Professional Documents
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CORRDATA® SYSTEM
REFERENCE MANUAL
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.
Contents
Chapter 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RDC Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CORRDATA Mate I & II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PC Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installing an RDC Unit on a Probe . . . . . . . . . . . . . . . . . . . . . . . 10
Intrinsic Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CORRDATA Mate I & II . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CORRDATA Basic PC Software . . . . . . . . . . . . . . . . . . . . . . . . 18
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Contents
Chapter 8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
RDC Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
CORRDATA Mate I & II . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
PC CORRDATA Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Software Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
ii
Contents
Chapter 9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
RDC Unit Power Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Checking Functional Operation of RDC
with Mate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Mate I & II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Checking Mate II Operation on Probes . . . . . . . . . . . . . . . . . . . . 95
Mate I & II Self Check System Reprogramming Utility . . . . . . . . . 95
PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
If Problems Still Occur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Appendix A
Theory of Operation of CORROSOMETER
Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Appendix B
Theory of Operation of CORRATER®
Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Appendix C
Special Conditions or Limitations for use of
Intrinsically of Safe Equipment to European
Harmonized Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Appendix D
Lithuim Battery Pack Material Safety Data Sheet,
Handling and Transportation . . . . . . . . . . . . . . . . . . . . . . 165
Appendix E
CORRDATA System Certification
Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Appendix F
Operation of CORRDATA Basic Software
With Windows 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
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Contents
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Contents
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Contents
vi
1
Chapter 1
Introduction
The CORRDATA Corrosion Management system is extremely flexible in its operation. The Mate
I & II operate with Remote Data Collectors (RDC's) to gather time-related corrosion data, even
from remote locations where power is unavailable. In addition, the Mate II allows for automated
data collection directly from CORROSOMETER, CORROTEMP CORROSOMETER and
CORRATER probes used without an RDC.
CORROSOMETER probes measure metal loss in any process environment. CORRATER probes
directly measure corrosion rates in sufficiently conductive fluids, normally water. CORROTEMP
versions of the probes add temperature measurement to assist in the correlation of corrosion rates
with temperature.
RDC's combined with probes take and store readings at pre-programmed intervals for retrieval by
the Mate I & II and transfer to your PC. This provides continuous time-related history,
complementary to the continuous, on-line ICMS (Integrated Corrosion Monitoring Systems) used
primarily in process plants.
CORROTEMP CORRATER units have a corresponding range of time intervals from 30 minutes
to 24 hours.
The Mate II also automates direct reading and logging of probes, without an RDC. This avoids
potential errors from incorrect recording of readings.
A basic CORRDATA software package is included free of charge with the Mate I & II for DOS
based PC's. This copyrighted software provides for system configuration, storage and
manipulation of the corrosion data.
5
Chapter 2
Specifications
RDC Units
Electronics
Ë RDC - CORROSOMETER unit (RDC-CO) compatible with all
CORROSOMETER probes
Ë Battery Life:
RDC4 - COT
14 Ah Battery Pack - Typical life 177 days @ 1 reading/4 hour
Ë Reading Storage:
RDC - CORROSOMETER:
Typical ± 0.1% of probe span on W40 carbon steel probe
Typical ± 0.5% of probe span on T20 carbon steel probe
Typical ± 0.5% of probe span between RDC units
Mechanical
Ë NEMA 4 (Version 1) or NEMA 4X (Version 2) weatherproof enclosure
Ë Battery Powered:
Mechanical
Ë Splash-proof enclosure
Environmental
Ë Temperature range:
Operating - 0oF to 122oF ( -18oC to 50oC )
Storage - 0oF to 150oF ( -18oC to 70oC )
PC Requirements
Ë IBM PC or compatible
Ë 640k memory
Ë MS DOS 3.3 or higher operating system ( MS DOS 4.01, 5.0, 6.0 or 6.2 preferred)
8 CORRDATA Reference Manual
Ë Serial port available (adapter cable provided for easy access to Mate I & II cable)
9
Chapter 3
Installation
Unpacking
Carefully remove the instruments from their packages. Included in the package you should
find:
WARNING! Before installing the RDC unit, verify that you have
the correct RDC for the CORROSOMETER, CORROTEMP
CORROSOMETER, CORRATER, or CORROTEMP CORRATER
PROBE to be monitored, and that the cable connector on the RDC
unit matches the probe connector.
The RDC unit should be mounted adjacent to the probe that is to be monitored and in a
position that permits easy access for data collection by the Mate I or II. Figure 3.1A shows
the RDC unit and its mounting hole dimensions.
The RDC unit is supplied with a 10 ft. long probe cable which meets most installation
requirements. Longer cable lengths are permissible on a special order basis with a
maximum length of 100 ft. No external power supply is necessary since the unit is battery
operated. For Solar powered options, and remote modem or cellular phone communication
contact Rohrback Cosasco Systems about Communication Power Modules (CPM's)
Within the RDC, memory back up of data is provided by a small rechargeable battery.
This battery is separate from the main battery supply to avoid loss of data even when the
main batteries have expired, and provides a back up for approximately 3 months. This
battery must be switched ON before connecting the main battery and before start up of the
unit by setting the DIP switches, item 1, to ON as shown in Figure 3.2A for metal
12 CORRDATA Reference Manual
enclosure units, or setting DIP switch number 1 to ON, item 1, as shown on Figure 3.2B
for plastic enclosure units.
The main Lithium battery pack is installed in the RDC unit as supplied, but with the plug,
item 2, left unconnected to avoid battery drainage. Lithium batteries are used exclusively
in the RDC because of their much greater capacity than conventional batteries. The two
pin plug, item 2, should be connected to the circuit board connector item 3 as shown in
Figure 3.2A, 3.2B or 3.2C prior to setting the RDC into operation.
To test the battery condition press push-button, item 4, and check that the red indicator,
item 5, adjacent to the battery connector illuminates (for more information see "RDC
Battery Check and Replacement" in Chapter 6).
Once the RDC unit has been mounted and the probe cable connected to the probe, the
connector clamp ring must be firmly tightened.
Chapter 3 Installation 15
Intrinsic Safety
The probes, RDC units, and Mate I & II systems have intrinsic safety ratings for use in
electrical hazardous area environments. Applicable certifications are identified on the
System components according to units ordered.
The intrinsically safe system has been certified with a rating of EEx ia IIC T4 at
temperatures of up to 500C. For temperatures from 500C to 700C the rating is EEx ia
IIC T3. This means that the system is safe for use in the severest of electrical hazardous
areas, where explosive gases are always present (Zones 0, 1, and 2; Divisions 1 and 2,
all groups) even with up to two fault conditions (designated by ia).
The gas classification IIC is the most stringent including gases such as acetylene and
hydrogen. This part of the rating relates to the spark energy that is required to create an
explosion.
Gases have a separate classification for explosive tendency based on hot surface
temperatures which are not necessarily the same as the spark ignition energy. The
temperature rating T4 indicates that no temperature of the equipment exceeds 1350C at
500C even under fault conditions. This rating includes all listed gases except carbon
disulfide (which requires T5 rating)
Care must be taken with intrinsically safe systems to maintain their carefully designed
integrity. The major features to note are as follows:
2. Only the correct RDC batteries must be used, since they have integral
current limiting devices to permit their replacement in the hazardous area.
3. Only the intrinsically safe "Mate to PC" cable should be used between the
Mate I or II and the PC even though this is in the safe area. This prevents
any excess power from being passed onto the Mate II, which could then be
carried into the hazardous area.
4. Absolutely no substitution of parts or unauthorized repairs must be
undertaken or the certifications are rendered invalid.
16 CORRDATA Reference Manual
To check that the unit is operational press the ON button. The screen should appear as
in Figure 3.4.
Chapter 3 Installation 17
ROHRBACK COSASCO
SYSTEMS
If the batteries are low or in need of replacement, the cursor on the screen will alternate
the standard cursor with cursor LB (see Figure 3.4).
Battery back up for memory in the Mate I & II is provided by lithium batteries mounted
internally within the unit. 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.
18 CORRDATA Reference Manual
Ë IBM PC or compatible.
Ë 640 K memory.
Ë Hard disk.
Ë MS-DOS 3.3 or higher operating system (MS-DOS 4.01, 5.0, 6.0 or 6.2
preferred).
The CORRDATA basic software package is included with the CORRDATA Mate unit
on 3 ½" diskettes.
To install the CORRDATA software, place the appropriate diskette in your floppy
drive. At the DOS prompt, change the drive to this floppy and type install. The
program gives the choice of the directory where the files are to be installed and the
serial port COM1 or COM2 to be used. Follow the on-screen instructions.
