in the UltraCorr Note CORRDATA Plus configured Probe IDs will take precedence over existing configured Probe IDs This will erase any previously stored data and settings in the selected IDs in the Ultracorr Note CORRDATA Plus must initiate the transfer When the countdown begins press Start F1 on Ultracorr Select OK Following dialogue box will appear Waiting for device to respond Press START on the UltraCorr y Fetching tag data Press the Start F1 on the Ultracorr Successful configuration will yield Ultracorr Configuration is complete message on the PC and Data transfer complete screen on the Ultracorr as shown below Ultracorr Corrosion Monitoring System 38 Corrdata Plus 1 UltraCorr Configuration is
24. ems provided cabling The transducer can be checked by using the instrument The most common cause of transducer malfunction is improper coupling to the surface This could be caused by improper surface preparation or improper use of the adhesive couplant See the following section on Troubleshooting Guide for common symptoms and solutions Ultracorr Corrosion Monitoring System 51 Troubleshooting Guide Symptom Ultracorr will not turn on Ultracorr turns off before 2 30 minutes auto shutdown Ultracorr will not transfer data to the computer Ultracorr not reading probe Ultracorr Corrosion Monitoring System Problem Batteries not installed Battery voltage low Batteries installed incorrectly Battery voltage low CORRDATA Plus is not running Cable is not connected properly No probe connected to Ultracorr Cable is not connected properly Solution Install batteries see Chapter on Ultracorr Instrument Install new batteries Check the polarities as indicated on the unit Install new batteries Launch CORRDATA Plus from the Start Menu Click the Receive Data button Refer to CORRDATA Plus manual Check that the cable is fully plugged into Ultracorr and that the other end is fully plugged into the USB connection or the optional 9 pin serial port on the back of the PC Check that the COM port selected in CORRDATA Plus is the actual COM port to which the Ultracorr is connected to
25. er This prevents the weight of the cable from pulling on the transducer and causing signal loss Do not let the cable bend in any way near its junction with the transducer Keep it straight and parallel to the pipe with as little tension as possible Any type of force put from the cable will try to pull the transducer face off the pipe surface and degrade the signal strength and measurement Ultracorr Corrosion Monitoring System 17 Figure 4 6 Transducers Being Mounted on Pipeline Once a signal reading of less then 44db is reached leave the transducer alone The cable can be moved beyond its wrapped point but do not touch the transducer or the cable up to the wrapped point Press and hold F4 on the Ultracorr unit to exit the continuous read screen The installed transducer can now be configured and stored into the Ultracorr unit by following the steps in chapter 8 After configuring the probe it is recommended to take the first reading and store it in the Ultracorr For instructions on this please refer to chapter 9 After the probe is configured and data is stored in the Ultracorr unit disconnect the cable from the Ultracorr Do not touch the transducer for 24 hours while the epoxy cures to full hardness Once epoxy is fully cured all securing tape straps etc may be removed Recheck probe reading and save data to Ultracorr unit per instructions in chapter 9 At this time since the epoxy has cured the db signal reading
26. guration from Inter PC Manual face Exit Pressing Manual F2 advance the Ultracorr to the Manual Configuration display shown below Manual Configuration Set Clear Probe Time Mem Exit Press Set Time F2 to go to the next screen shown below Jan 01 2000 00 00 00 Set Press Set F2 to advance to the next screen Set Date Time YYMMDDHHmmss Enter Cir Bksp Exit From the keyboard enter the last two digits of the year two digit month and date followed by the time in hours minutes and seconds it is possible to enter 00 for seconds for user convenience Clr F2 button will clear all entered data and reset the cursor to the beginning Bksp F3 button will backspace one field to re enter one character When the time is set correctly press Enter F1 to start the clock The Set Time screen will show the user entered time and date Press the Exit F4 to return to the Main screen where the set time will display NOTE The hour is set on the military 24 hour clock where 00 00 00 hours is midnight at the start of the day and 12 00 00 is mid day Ultracorr Corrosion Monitoring System 30 Clearing Memory on Ultracorr Normally it will not be necessary to clear the memory on the Ultracorr unless extraneous entries have been made for example when initially experimenting with the system Alternatively if the equipment is to be transferred to a new location then it is recommended to clear the memory to avoid
27. m 46 Chapter 11 Transfer Readings from Ultracorr to the CORRDATA Plus The last reading for any probe may be displayed on the Ultracorr display For maximum functionality and data management all the data contained in the instrument may be downloaded to a personal computer running CORRDATA Plus Corrosion Management Software package The CORRDATA Plus package is a flexible corrosion data management system that allows integration of all corrosion monitoring parameters Refer to the CORRDATA Plus Corrosion Management Software documentation for installation site setup capabilities and other details CORRDATA Plus Installation The CORRDATA Plus Corrosion Management Software can be found on the CDROM included with the instrument Insert the auto run CD ROM and follow the onscreen instructions to install The default installation directory is C Program Files RCS Corrdata Plus Configuring CORRDATA Plus When the installation is complete launch the CORRDATA Plus program from All Programs gt Rohrback Cosasco Systems Follow the instructions on the CORRDATA Plus User Manual provided on the CD ROM for site setup and configuration The manual can be accessed by right clicking and selecting open on the CD ROM device of the computer if the auto run feature is disabled Connecting the Ultracorr to the PC Connect the Ultracorr instrument to an USB port on the PC using the provided Lemo to USB cable optional Lemo to RS232 cable is available cons
28. ndheld Ultracorr Corrosion Monitoring Systems Ultracorr provides a cost effective ultrasonic thickness measurement and temperature measurement of a pipe or vessel wall using fixed transducers mounted at various locations throughout a site After initial installation access to the monitoring point is no longer required The transducer connector can be located at some convenient location for taking thickness and temperature readings These readings can then be downloaded to a personal computer running CORRDATA Plus Corrosion Management Software for storage and trend analysis The Ultracorr transducers are equipped with an integral temperature measuring RTD which enables the taking of simultaneous metal thickness and metal temperature readings The instrument will use the temperature data to compensate for changes in the metal thickness reading due to temperature variations The new generation of transducers are embedded with smart sensors that retain user configured ID characteristics Note The corrosion monitoring industry commonly uses the term probe to refer to the corrosion measurement sensor which could be an ultrasonic probe In the non destructive testing industry it is common to see the term ultrasonic transducer used For the purposes of this manual these terms are equivalent andmay be used interchangeably A basic system consists of a smart transducer the new Ultracorr handheld instrument and the CORRDATA Plus Software package
29. obe is a smart transducer the following screen will appear Probe ID XX Tag XXXXXXXXXXXX Read Exit Ultracorr Corrosion Monitoring System 41 Note If the smart probe has never been configured Ultracorr will detect this and provide the user with the option to manually setup the probe at this time refer to Configuring a Probe section Select Read F1 to start reading the probe When Ultracorr completes the reading it will display the following screen Probe ID XX Tag XXXXXXXXXXXX Thickness X XXXX in Read More Save Exit Pressing the Read F1 will reread the probe To save the reading to the internal non volatile memory press Save F3 Press More F2 to see additional information below Pressing Back F2 will return the display to the above screen Thickness x xxxx in Mat Temp xxx x C Signal xx x db Back Reading Previous Generation UST Probes To begin reading a probe press the Read F1 key from the Main display screen On the Connect to Probe screen press Read F1 shown below Connect to Probe Test Probe Exit Ultracorr will automatically detect whether the probe is smart or of the previous generation In this situation the following screen will appear Ultracorr Corrosion Monitoring System 42 Not smart probe Read Read by by ID Tag The user can choose to read the probe by ID or by Tag Press Read by ID F1 or Read by Tag F2 and one of the following 2
30. on UST Prob S ooooonoccnnnconocononcnconncoonnnonncnnn nono ncconcnnnos 42 Chapter d O ansia 45 Displaying Data on the Ultracom euuseunesnenenutanunenne ande 45 Displaying the Last Readine ae aaa 45 Chapter I ke le 47 Transfer Readings from Ultracorr to the CORRDATA Plus u seen 47 CORRDATA Plus Installation as ee 47 Configuring CORRDATA Plus ad eeu auictoe te ail agetei 47 Connecting the Ultracorr to the PC rer 47 Ultracerr Data Transfer Procedure cist ian ois deed a 48 Chapter A rt o diana ats here unlit edo od mins des ct etna ag 51 Troubleshooting nisse ii 51 Troubleshooting Cuide ont toa 52 vi List of Figures and Drawings Figure 1 1 Ultracorr Instrument and Transducer oooonoccnonccnonnnonncooncnonnnnonnnnn nono ncnoncnnnnnnnn no 2 Figure 1 2 System ONCE int een Clot tdo Da a 3 Figure 2 1 Ultracorr Instrument Specifications ooocooccconcnoncnnonnconncconnconanonn nono nccnnncann crac 7 Figure 31 gt Transducer Location ae is 9 Figure 4 1 Installed Transducer ucraniana da 11 Figure 5 1 Weather Resistant Connector a er 21 Figure 5 2 Pole Mount Junction Box 2 2 2 2 A ee 22 Figure 5 3 Wall Mount Junction Bor a u 23 Figure 6 1 Battery Cover of Ultracorr InstruMeNt ooooonnncnoncnonncnonnnnnnncnnncnoncconnnonn nono ncnns 26 Figure 7 1 Ultracorr Function Keys iii ea 29 vii viii Chapter 1 Introduction System Overview The new Ultracorr is the next evolution in ha