The default for the directory is CORRDATA installed in the root directory on the C
drive.
When the installation is complete, remove CORRDATA Software diskette and save as
a backup.
To commence the program in DOS select the CORRDATA directory and then type
"CD2". If using Windows double click on the Icon for CORRDATA.
Fit the "Mate to RDC" cable to the Mate I or II and connect it via the "Mate to PC"
cable to the required serial port, COM 1 or COM2, of your PC. The "Mate to PC"
cable brings the Mate I or II to PC connection to the front of the PC for ease of use. On
intrinsically safe units this cable also includes special isolation components.
Chapter 3 Installation 19
The serial port on the PC has either a 9 pin or 25 pin connector. If it has a 9 pin serial
port, you will need to use the 25 pin to 9 pin adaptor supplied with the cable assembly.
20 CORRDATA Reference Manual
21
Chapter 4
System Overview
PROBES
1
Default display with open circuit temperature loop
For CORRATER and CORROTEMP CORRATER systems the options and capabilities
are as follows:
PROBES
1
Default value with open circuit temperature loop
22 CORRDATA Reference Manual
Once programmed with the probe parameters and the frequency of readings required, the
RDC unit "sleeps" between readings to minimize power consumption. At the appropriate
time it powers up the probe and electronics, processes the probe reading, and stores the
value before going back to sleep. The stored probe reading and times are retrieved as
required when interrogated by the hand held Mate.
The system configuration can be made with the Mate I or II alone. However, it will
normally be more convenient to set up the probe configuration on the PC and then to
transfer this to the Mate I or II, which in turn configures any RDC units.
A typical RDC CORROSOMETER entry screen is shown below in Figure 4.1, and a
typical metal loss graph output is shown in Figure 4.2
Chapter 4 System Overview 23
Chapter 5
System Configuration Procedures
To commence system configuration on the PC, select the CORRDATA directory in which
the CORRDATA program is located and type CD2. Press Enter to clear the RCS
CORRDATA introduction screen, and display the main menu. Help screen information
is available via the F1 key for the menu items.
NOTE: Menu items may be selected using the cursor keys, space bar,
tab (forward), shift + tab (backward) keys and Enter, or by typing the
highlighted letter.
Select Mate/RDC. This will display any existing entries on the probe list together with an
entry menu bar, such as the list in Figure 5.2.
For this first time configuration, or for new additions to the existing list, select NEW to
display the sub-menu of input selections.
Chapter 5 System Configuration Procedures 27
Select the appropriate configuration required according to the probe type and whether an
RDC will be used with the probe. Press Enter to bring up the information entry screen.
For a CORROSOMETER probe with an RDC, the screen would appear as follows.
Use the 8 or 9 keys to move between the highlighted entry fields. Press the Enter key to
gain access to the data entry box. Type in the required data, using the backspace, 6 or 7
arrows, or delete keys as necessary. For fields with pre-selected values use the 6 or 7
arrows. When a field entry is correct, press Enter to complete.
The entry screens for each type of probe are similar except as noted below:
Probe Tag This is an optional field of 12 character maximum, normally used for probe
tag numbers such as AE 3041. Alternatively, a brief description or location
may be used. The tag is the only ID description that appears on the Mate
II. The location field appears only on the PC.
Alloy This is the field for identification of the probe element alloy for
CORROSOMETER and CORROTEMP CORROSOMETER probes or the
probe electrode alloy for CORRATER and CORROTEMP CORRATER
probes. Typically the UNS alloy code is used such as K03005 for pipe
grade carbon steel. Alternatively Carbon Steel, 304 SS, Monel 400, or
other appropriate alloy references may be used if within the 8 character
maximum.
Alarm This is provided for informational purposes only. Since the corrosion
Rate data is historical, active current alarms in the normal sense are not
applicable.
Reading This entry only applies to probes using an RDC, and sets the frequency
Interval with which readings will be taken automatically by the RDC unit. For
information on the selection of the most suitable interval see "Choosing
Probe Reading Frequency" later in this chapter. For the CORRATER or
CORROTEMP CORRATER probe, the only minutes selection is 30
minutes. Shorter times are not permitted since under some operating
conditions cycle times of up to 30 minutes are required to obtain accurate
measurements. For RDC4-COT multiplexer units the minimum time that
MUST be set is 15 minutes. If set to a shorter time it will default to 15
minutes when configuring the RDC4-COT.
Once all the necessary information has been completed on this screen and is correct, press
F2 to save the information. This will then return to the configuration mode - input
selection Figure 5.3.
Repeat the procedure with the next probe or probe/RDC entry until all the necessary entries
have been completed. When the final entry has been saved, use the Esc key as necessary
to move back up the menu tree.
To edit any of the entries, select Configure from the main menu to display the existing
probe list summary. Use the arrow keys to move the highlight bar to the required probe.
Select Edit from the menu bar. The information entry screen will appear which may then
be edited as required and saved with the F2 key. If you wish to exit without making any
changes use the Esc key.
has been collected may distort the data and may show up as a
discrepancy for resolution at data merge on the PC (See
"Transferring Collected Data to PC in Chapter 6).
To delete an entry select Configure from the main menu to display the probe list. Select
the required entry with the highlight bar, and select Delete from the menu bar.
Once all the configuration information has been loaded into the PC, the data is ready for
transfer to the Mate I or II, and from there to each probe/RDC combination to configure
the RDC for data collection.
Before loading the configuration information from the PC to the Mate I or II, check that
the "Mate to PC" serial cable assembly, labelled "Mate to PC,"is connected to the correct
serial port of the PC. The cable assembly is provided with a 25 pin connector for the serial
port, and a 25 to 9 pin adapter for use with a 9 pin serial port connection.
Attach the "Mate to RDC" cable to the Mate I or II and plug the Mate I or II into the "Mate
to PC" serial cable assembly. Select Configure from the main menu of the CORRDATA
software, and then Load. Press the green ON switch on the Mate I or II. A short self test
is made before the main menu appears.
ROHRBACK COSASCO
SYSTEMS
Configuration
Options
Mate Configuration
Connect Mate to PC
PC must be running
CORRDATA Software
START EXIT
Press START (F1) to commence the configuration information transfer from the PC to the
Mate I or II. During this process the Mate I or II will display the following message:
32 CORRDATA Reference Manual
Configuring Mate
Please Wait
ABORT
On completion of the configuration the CORRDATA Mate will display the message:
Mate Configured
EXIT
Press the red OFF key on the Mate I or II to switch off the unit, and disconnect it from the
serial cable assembly to the PC. The Mate I or II is now configured ready to transfer the
configuration information to any probe/RDC units. Now for the Mate II only, the clock
must be set on the Mate II before it can gather readings directly from probes without
RDC's, as described in the next section. This is required so that the probe readings are
correctly date and time stamped. For probes with RDC units, the controlling clock is in
the RDC and is set by the Mate I or II as described in the section "Configuration of the
RDC" later in this chapter. Exit the CORRDATA PC software if required with the Esc key
and Quit from the main menu.
To configure the RDC units with the CORRDATA Mate see "Configuration of the RDC"
later in this chapter.
2. After the self test screen clears, press: SetUp (F4); Mate (F1); MANUAL CONF
(F1); SET TIME (F2); SET (F2). Enter the date and time in the format indicated:
Chapter 5 System Configuration Procedures 33
It is generally easier to set up all the probe information on the PC and transfer it to the
Mate I or II, which in turn is used to program any RDC units on the system. However, it
is also possible to configure the system entirely from the Mate I or II, and transfer this
information back to the PC later.
The Mate I or II may be programmed with the probe information for the whole system and
then taken to configure any RDC's on the system. Alternatively, the Mate can be
configured one probe at a time and then used to configure any RDC's as you progress to
various probes and RDC's. Before configuring the Mate, first check that the batteries have
been installed. Switch on the Mate. After the self test screen clears, the main menu is
displayed.
ROHRBACK COSASCO
SYSTEMS
Configuration
Options
Phone
Mate RDC Timer EXIT
Select Configure Mate (F1) to program the probe data into the Mate II which will be
used to configure any probes with RDC's. The following screen will be displayed:
Mate Configuration
For Mate I, press MANUAL CONF (F2). For Mate II, press MANUAL CONF (F2)
and CONFIG ID (F1)
The system has a capacity of up to 50 probes per route. Each probe or probe with RDC
is identified by its allocated ID number.
Chapter 5 System Configuration Procedures 35
Enter the ID number from the keyboard, using CLR (F2) and BkSp (F3) if necessary,
and press ENTER (F1) when complete. The screen then displays:
There is a provision for 12 alpha numeric probe identification or tag number characters.