31. osion Monitoring System 36 Use the Up F2 and Down F3 keys to scroll through to find the alloy of the pipe or vessel Press Enter F1 to proceed to the next screen If the probe being configured is a previous generation probe the user will be prompted to Select Cable Length Use the Up F2 and Down F3 keys to scroll through to find the correct length of the probe and press the Enter F1 Ultracorr has now completed programming the probe with the chosen ID and saved the settings on its memory Following screen will display on the Ultracorr Probe Configured Read Probe Press Exit F4 to return to the Main screen or Read Probe F1 to conduct a reading of the configured probe Refer to Reading Ultracorr Probes for details Use a PC to Configure Probe and Save Setting to the Ultracorr Create the desired Site Group and Probe list running the CORRDATA Plus Corrosion Management Software program on the PC To configure the Ultracorr with the above created probe list click the Device Configuration command button on the CORRDATA Plus software program Choose the Mate radio button on the Select Device area and choose Ultracorr from the Select Method drop down menu Now select a complete group or an individual probe from the list to configure the Ultracorr Refer to the CORRDATA Plus Corrosion Management Software User Manual for more information on creating Sites Groups and Probes CORRDATA Plus configured Probe IDs will take prec
32. r back on and navigate back to the continuous read screen as done before A Place the transducer with the epoxy on the pipe surface in the noted place Let the magnet pull the transducer onto the surface Slight pressure on the back of the transducer is allowed to let the transducer make full contact with the pipe surface Do not push excessively as you can damage the piezoelectric element Again while monitoring the db signal on the Ultracorr unit slightly adjust the transducer on the pipe until you find the lowest db reading Using the soft epoxy as a couplant the db signal will be slightly higher then with the glycerin An acceptable db signal now would be under 44db for pipe thickness of 4 46db for 4 to 7 and 48db for 7 and up Anything higher is unacceptable and will result in an inaccurate thickness measurement If you are not able to achieve the required db reading then the transducer must be taken off the pipe Thoroughly clean the transducer face and the pipe surface free of any epoxy with the alcohol wipes and further sand the pipe surface Test again with glycerin before applying more epoxy Ultracorr Corrosion Monitoring System 16 Figure 4 8 After locating the best spot for mounting with the epoxy A preferred method of installing the transducers is to run the transducer cable parallel to the pipe line Secure the cable with tape straps or other material to the pipe about 6 inches or further from the transduc
33. r and pipe surface as it will prevent the epoxy from affixing to the pipe surface Remove the supplied epoxy kit from its packaging The epoxy kit is a two part epoxy It is pre measured to the required A to B ratio All that is needed to be done is to combine the two parts and mix Part A is supplied in the mixing cup and Part B is supplied in the syringe Squeeze Part B out of the syringe and into the mixing cup with Part A and mix with the supplied mixing stick The part B material in the syringe can become hard and difficult to squeeze out If this is the case simply snip the tip of the syringe with a pair of scissors to make the opening larger and then squeeze out Mix the two parts together for at least one minute scraping the walls of the mixing cup to insure all the epoxy is mixed thoroughly Do not mix vigorously as it can trap air bubbles in the epoxy and degrade the measurements Ultracorr Corrosion Monitoring System 14 Figure 4 6 Mixed Cup of Epoxy A After the epoxy has been mixed thoroughly use the mixing stick to scoop a generous amount of epoxy and place on the face of the cleaned transducer Recommended installation is one epoxy kit per transducer however one kit can be sufficient enough to install two transducers Use enough epoxy to cover the entire face of the transducer with a thick layer Ultracorr Corrosion Monitoring System 15 Figure 4 7 Epoxy Applied to the Face of the Transducer A Turn the Ultracor