Enter the required designation and press ENTER (F1).
The next screen involves setting the frequency with which readings are taken if an RDC
is used. On the RDC CORROSOMETER unit or RDC CORROTEMP
CORROSOMETER unit the options are intervals of 5, 10, 15, and 30 minutes, or 1, 2,
3, 4, 6, 8, 12 or 24 hours. For the RDC4-COT multiplexer unit this MUST NOT be set
less than 15 minutes. For the RDC CORRATER unit or the RDC-CORROTEMP
CORRATER unit the hourly settings are the same but the minute setting is limited to
30 minutes due to the automatic cycle time of the unit required for the measurement.
For choice of the most appropriate interval see "Choosing probe reading frequency",
later in this chapter. For the Mate II, if the probe to be read does not have an RDC
enter 0 and press ENTER (F1).
The first of the two selection screens shows the hourly selections.
36 CORRDATA Reference Manual
Either enter the number of hours required from the keyboard, using the CLR (F2) if
required and then press ENTER (F1), or press mins (F3) for selection of a minutes
range in which case the display will show the following for an RDC
CORROSOMETER unit or an RDC CORROTEMP CORROSOMETER unit:
For a minute selection, only the preset values will be used. Enter the required value and
press ENTER (F1).
Chapter 5 System Configuration Procedures 37
The next screen to appear is for selection of the element alloy of CORROSOMETER
or CORROTEMP CORROSOMETER probes or electrode alloy of CORRATER or
CORROTEMP CORRATER probes being monitored.
Up to 8 alpha numeric characters may be used for the alloy description. This may be
an abbreviated verbal description such as "C.Steel", "304 S.S.", or the 6 digit UNS
material code designation on the probe model or electrode set such as "K03005" or
"S30400". Type in the description and press ENTER (F1). This will display a
selection screen for the probe type.
A=WIRE E=CA
B=TUBE F=CA-FLUSH
C=STRIP
D=CYLINDRICAL EXIT
Is this a CORROTEMP
CORROSOMETER Probe?
NO YES
CORRATER probes either have standard projecting electrodes or flush electrodes. The
former have a surface area of 5 cm2 per electrode and the latter have a surface area of
0.5 cm2 per electrode. The letters E and F on the probe type screen have been added for
these two selections.
Enter the appropriate probe type and press ENTER (F1). For the case of an RDC
CORROSOMETER the following screen will appear:
The CORROSOMETER probe span is specified on the probe or may be obtained from
Table 5.5.
For the RDC CORRATER the corresponding screen requests input of the Alloy
Multiplier, as the following screen depicts.
F1 F2 F3 F4
Enter the appropriate span or multiplier and press ENTER (F1). The screen will
confirm the configuration information for this RDC is complete, and display the ID
number and Tag.
Press EXIT (F4) to complete the entry for this RDC unit and return to the second
configuration options screen.
At this point, the information for this particular RDC has been completely loaded into
the Mate and is now ready for the next entry, or for loading directly to the RDC unit.
ROHRBACK COSASCO
SYSTEMS
Configuration
Options
Enter the number of the RDC unit to be configured using CLR (F2) or BkSp (F3) if
required.
42 CORRDATA Reference Manual
RDC Configuration
Connect Mate to RDC
DATE CONF TEST
TIME RDC MODE EXIT
When configuring an RDC for the first time, it is necessary to set its internal clock that
is used for date stamping the recorded probe values. The clock on the RDC unit itself
has a battery backup so that it is unaffected by changing the main RDC batteries. Once
set the clock should not normally require resetting. In fact, resetting the clock will
cause loss of existing data in the RDC.
Attach the "Mate to RDC" cable to the Mate I or II, if not already connected, and
remove the protective cover from the connector on the front of the RDC. Plug in the
cable from the Mate I or II.
Before configuring the RDC, check that the unit has been set up and the batteries
connected as described in the "Installation of RDC unit" in Chapter 3. Press
DATE/TIME (F1) to display the following screen.
To check the existing time, if previously set, on the RDC, press READ (F1). To set or
reset the time press SET (F2) to display the screen.
Chapter 5 System Configuration Procedures 43
Type in the current year, month, date, hour (24 hour), minutes, and seconds, using the
CLR key (F2) and BkSp key (F3) as necessary. Once the entry is correct and the
selected time is reached, press ENTER (F1) to set in the selected time. The previous
screen reappears to confirm the entry.
This completes the clock entry and the RDC unit may now be configured for the probe
parameters.
To exit the clock setting screen, press EXIT (F4) and return to the screen.
RDC Configuration
To prepare the Mate I or II for loading the configuration information into the RDC
press CONF RDC (F2). If the RDC to be configured is a CORROSOMETER unit the
display will be:
44 CORRDATA Reference Manual
Mate connected
to RDC-CO
NEW
START PROBE EXIT
Configuring RDC
Please Wait
Followed by:
RDC # . .
Configured
EXIT
Pressing EXIT (F4) will return the screen to the RDC configuration screen ready for
the next RDC unit.
If there should be any problems with the RDC unit, the probe, or its connections, one
of the following messages will appear:
Chapter 5 System Configuration Procedures 45
In general, the greater the number of readings taken the better is the resolution on
corrosion events. This must be balanced against battery life, battery costs and the
frequency with which data will be collected.
Chapter 5 System Configuration Procedures 47
CORRATER
Using the tables shown in Figure 5.7 and 5.8 the reading intervals should be chosen
so that the battery pack will last at least through the time period between collection
of data from the RDC.
Normally it will not be necessary to clear the memory on the Mate I or II 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, or
is used on more than one data collection route then it is recommended to clear the
memory on the Mate to avoid conflict or the addition of other probe data to the probe
list. To clear the memory of the Mate I or II it is necessary to enter the Configure
mode. From the initial screen,
48 CORRDATA Reference Manual
ROHRBACK COSASCO
SYSTEMS
For the Mate I press SetUp (F4) and CLRMEM (F3). For the Mate II press SetUp
(F4), Mate (F1), MANUAL CONF (F2), and CLR MEM (F3). On either Mate I
or II the following screen will appear:
CLEARING MEMORY
Please Wait
This will take approximately 30 seconds to clear, indicating that the memory is now
cleared.
Chapter 6
Normal Operating Procedures
Once the system has been configured as described in Section 5, data may be collected from probes
and RDC's at any time for transfer to the PC. Probes with RDC's normally will be left to
automatically collect data, and later at some convenient time, the data may be gathered. The
advantage of probes with RDC's is the improved resolution of corrosion dynamics due to the
increased reading frequency.
ROHRBACK COSASCO
SYSTEMS
The following screen will appear. Press Read (F1) which displays the screen:
What to Read?
START EXIT
Remove the protective cover on the connector of the front of the RDC unit and connect the
cable from the Mate I or II.
The following screen will show during initial interrogation and data collection by the Mate
I or II.
Interrogating RDC
Please Wait
ABORT
If the following message appears check the connection between the Mate and RDC and try
the reading again. If the same message appears, check the RDC batteries as described later
in this chapter.
WARNING!
No Response from RDC
Try again in 30 sec.
EXIT
Once data collection commences the following screen will appear briefly.
Chapter 6 Normal Operating Procedures 51
Collecting Data
Please Wait
ABORT
This latter process takes only a second or two depending on the amount of data to transfer
so that they may barely be visible unless there is a problem with either process.
On completion of the data collection, the screen will display the identification of the RDC
from which data has been collected as follows:
If for any reason there is a problem with data collection, one of several messages may
appear.
52 CORRDATA Reference Manual
Data collection is complete and pressing EXIT (F4) returns to the initial screen shown at
the start of this section ready for the next RDC unit.
Remove the "Mate to RDC" cable from the RDC, replace the protective cover on the RDC
unit connector and switch off the Mate I or II.
With the Mate II configured, proceed to the first probe location without an RDC. Attach
the "CORROSOMETER" cable to the Mate II if the probe is a CORROSOMETER or a
CORROTEMP probe. Attach the "CORRATER" cable to the Mate II if the probe is a
CORRATER probe. Switch on the Mate II. After the self test screen clears, the main
menu is displayed.
ROHRBACK COSASCO
SYSTEMS
Read CA or CO Probe
by
ID TAG EXIT
To select the probe by ID number, select ID (F1); to select the probe by TAG number,
select TAG (F2)
Enter the appropriate ID or TAG for the selected probe, and press ENTER (F1). For a
CORROSOMETER or CORROTEMP CORROSOMETER probe the screen will display:
Connect Mate to
CORROSOMETER PROBE
ID: . . . . . . . . . . . .
START EXIT
Connect Mate to
CORRATER PROBE
ID: . . . . . . . . . .
START EXIT
Check carefully that the correct probe to be monitored has been selected and press START
(F1). The screen will indicate that the probe is being read as it occurs. This time will vary
in length according to the probe being monitored. When complete, the probe reading will
be displayed as follows for a CORROSOMETER probe:
CO PROBE READINGS
Div: . . . Check: . . .
EXIT
CO PROBE READINGS
Div: . . . Check: . . .
Temp: . . . degs C
EXIT
The readings with their time and date are automatically recorded by the Mate II, each time the
probe is read. When readings are complete, switch OFF the Mate II and proceed to the next probe
to be monitored.
To view the data, switch on the Mate I or II. After the self test screen clears, the main
menu is displayed.
ROHRBACK COSASCO
SYSTEMS
To display the last recorded reading from the most recently read probe, press CURR
PROBE (F1). To select the reading from a different probe, press ID (F2) and the display
will request the ID number.
56 CORRDATA Reference Manual
Enter ID (1-50)
>..<
Alternatively, to select a probe by it's tag, press TAG (F3) and the display will request the
tag number:
Type in the tag number including trailing spaces to fill the field and press ENTER (F1).
This search is not as fast as for the ID number. During the search the following screen is
displayed:
EXIT
After completing the probe search, data is displayed in the following manner:
Two screens are used to display data which vary slightly between standard and
CORROTEMP units. For example, reading a RDC CORROSOMETER the first screen
will display:
Chapter 6 Normal Operating Procedures 57
ID: . . . . . . . . . .
Type . . . Span: . . . . .
Div: . . . Chk: . . . (. . .)
MORE EXIT
"Div" is the probe reading, where 0 to 1,000 is the useful probe life or span. "Check" tests
the integrity of the reference element, and should be within ± 25 of its initial value given
in the parentheses.
. . . . Readings @ . . hrs
Alloy: . . . . . . . .
EXIT
For CORROTEMP versions the temperature is added to the second screen as follows:
. . . . Readings @ . . time
Alloy: . . . . . . . .
Temp:. . . . Deg C
EXIT
On probes with RDC's, the number and frequency of readings is indicated. On probes
without RDC's (Mate II only), the reading frequency is set to 0. The number of readings
is indicated to a maximum number of 2048 for CORROSOMETER RDC's, 1024 for
CORROTEMP CORROSOMETER RDC's, CORRATER RDC's, and 512 for
CORROTEMP CORRATER RDC's. For the Mate II reading probes directly the maximum
number of stored readings is 256. At the maximum number of readings the oldest reading
will be discarded whenever a new reading is added.
NOTE: During the RECEIVE operation the new data and the old
data will be merged in the current file and the old data will be
converted to a backup file automatically with a .BAK extension.
58 CORRDATA Reference Manual
To return to the main menu screen press EXIT (F4). The rest of the collected probe
readings must be viewed on the PC where the data is shown graphically.
NOTE: Even if faulty check readings have occurred, probe data will
still be collected. The graphical display on the PC however, will
indicate a faulty check by a half thickness graph line.
After the collection of the probe data indicating that the probe needs replacement, plug the
Mate I or II cable into the RDC before disconnecting the probe. This suspends probe data
collection and avoids spurious readings while the RDC and probe are disconnected.
Unscrew the probe cable connector and carefully replace the probe with the new probe.
Make sure the probe and plug connections are clean. Tighten the connector clamp ring
firmly to ensure a good connection.
On the Mate I or II, select SET UP (F1) from the main menu.
Configuration
Options
Phone
Mate RDC Timer EXIT
RDC Configuration
Connect Mate
to RDC-CO
SET NEW
START MUX PROBE EXIT
Select NEW PROBE (F3), and EXIT (F4) twice to return to the main menu. Data
collection of the new probe will commence, taking account of the new initial check
reading.
After replacement and re-connection of the new probe, the RDC must be configured for the
new ID number. If the new ID number has already been entered on the PC (see "System
Configuration from the PC in Chapter 5 ) and the Mate I or II configured accordingly, then
proceed with configuration of the RDC as described in "Configuration of probes with
RDC's" in Chapter 5. If the PC and Mate I or II have not been configured for a new ID
number, follow "System Configuration from Mate I or II" in Chapter 5. The transfer of the
information to the PC will be done during the Receive operation and automatically entered
into the probe list.
Mate Configuration
Press NEW PROBE (F3) and Select the ID of the probe being changed and press Enter
(F1) to zero the initial check reading and adjust the installed date. Replace the old probe
if not already done so. Press EXIT (F4) twice to get to opening menu screen. Then read
the new probe in the normal way. This will then generate a new initial check (which will
display in the parentheses) and will change the installed date. The probe list on the PC will
indicate the new installation date.
Chapter 6 Normal Operating Procedures 61
Indication Action
CORRATER or CORROTEMP CORRATER probes require that the electrodes are always
fully submerged in a sufficiently conductive electrolyte. Consequently, the probes should
NOT be positioned in an environment where:
If the probe electrode alloy or probe type is changed, then the RDC must be reconfigured.
In fact if the probe alloy is changed it will be preferable to reallocate an ID number to
avoid two different alloy corrosion rates appearing on the same graph of the PC. Re-
configuring an RDC is the same as initial configuration which is described in Chapter 5.
3) Replace the battery connector and push the test button (2) to check the new
battery is operating correctly, by illumination of the red indicator (3).
4) Do not switch off the back up battery during this main battery replacement.
To clear the initial identification screen, press ENTER and the main menu will appear.
Select Receive on the main menu. The PC will indicate when it is "Ready to Receive".
Attach the "Mate to RDC" cable to the Mate II.
ROHRBACK COSASCO
SYSTEMS
Connect Mate to PC
PC must be running
CORRDATA Software
START EXIT
Connect the Mate II to the serial port of the PC with the cable assembly supplied, using the
25 pin connector or the 25 to 9 pin adapter as necessary.
To commence data transfer press START (F1). Warnings will show on the Mate II screen
if no communication occurs, or if any bad communication is detected.
WARNING ACTION
No response from PC Check connections and
Check connections. verify that correct serial
port is being used.
Error while dumping Bad communication.
data. TRY AGAIN. Repeat the transfer
operation.
During copying of the data to the PC, the following screen will appear on the Mate II,
showing the data copying by ID number.
Dumping Data to PC
Please Wait
RDC # . .
ABORT
The PC will show the file copying as it occurs, and the subsequent merging of the new data
into the existing data files. If any configuration mismatches are detected between the Mate
Chapter 6 Normal Operating Procedures 65
I or II and the PC these will be displayed for resolution by a series of options, as described
in the next section of this chapter.
On completion of data transfer, the Mate I or II will revert to its normal main menu. At the
time of merging the new data into the existing files in the CORRDATA directory, backup
files of the previous data are also created with a .BAK extension in the same directory.
The Mate I or II also retains the new data files after the copying process, thereby acting as
a new data backup file. Any new files that have been set up on the Mate I or II in the field
will automatically be added to the probe list, provided they do not conflict with any other
file entries.
If an RDC is to be reconfigured because of a probe type change, the data from the RDC
should first be collected, and then the RDC should be reconfigured using a new ID number
(See "Replacing probes" earlier in this chapter).
When the PC attempts to merge data from the Mate II following the Receive operation, any
discrepancy in the key configuration fields will be displayed in the following manner.
66 CORRDATA Reference Manual
Of the key configuration fields, only probe type, probe span, probe multiplier or time
interval actually can change the basic corrosion data. Discrepancies in these fields will not
allow merging, even if F2=MERGE is pressed. Discrepancies in the other configuration
fields permit F2=MERGE, since these fields are only descriptive. In this case the existing
PC fields will be retained.
F3=OVERWRITE will cause the existing file on the PC to be overwritten by the new
configuration and data from the Mate II, deleting the previous data on the PC.
F4=RENAME enables the configuration and data on the Mate II to be saved as a separate
file leaving the existing one un-disturbed. If this option is selected, a box will be displayed
for the pathname (i.e. directory and filename) where the data is to be saved. The current
CORRDATA directory may be used, provided a different filename is used from any of the
existing files.
F5=DELETE deletes the file received from the mate, and leaves the existing file on the PC
intact.