34. should have dropped down to a lower number If the db reading is above 45db for any pipe thickness the probe has been incorrectly installed The pipe line is now ready for repair and backfill if applicable RCS provides a pipeline repair kit that is well suited for the Ultracorr transducers Please contact and RCS sales representative for information on this With the epoxy fully cured the transducer is firmly attached to the pipe line However it still can be easily damaged or knocked off the pipe if bumped Take extreme care with the pipeline repair and backfill process so as to not damage the transducer and its mounting Ultracorr Corrosion Monitoring System 18 Figure 4 7 Different transducers affixed to pipelines and pipe repair being applied Ultracorr Corrosion Monitoring System 19 20 Ultracorr Corrosion Monitoring System Chapter 5 Transducer Connection and Signal Cabling Cabling The standard transducer is fitted with a weather resistant connector see figure 5 1 This connector is suitable for outdoor environments and therefore can be left at a convenient reading point without any further protection If required cable can be run through conduit to its desired location Conduit must be 1 1 4 or larger to accommodate the 1 25 diameter connector housing Two types of cable are available The standard has a thick black polyurethane outer jacket and is suitable for most environments For more severe
35. t in position while the adhesive cures The temperature sensor on the transducer allows for automatic correction of acoustic velocity as a result of the metal temperature This provides a significantly more accurate reading of thickness These newest generation transducers also have the capability of storing and transmitting location and configuration information to the Ulltracorr instrument for ease of operation and to eliminate operator errors Ultracorr Corrosion Monitoring System 3 Signal Cabling Two types of cables are available to bring the reading point to a convenient location For example if a monitoring point is on a vessel 20 feet above the ground then access to the monitoring point location is only required for the initial installation of the transducer A cable may then be run from the transducer to a junction box located at ground level Each installation must be evaluated for the proper type of cable installation Standard cables have a weather resistant polyurethane jacket and a stainless steel armored cable is available for severe applications Reading Point There are various options available for a remote reading site For a location with a single monitoring point the transducer cable is fitted with a weather resistant connector An optional NEMA 4X junction box with provision for up to seven connectors is available Larger junction boxes are also available For underground applications standard above ground or flush with gra
36. trument Battery Requirements 6 AA Alkaline Cells Battery Life Over 600 readings Operating Temperature 32 F to 122 0 C to 50 C Storing Temperature OF to 150 F 18 C to 70 C Dimensions 7 75 H x 4 30 W x 2 D 196 8 mm x 109 2 mm x 50 8 mm Weight 1 6 lb 0 71 kg Supplied With Ultracorr Instrument 6 AA batteries Ultracorr to computer cable Lemo to USB CD ROM with Ultracorr Corrosion Monitoring System User Manual and CORRDATA Plus Corrosion Management Software and Manual Carrying Case Ultracorr Corrosion Monitoring System GAGE IS E id un Figure 2 1 Ultracorr Instrument Specifications Ultracorr Corrosion Monitoring System Ultracorr Corrosion Monitoring System Chapter 3 Location of Monitoring Points The small size of the transducer allows it to be mounted almost anywhere The only requirement is a two inch diameter area of clean metal Some of the factors to consider when selecting a monitoring point include 4 Access must be provided to the monitoring point for the initial transducer installation After installation access to the monitoring point is not required A Insulated vessels must have the insulation removed at the monitoring point An access port can be installed at that location A Generally the most cost effective installation is the shortest cable run to the most convenient and safe man access to the test station ABOVE GROUND VESSEL TRANSDUCERS
37. ult Rohrback Cosasco Systems for details Check the port number used by the USB or the RS232 and make sure the same COM port is selected on the CORRDATA Plus in most cases with RS232 this will be COM 1 however verify this in the device manager Make sure to select the proper interface type on the Ultracorr instrument refer to Setting Ultracorr to PC Interface Launch CORRDATA Plus and Open an Existing Site or Create a New Site Ensure the port number selected on the CORRDATA Plus software Preferences gt Settings gt Default Port matches the port number of the Ultracorr connection Ultracorr Corrosion Monitoring System 47 Ultracorr Data Transfer Procedure To begin the data transfer from the Ultracorr to the CORRDATA Plus press Dump F3 from the Main display screen following display will appear First press START on Ultracorr Then run Corrdata Plus on PC Start Exit Note Ultracorr must initiate the data transfer Press START on Ultracorr before Read from Device button is pressed on the CORRDATA Plus software On the CORRDATA Plus Corrosion Management Software program click the Receive Data command button select Mate as the Select Device and Ultracorr as the Select Method Choose the appropriate To Group selection Press Start F1 on the Ultracorr first then click the Read from Device command button to begin downloading data to the PC The Ultracorr will show the following screen Dumping data to PC Ple
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