The basic CORRDATA software provides for saving of files one at a time for archiving
purposes, and for retrieving files for viewing one at a time. Any files saved are
automatically given the extension .SAV to avoid any overwriting even if the files are saved
to the CORRDATA directory. For archiving, sub-directories should be set up for the
required time periods (such as CD_MAR94) for storage of data at that time. Each file will
store up to 9,000 data points.
To save the current data to a sub-directory, first create the sub-directory in DOS at the
required location before entering the CORRDATA program. Start the CORRDATA
program and select Save, to select the directory as shown. Pathname is initially defaulted
to the current directory. Press Tab to display files in this directory.
Chapter 6 Normal Operating Procedures 67
Use the 8 or 9 keys to make the required selection, and press the Tab key. This will
display the selected file into the "Save to" box with the cursor and a .SAV file extension,
and leave a gray highlight bar at the selected probe in the file box above. Modify the
pathname as necessary for the destination sub-directory (such as c:\CORRDATA\MAR
94\RDC_11.SAV) already created in DOS. Press INSERT KEY to change to insert mode
(shown by thin cursor, typeover shown by thick cursor). Press Enter to save the file , or
use Esc to leave this screen without saving.
Archived data files may also be retrieved for the full viewing and analysis capability of the
CORRDATA program via the Display menu. Only one data file at a time may be viewed
from the archive files in the basic software. Exiting the View or Range on the Display sub-
menu to List or back to the main menu will automatically cancel the archived data file
selection. However range zooming and rate calculations on graphs are fully operational
on the retrieved file before exiting as described.
NOTE: A retrieved file is never added to the probe list in the current
CORRDATA program directory. This may only be achieved by
changing the filename outside the program to an unused ID number,
installing the file in the CORRDATA program directory, and then
selecting this ID number through the NEW entry screen in the
Configure mode, and View in the display mode.
68 CORRDATA Reference Manual
To Retrieve an archived file, select File from the main menu, and Retrieve from the sub-
menu. The box that appears will show a pathname box with a cursor present, and a blank
file box. Modify the pathname as required to select the required directory and files using
wildcards and extensions as convenient to simplify the displayed list of files (example:
C:\CORRDATA\CD_MAR94\*.SAV). This will produce a display similar to the
following.
Press Tab to switch from the pathname box to a highlight bar in the file list box. Use the
8 or 9 arrows to select the required RDC and press Enter. Press Display and View to
display the graph. The graph may be zoomed as required, and corrosion rates displayed
with the cursor keys and Enter. To return to the current operating probe list, press Esc and
List.
Chapter 6 Normal Operating Procedures 69
71
Chapter 7
Corrosion Data Analysis
In the basic software package the corrosion data may be viewed one probe at a time in a graphical
format which is generally the most useful to interpret corrosion events and trends.
Once data has been collected by the Mate I or II and transferred to the PC, the CORRDATA software
program is ready to display that data.
It should be made clear here the fundamental difference between CORROSOMETER or and
CORRATER probes. CORROSOMETER probes directly measure metal loss whereas CORRATER
probes directly measure corrosion rate. A single reading from a CORRATER prove gives the corrosion
rate at that time. For a CORROSOMETER probe the metal loss over some finite period of time must
be used to calculate corrosion rate.
For a CORROSOMETER probe, the "current corrosion rate" must actually be calculated on the metal
loss occurring over some finite period of time, normally ranging from a few hours to a few days. Hence
for the CORROSOMETER probe corrosion rate is always a calculated number.
The Mate II collects corrosion data both from probes with RDC's, and directly from probes without
RDC's. The advantage of RDC's is to provide much higher frequency of measurements and a much
improved resolution of corrosion dynamics. The graphical display of RDC generated data is similar
to data generated by individual probe readings, in that straight lines are drawn between the individual
readings. The only difference between the two types of data is that data points from direct probe
measurements are identified with small circles around each point.
72 CORRDATA Reference Manual
Select Display from the main menu and then List from the sub-menu to display the current
probe list.
A probe list summary of all the probes on the system will be added to the screen. To select the
required CORROSOMETER or CORROTEMP CORROSOMETER probes use the cursor
keys. Press Esc to return to the display sub-menu, and View to display a metal loss against
time graph such as the following.
NOTE: If a probe has not been selected from the probe list or no probe
data has been collected for the selected probe or only a single data point
has been collected, a blank graph will briefly appear and then disappear
when VIEW is selected.
Initially the y-axis of the graph is scaled to the full span of the probe life e.g. a T10 probe has
a 5 mil span, a T20 has a 10 mil span (see Table 5.1) and the x-axis has a time period
corresponding to the period of data collected, up to a maximum of 9,000 readings depending
on the type of data. The last recorded probe data is on the right hand side of the screen.
74 CORRDATA Reference Manual
Once the file is filled to its maximun size the oldest data is discarded as new data is added. If
data older than this is to be kept, this may be done by saving the data to a separate file at
intervals as described in Chapter 6 "Archiving and Retrieving Old Data Files".
On the X-axis the scale is identified in days. The date of the last recorded reading is shown on
the bottom of the graph (for example, on the above graph the last data was recorded on April
2, 1992, where April 2 is from 16.0 to 17.0. The first day is from 0.0 to 1.0)
Select the required portion of the graph with the vertical cursors. To adjust the cursor for this
purpose, use the 6 or 7 arrow keys to move the cursor, and the Space bar to switch between
the two cursors.
NOTE: Initially the cursor lines are on the sides of the graph and may
not be readily visible. The selected cursor at entry is the left hand line.
Once the desired selection has been made press Enter. The corrosion rate will be calculated
and displayed along with the start and finish dates corresponding to the cursor positions. The
corrosion rate is determined by Linear Regression (i.e. the slope of the best straight line through
the selected data)
Figure 7.3 CORROSOMETER Metal Loss Graph from an RDC with Rate and Date Display
To zoom in on the corrosion data graph press Esc to return to the display sub-menu and select
Ranges. Choose either the X-Select or Y-Select as required. If the Y-Select is chosen the
graph will reappear with two horizontal cursors lines at the top and bottom of the graph.
Use the 8 or 9 keys to move the cursor lines, and the Space bar to toggle between the two
cursors as shown in Figure 7.4. When you are satisfied with the selection press Esc.
If you also wish to zoom in on the X-axis choose the X-Select. The graph will reappear with
the X range zoomed in. Use the 7 or 6 keys to move the cursor lines and the Space bar to
toggle between cursors, and to select the required range. Press Esc twice and View to display
the zoomed in graph.
76 CORRDATA Reference Manual
Re-entering Ranges on the display sub-menu will cause the X and Y axes to return to the fully
zoomed out ranges ready for the next selection.
The metal loss graph line will normally be thick for most or all of the graph (2 pixels wide) but
may be thinner near the end of probe life (1 pixel). This is determined by the condition of the
CORROSOMETER or CORROTEMP CORROSOMETER probe check reading. The probe
Chapter 7 Corrosion Data Analysis 77
check reading should remain constant within ± 2.5%. If it does not, it indicates possible
damage to the probe's internal reference element. A bad check reading condition is recorded
along with the metal loss and causes the graph to change to a thin line.
The thin graph line indicates that this part of the metal loss graph may be suspect, and that the
probe should be replaced. Corrosion occurring on the reference element will generally cause
a decrease in the recorded metal loss.
From the main menu of the CORRDATA software select Display and then List from the sub-
menu.
The probe list summary will be added to the screen and the required CORRATER or
CORROTEMP CORRATER probe may be selected with the cursor keys followed by the Enter
key. Press Esc to return to the display sub-menu, and View to display a corrosion rate versus
time graph such as the following:
Data older than the maximum file size is discarded as new data is added. If data older than this
period is to be kept, this may be done by saving the data to a separate file at intervals as
described in Chapter 6 "Archiving and Retrieving Old Data Files".
On the X-axis the scale is identified in days. The date of the last recorded reading is shown on
the bottom of the graph. (For example, on the above graph the last data was recorded on April
2, 1992, where April 2 is from 15.0 to 16.0. The first day is from 0.0 to 1.0)
From the graph it is very simple to identify high corrosion rates and the corresponding period
over which they occurred. The average corrosion rate over any period of the graph can be
displayed at the bottom of the graph, and is the arithmetic mean of the readings selected. The
start and finish dates corresponding to the cursors are also displayed.
To adjust the cursors for this purpose, use the 7 and 6 keys to move the cursor, and the Space
bar to switch between the two cursors. Once the desired selection has been made press Enter.
The average corrosion rate will be calculated and displayed, along with the start and finish
dates.
NOTE: Initially the cursor lines are at the left and right sides of the
graph and may not be readily visible. The selected cursor at entry is the
left hand line.
In addition to corrosion rate measurement the CORRATER system also makes a form of
"Electrochemical Noise" measurement, which is a measure of the current flow between two
nominally identical electrodes. Rohrback Cosasco has been using the measurement for many
years in its CORRATER range under the name of pitting or imbalance. The measurement is
still qualitative rather than quantitative. However, pitting systems will generate current and
potential noise between nominally identical electrodes as a result of the non-uniformity of such
systems. The result in pitting environments is a general increase in the current between the
electrodes and an increasingly erratic signal (for further information see Appendix B).
To obtain the imbalance or pitting values on the corrosion rate graph press "I" on the keyboard
to toggle the readings back and forth. The ranges for Imbalance are separately adjusted in the
same manner as the main corrosion rate displays.
Chapter 7 Corrosion Data Analysis 79
For convenience of comparison, the x-axis zoom automatically applies to both the corrosion
rate and imbalance graphs. The y-axes are independent.
Imbalance readings have no units corresponding to a pitting rate. The scaling of the units has
been arranged such that imbalance readings in excess of the corrosion rate value indicate a
higher probability of pitting. Lower values than the corrosion rate value indicate low
probability of pitting.
It is also possible to zoom in on the graph both on the X-axis and the Y-axis. To do this, press
the Esc to return to the display sub-menu and select Ranges. Then choose either the X-Select
or Y-Select. If the Y-Select is chosen the graph reappears with two horizontal cursor lines at
the top and bottom of the graph.
Use the 8 or 9 keys to move the cursor lines, and the Space bar to toggle between the two
points as shown in Figure 7.7. When you are satisfied with the selection press Esc. Either
press X-Select for further X range zooming, or press Esc and View to display the graph. After
a few seconds the graph will reappear to display the zoomed in range.
Automatic determination of average corrosion rate is made by movement of the vertical cursor
lines on the graph in the View mode, and pressing Enter. This is particularly useful if
80 CORRDATA Reference Manual
comparison is required with weight loss on the electrodes or coupons over a particular period.
With an imbalance graph, a similar average imbalance value may be automatically read off the
graph.
The average temperature measurement may be computed automatically over a period of time
by using the vertical cursors to select the desired time span and pressing Enter.
On CORROTEMP CORRATER probe data, these parameters are recorded, namely Corrosion
Rate, Imbalance (pitting), and temperature. To change between the three graphs press "R" on
the keyboard to display rate, "I" to display imbalance, and "T" to display temperature. Only one
graph at a time may be zoomed in on the Y-axis. Zooming in on the X-axis is applied to all
graphs simultaneously.
capability. DOS 4.01 added graphics printout for dot matrix printers. DOS 5.0 added laser jet
and deskjet options. DOS 6.0 has the same capabilities as DOS 5.0. The printer selections are
detailed below:
CORROSOMETER and CORRATER test graphs are included with software to show the
appearance of several fixed corrosion rates. These graphs may be viewed and allow use of the
cursors to measure the set corrosion rates.
These graphs may be retrieved from the CORRDATA sub-directory through the File and
Retrieve sequence of the CORRDATA software. At the appearance of the pathname and file
box following the Retrieve sequence, change the pathname from *.DAT to *.SAV and press
Enter. This will display the two files CA_TEST.SAV and CO_TEST.SAV, in addition to
any other files that may have been archived or saved to this directory. Press Tab to change to
the file box with a highlight bar. Use the 8 and 9 keys to select CO_TEST.SAV and press
Enter. To view the graph, press Display and View to show the following graph.
82 CORRDATA Reference Manual
The slopes on this graph are 20 mpy, 10 mpy, 5 mpy, and 0 mpy respectively. Move the
vertical cursor lines to select any constant slope portion of the graph. Press Enter to display
the calculated corrosion rate between the cursors of the metal loss graph displayed.
Similarly the CORRATER test graph may alternatively be selected from the file retrieve box,
to display the following graph with corrosion rates of 20 mpy, 10 mpy, 5 mpy, 2.5 mpy, and 0
mpy respectively.
To exit either of these displays press Esc three times to return to the main program menu.
85
Chapter 8
Maintenance
RDC Units
There is little requirement for maintenance on the RDC unit other than battery change-out and
ensuring that the probe connections remain clean.
Battery check and replacement is described in "RDC Battery Check and Replacement" in
Chapter 6. For guidance on the selection of probe reading intervals, see "Choosing Probe
Reading Frequency" in Chapter 5.
The RDC unit also includes a small rechargeable battery for memory backup on one circuit
board, which is charged by the main battery. This rechargeable battery is set into operation at
start up of the RDC (see Figure 3.2). Its storage capacity with a dead main battery is
approximately three months.
CORRDATA Mate I or II
The only requirements for maintenance on these units are battery change-out, general care and
cleanliness of the unit, and occasional inspection of the connectors for damage.
The Mate I or II operates with six AA battery cells. The use of alkaline batteries is
recommended which will give an average operating time of 40 hours when continuously used
with RDC's only, or as few as 8 hours if used with probes only. ( Mate II only)
Low batteries are indicated by the screen cursor which changes from:
~ to LB
The Mate I & II have a small lithium battery back up on an internal circuit board with an
anticipated life of 7 - 10 years. The unit must be returned to Rohrback Cosasco or its
authorized representative for replacement of this battery.
86 CORRDATA Reference Manual
PC CORRDATA Software
This requires no maintenance. If any problems occur contact the factory for assistance.
Software Revisions
The revision level of the PC software can be checked from the part number revision on the
system diskettes.
The revision levels of the RDC unit and the Mate I or II may be checked with the Mate I or II
as follows:
Press the ON switch on the Mate I or II. Select Read (F1) from the start up screen to display:
What to Read?
SOFTWARE REVISION
MATE = 7.4
RDC = 6.8
EXIT
If the Mate I or II is not connected to an RDC, the following screen will be displayed:
WARNING!
No Response from RDC
Try again in 30 sec.
EXIT
Press EXIT (F4). This will display the revision of the Mate I or II without that of the RDC.
SOFTWARE REVISION
MATE = 7.4
RDC = 0.
EXIT
Chapter 9
Troubleshooting
Troubleshooting any CORRDATA system problem will generally be done by treating the electronic
sections as black boxes. By cross checking the basic components of the system i.e. batteries, probe,
RDC, Mate I & II and PC it is possible to narrow down the problem unit. Any faulty electronic units
must be returned to the factory for repair.
1) Test RDC unit batteries with test switch adjacent to the battery connector
inside the RDC unit. Illumination of the red indicator shows a good battery.
No illumination indicates a new battery is required.
2) A number of warning messages are displayed by the RDC unit which are self
explanatory.
To carry out the test, it is first necessary to suspend the normal data collection of the RDC.
This is accomplished whenever the Mate I or II is connected to the RDC.
90 CORRDATA Reference Manual
ROHRBACK COSASCO
SYSTEMS
Configuration
Options
Phone
Mate RDC Timer EXIT
Enter the ID number of the RDC unit or alternatively "0" if the RDC number is not known.
Press ENTER (F1).
Chapter 9 Troubleshooting 91
RDC Configuration
Connect Mate to RDC
DATE CONF TEST
TIME RDC MODE EXIT
With the "Mate to RDC" cable attached to the Mate I or II, connect the Mate I or II cable to
the RDC and press TEST MODE (F3). Any problem of communication with the RDC will
be indicated by warning messages.
Disconnect the RDC cable from the corrosion probe and connect it to the test probe. Return
to the Mate I or II and press START (F1). This will cause the RDC to take a single probe
test reading. The Mate I or II will indicate that a reading is being taken, as the following
screen depicts.
Press EXIT (F4) to return to the previous screen. Allow at least 3 minutes for completion
of the reading and press READ (F3).
For a CORRATER or CORROTEMP CORRATER RDC unit, the display will display a rate
value and imbalance value corresponding to that printed on the test probe thus:
If the displayed values are beyond the limits shown on the test probe, the RDC unit may need
repair.
Chapter 9 Troubleshooting 93
Remove the test probe and reconnect the cable to the working probe. Press EXIT (F4) to
return to RDC Test Modes.
Press READ CONF (F2) if you wish to verify the configuration information for the RDC
unit. For an RDC CORROSOMETER the display will be as follows:
RDC . . CORROSOMETER
Tag . . . . . . . . . . . .
Type . . . . . Span . . . .
Alloy . . . . . . . . MORE
RDC . . CORRATER
Tag . . . . . . . . . . . .
Type . . . . .
Alloy . . . . . . . . MORE
In either case to read the rest of the configuration data press MORE (F4). The screen will
display the readings information. For readings set in hours the display will be:
Interval . . hours
Num. Readings . . . . .
Next. Reading . . . . .
EXIT
Interval . . . minutes
Num. Readings . . . . .
Next Reading . . . . .
EXIT
The Num. Readings shows how many readings have been collected (the maximum number
of readings for a CORROSOMETER RDC is 2048 readings for a CORRATER RDC or
CORROTEMP CORROSOMETER RDC is 1024, and for a CORROTEMP CORRATER
RDC is 512 readings).
Mate I or II
If the problems are common to all the RDC units, then the problem is probably with the
Mate I or II or the PC. It is possible to distinguish the difference between Mate I or II and
PC problems, since RDC information can be displayed on the Mate I or II and at the PC.
To verify if the Mate I or II is operational, check the batteries and collect data from an RDC
or probe which is known to be "good" (as much as this is possible) and use the display
routine described in "Displaying Probe Data", in Chapter 6 of the manual. If the reading
displayed is correct the Mate I or II is functioning and the problem may be with the PC or
communication to the PC.
To run this utility, plug the Mate I or II into the PC serial adapter cable. From the
CORRDATA sub-directory type pmate and press Enter. The PC will display the
instructions of keys to press on the Mate I or II. This re-programs the Mate without losing
any of the stored data.
Please Wait!
96 CORRDATA Reference Manual
Normally as the message clears the normal main menu screen will appear. However, if the
following screen appears the Mate should be reprogrammed.
Pressing EXIT (F4) will clear the screen and allow operation of the unit. However, it is
recommended the Mate be reprogrammed as the effect of corrupted software may be difficult
to predict.
PC
If the CORRDATA program does not start up on your computer, check to see if the
specification of your system meets the requirements listed in Chapter 2 of the manual.
If the program starts up but does not communicate with the Mate I or II, check the interface
connectors and ensure that the correct serial port is being used, and that the appropriate
COM1 or COM2 version of the software has been installed. If another device is using the
selected serial port, either change the serial port being used by CORRDATA or use a switch
box.
Installing the alternate version of CORRDATA software for the other serial port is described
under Installation in Chapter 3.
The CORRDATA program may be run under Windows 3.1 as a DOS application as
described in the Windows operating manual. Care must be taken with Windows set up,
particularly with regard to other devices, such as a mouse, modem, or a network, that may
use the same interrupt as the COM port used for communications with the Mate I or II. If
difficulties are experienced contact RCS for assistance.
Chapter 10
ASCII Transfer Utility
When the CORRDATA Software is installed to the hard disk of the PC, a spreadsheet utility file
MAKE_ASC.EXE is also included. This utility may be used to convert the CORRDATA data
files (with extension.DAT) to ASCII files which may be imported directly to spreadsheets such
as Lotus 1-2-3. The file names are automatically created by the utility with the general form
ID_X.PRN, where X is the probe ID number, and saved in the CORRDATA directory.
To operate this utility, change to the CORRDATA directory and type MAKE_ASC.EXE. If
running under Windows, double click on the MAKE_ASC.EXE file in the CORRDATA directory
in File Manager. This will immediately generate converted .PRN files for each .DAT file.
To import the file into Lotus 1-2-3, start the Lotus 1-2-3 program. Select the menu, and enter
File; Import; Numbers. Modify the directory to the location of the saved .PRN files and press
Enter. In Lotus version 4 or 5 for Windows, select File; Open; select the File Type to text (txt,
prn); change the Directory to CORRDATA; click on the required file ONCE; select the
COMBINE button and select formatted and OK. For Excel or other spreadsheets make sure that
the field delimiter is set to comma. Select the file or files as required. The ASCII format for a
CORROTEMP probe, for example, is as follows:
A B C D
1 Rohrback Cosasco Systems, Inc.
2 CORRDATA ASCII TRANSFER UTILITY
3 (C)Copyright 1992
4
5 CORROTEMP PROBE
6
7 TAG 0023
8 ID 23
9 TYPE D
10 SPAN 10.00
11 INTERVAL -
12 INSTALLED 30 Sep 92
13 LAST READ 15:34 30 Sep 92
14
15 TIME TEMP METAL LOSS
16 (DAYS) (DEG C) (MILS)
17 0.649 28 .98
The first column is the time base in days from midnight at the start of installation. The decimal
portion indicates the time of day, i.e. 0.25 is 6:00 a.m., 0.5 is mid-day, 0.75 is 6:00 p.m., etc.
This time is computed for every probe reading independent of whether an RDC is used or not. If
the readings are from probes with RDC's, the INTERVAL above will indicate the reading interval
in addition to the actual times computed for column 1.
For graphical displays, set graph type to XY, and select the data range to be displayed as required.
99
Chapter 11
Mate Operation with Downhole Corrosion
Monitor System (DCMS)
The operating of the CORRDATA System with the downhole corrosion monitor is almost identical
to that with an RDC. The main difference is that communication with the downhole tool is carried
out at a data transfer rate of 300 Baud instead of 9600 Baud used between the Mate and RDC, and
the Mate and PC.
This requires that the baud rate is set to 300 to communicate with the downhole corrosion monitor
and then reset to 9600 baud to communicate with its PC.
To change the baud rate, switch ON the Mate. After the self test screen clears and the main menu
appears.
ROHRBACK COSASCO
SYSTEMS
Press 300 (F1) for downhole corrosion monitor tool. This Mate will automatically shut off and
restart with the Baud Rate Changed.
Appendix A
FIGURE 1
102 CORRDATA Reference Manual
As with coupons, CORROSOMETER probes must be allowed to corrode for a period of time
before accurate corrosion rate measurements can be made. The actual length of time required
depends upon the corrosion rate--the higher the rate, the shorter the time required, and vice-versa.
CORROSOMETER probes are available in a variety of styles and with useful probe life ("span")
ranging from 2-25 mils, in styles commonly used in process piping systems. Instrumentation to
measure electrical resistance probes divides the probe span into l000 "divisions." A probe with
a 2 mil span is therefore theoretically capable of measuring thickness changes of 0.002 mils. In
practice, however, we recommend that a change in indicated metal loss of l0 divisions be required
before the data is used to calculate corrosion rate. Indications of an upward or downward trend
can be obtained with as little as a 4-division change, but care must be exercised in interpreting
such small changes because other factors (e.g. temperature changes) can also be responsible. The
actual time required to produce meaningful corrosion rate information with common probe spans
at different corrosion rates is shown in Figure 2 and summarized in Table 1.
FIGURE 2
Appendix A 103
TABLE 1
TABLE 2
From Table 1, it would appear desirable to always choose probes with the lowest span available
in order to get the greatest sensitivity. However, the more sensitive the probe, the faster the entire
probe span will corrode away and require a new probe to be installed.
104 CORRDATA Reference Manual
Table 2 illustrates this relationship.
It is our experience that the objectives of most monitoring programs can be achieved cost-
efficiently by selecting CORROSOMETER probes which will reach the end of their useful life in
6 - 9 months at the expected corrosion rate. Unlike a monthly coupon replacement program, this
electrical resistance probe will continuously produce data that verifies that the average corrosion
rate over the previous 2-3 days is still at the originally-expected (design) rate. If the corrosion rate
increases to twice the design rate, meaningful data to permit the new rate to be calculated will be
available in a day and a half. Conversely, if the actual corrosion rate is below design, a longer
period is required before meaningful data are available to calculate the new rate.
FIGURE 3
CORROSOMETER monitoring systems can be applied to all processes. However, some types
of CORROSOMETER probes are better suited to the requirements of particular applications than
others.
Different styles of CORROSOMETER probes are affected to different degrees by pitting attack.
Figure 4 shows the results of pitting attack on a wire loop probe. Although the remaining wire
thickness shows that only 30% or so of the probe span has been consumed, the probe is obviously
out of service. Cylindrical elements on the other hand, are affected to a much lesser degree by
pitting because of the much larger circumference of the measuring element. Wire loop and tube
Appendix A 105
loop elements also have a tendency to be electrically shorted by a bridge of iron sulfide corrosion
product. This is especially prevalent in low-velocity streams over an extended period. The effect
of such bridging is to reduce the measured metal loss of the probe, creating a misleadingly low
corrosion rate. Cylindrical probes demonstrate more resistance to iron-sulfide bridging due to their
construction and lower inherent resistance per unit length, thus minimizing the effect of the shunt
resistance. Where pitting or substantial FexSy deposition are expected to be problems, cylindrical
probes should be chosen wherever possible over loop-style probes.
FIGURE 4
Most cylindrical probes are of all-welded construction in order to eliminate the need for sealing
metal elements to non-metallic glass, epoxy or ceramic. This all-welded construction gives the
probe superior resistance to leaking. Probes with higher temperature ratings can also be
constructed in the all-welded style. A drawback to the all-welded style is that the element is
electrically connected to the pipe wall which can, in certain conditions, interfere with the corrosion
reaction on the probe. Also, because cylindrical probes are welded, in some conditions preferential
corrosion can occur in the heat-affected zones near the weld.
Flush probe elements are thin, flat metal sections embedded in epoxy or a hermetic glass seal
inside a metal probe body. Flush probes also experience certain characteristic problems, most
notably: lack of adhesion of the metal element to the epoxy, cracking of glass seals due to
differential expansion and erosion of the epoxy or glass due to high velocities, abrasive materials
in the flowstream or both. Flush CORROSOMETER probes mounted on the bottom of the line
have been shown to provide good results in a sour gas gathering system.
Because the measurement element is part of the primary pressure seal, and because it's designed
to corrode, CORROSOMETER probes have a reduced resistance to leaking after prolonged
exposure. Once the measurement element has corroded through, the internals of the probe body
are exposed to the process fluid. Although materials are chosen in part for their strength and lack
of permeability, it is our experience that process fluids will permeate throughout the probe packing
material. For this reason, quality probes are constructed of corrosion-resistant body materials and
include a secondary pressure seal, often consisting of a hermetic glass-sealed connector. Other
back-up seals are utilized in special cases, especially where process fluids will attack glass (e.g.
106 CORRDATA Reference Manual
hydrofluoric acid service). Please contact the factory if you have any questions about the
compatibility of probe materials with your application.
The reference and check elements are protected from the process to which the measurement
element is directly exposed. Temperature changes in the process will, therefore, affect the measure
element before the reference and check elements. Because of the very low resistances involved,
these changes can significantly affect the metal loss readings. CORROSOMETER probes
incorporate special design features to minimize the thermal resistance of the materials insulating
the reference and check elements from the process. It should also be noted that cylindrical probes
are inherently better able to react to temperature changes due to location of the reference and check
elements concentrically inside the measure element.
107
Appendix B
Sterns and Geary originally demonstrated that the application of a small polarizing potential
difference ()E) from the corrosion potential (E ) of a corroding electrode resulted in a measured
corr
current density (i ) which is related to the corrosion current density (i ) by equation (1):
meas corr
)E = b ba c (1)
i
meas (2.303 i ) (b + b )
corr a c
Since the Tafel coefficients are more or less constant for a given metal/fluid combination, i is
meas
proportional to i which is proportional to the corrosion rate. Equation (1) and the entire LPR
corr
technique are only valid when the polarizing potential difference is very low (typically up to 20
mV). In this region the curves are linear, hence the term LPR.
Inspection of Equation (1) shows that the result is a resistance, the Polarization Resistance, R . p
While strictly speaking, there are both anodic and cathodic R values, which can differ, they are
p
usually assumed to be equal. The resistance to current flow between anode and cathode on the
LPR probe is the sum of both polarization resistance values and the resistance of the solution
between the electrodes (R ) as shown in Equation (2):
S
E = i meas (2R + R )
p S (2)
From Equations (1) and (2), obtaining results from the LPR technique would seem to require only
instantaneous readings of resistance. In practice, however, the determination of polarization
108 CORRDATA Reference Manual
effects.
The effect of the double-layer capacitance is to require the direct current flow to initially charge-up
the capacitors, resulting in a decaying exponential current flow curve vs. time after application of
the polarizing potential difference. A typical LPR current vs. time curve is shown in Figure B-2.
Each metal/fluid interface has its own characteristic capacitance which in turn determines the
amount of time required to obtain valid measurements of i and corrosion rate. The actual time
corr
required can vary from a few seconds up to 20 minutes, depending upon the metal/process
combination being measured. Choosing too short a polarization time can result in current readings
much higher than the true i thus causing measured corrosion rate to be lower than actual,
corr
Solution resistance can also have a significant effect on accuracy if it is relatively high compared
to the polarization resistance. In most industrial water applications, conductivity of the solution
is high and solution resistance is low compared to the polarization resistance, so i is an accurate
meas
A serious problem develops, however, when the solution resistance increases or the polarization
resistance decreases enough to make the solution resistance a significant portion of the total
resistance to current flow between the electrodes. In these cases, the accuracy of the LPR
measurement is affected. This situation tends to occur at high corrosion rates (low polarization
resistance) and in solutions with low conductivity (high solution resistance) and is manifested by
the indicated (measured) corrosion rate being lower than the actual corrosion rate. The graph in
Figure B-3 shows the effect of this limitation on the recommended operating range of LPR
instruments.
110 CORRDATA Reference Manual
Several techniques have been used over the years to minimize the impact of solution resistance on
LPR measurements. The most common techniques involved the use of a three electrode probe.
The effectiveness of the reference electrode in reducing the effect of solution resistance has been
shown to be dependent upon the proximity of the reference electrode to the measurement electrode.
Rohrback Cosasco three-electrode probes (see Figure B-4) are unique compared to other major
LPR probes because they utilize a closely-spaced electrode.
A better way to deal with this problem, however, is to directly measure and compensate for the
solution resistance. Rohrback Cosasco has exclusive patent rights to the Solution Resistance
Compensation (SRC) technique incorporated in top-of-the-line RCS-8, RDC CORRATER, 9030
and 9134 instruments. In this method, a high-frequency a.c. voltage signal is applied between the
electrodes short-circuiting R through the double-layer capacitance, thereby directly measuring the
p
solution resistance. The state-of-the-art, patented SRC technology also eliminates the need for a
third electrode, even in low conductivity solutions. Consequently, Rohrback Cosasco's two-
electrode probes have become the standard RCS offering, with the three-electrode probe available
on special order only.
The above points are clearly indicated in ASTM Standard Guide G96 which quotes:
"3.2.8 Two-electrode probes and three-electrode probes with the reference electrode equidistant from the test and
auxiliary electrode do not correct for effects of solution resistance without special electronic solution resistance
compensation. With high to moderate conductivity environments, this effect of solution resistance is not
normally significant.
3.2.9 Three-electrode probes compensate for the solution resistance R by varying degrees depending on the position
S
and proximity of the reference electrode to the test electrode. With a close-spaced reference electrode, the effects
112 CORRDATA Reference Manual
of R can be reduced up to approximately ten fold. This extends the operating range over which adequate
S
3.2.10 A two-electrode probe with electrochemical impedance measurement technique at high frequency short circuits
the double-layer capacitance, C , so that a measurement of solution resistance R can be made for application
dl S
as a correction. This also extends the operating range over which adequate determination of polarization
resistance can be made."
CORRATER Instruments
Rohrback Cosasco's current CORRATER product line includes the Model 9000 portable
CORRATER instrument which has a fixed time cycle and does not include the SRC feature; the
Model 9030 single-channel instrument with user-selectable cycle time which pioneered the use of
SRC in CORRATER instruments; and three instruments - the Model RDC - CORRATER, the
Model RCS-8 and the Model 9134 CORRATER Probe Interface Module, which incorporate
proprietary, fully-automatic cycle time selection and advanced SRC features.
In addition to general or uniform corrosion, localized corrosion (pitting) may occur in a system.
This can result in much more rapid failure of a structure than a simple measure of corrosion rate
would indicate. A pit on the metal surface is the result of a localized, high anodic current density.
Positive ions flow away from the pit into the solution and electrons flow away from the pit into
the surrounding metal.
If it were possible to place a zero-impedance ammeter between the pit and the nearby metal
surface, the current in the anode-cathode system of the pit could be measured. Individual
measurements are not practical because the areas are small. Instead, current flow between the two
metallurgically identical electrodes of a CORRATER probe under short-circuit conditions can be
used to indicate pitting tendency. All Rohrback Cosasco CORRATER instruments include a
imbalance/pitting reading. The user should note that this is a qualitative measurement (or index)
and utilize it accordingly. It has proven very useful in many applications (e.g. cooling water
treatment) and offers information not generally available about a system except by coupons which
lag behind actual events and offer no way of detecting upsets.
If the pitting reading is low compared to the corrosion reading, the pitting problem will probably
be minimal. On the other hand, a pitting reading which is high compared to the corrosion reading
can indicate that pitting or crevice corrosion will be the main form of corrosive attack. When the
readings are about equal, some pitting is indicated, but the pits will probably be broad and shallow.