PT.

KOROSI SPECINDO
Corrosion Monitoring System Doc. No.: KS-RND-MNL-05

User’s
Manual

Corrosion Transmitter Model:

DCI- Tx-D-ER-A
(Ex d Version)

Revision Date Prepared Approved Descriptio

1 06/05/2009 SD YS Analog TX Added
2 28/05/2009 SD YS Separate Analog TX & Digital TX
3 13/04/2016 SD YS IEC Clarification
4 11/10/2019 JS YS Add note
 Table of Contents

1. S AFETY INSTRUCTION ............................................................................................................................... 3

2. INTRODUCTION ........................................................................................................................................ 4
2.1 General Overview ................................................................................................................................. 4
2.2 Equipment List: ...................................................................................................................................... 4
2.3 Technical Specification ........................................................................................................................ 5
2.4 Enclosure .............................................................................................................................................. 5
3. INSTRUMENT INSTALLATION ..................................................................................................................... 5
3.1. Preparation ........................................................................................................................................ 5
3.2 Equipment or Special Tools Requirement .......................................................................................... 6
3.3 Transmitter Connection ........................................................................................................................ 6
3.4 Incoming Inspection: ............................................................................................................................... 6
3.5 Instrument Connection: ........................................................................................................................ 7
4. Setup and Operation. ................................................................................................................................ 9
4.1 Transmitter Integration ....................................................................................................................... 9
4.2. Installation ............................................................................................................................................. 9
4.3. Probe Selection ..................................................................................................................................... 10
4.3. Corrosion Rate Calculation .................................................................................................................... 12
5. Maintenance ............................................................................................................................................... 12
5.1 Self Calibration....................................................................................................................................... 12
5.2 Probe Life ............................................................................................................................................... 13
5.3 Firmware ............................................................................................................................................... 13
6. Special Condition for Safe Use (X) ........................................................................................................... 13
Appendix 1. Probe Code ................................................................................................................................ 14
Appendix 2. Sample of Inspection Checklist........................................................................................................ 18
Appendix 3. Checklist for DCI-Tx-d-ER-01 Ex d LCD Display (Transmitter check) ............................................. 20
Appendix 4. Other wiring option with Corrosion meter....................................................................................... 21
Appendix 5. Other wiring with 24V Power Loop DCS........................................................................................... 22
1. S AFETY INSTRUCTION

The following Safety Standard should be followed in the field

a. Safe operation requires 1-trained operator.
b. Make sure you have complied with all plant safety requirements and environmental regulations
procedure.
c. Ensure you have all the required safety equipment, i.e.: protective clothing, safety helmet,
safety glasses, safety gloves, ear plug, safety shoes and breathing apparatus when toxic
atmosphere exists.
Test and check should be done to all equipment before attempting to use in the field.

Importance Safeguards

All safety instructions must be read carefully & understood, before attempting to use any KS Product
(instrument, probe, equipment). This manual contains the safety instructions that must be observed in
order to avoid potential hazards that could result in personal injuries or could damage your (instrument,
probe, equipment). This safety instruction has been classified according to the seriousness
of the risk, as follows and all identified risks categorized accordingly.

"DANGER" indicates the existence of a hazard that

DANGER could result in death or serious bodily injury
if the safety instruction is not observer
"WARNING" indicates the existence of hazard that
WARNING could result in bodily injury if the safety instruction
is not observed
"CAUTION" indicates the existence of a hazard that
CAUTION could result in property damage if the safety
instruction is not observed
"NOTICE" contains general information that
NOTICE relates to the safe operation of
the equipment

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2. INTRODUCTION

2.1 General Overview

DCI-Tx-d-ER is corrosion transmitter unit which is capable of measuring and transmitting data from any
standard ER probe. It is a simple, accurate and computer-compatible corrosion monitoring instrument. DCI
is uniquely designed to provide three different industrial standard output, such as 4-20mA, RS-232, or
RS-485. Corrosion data will be transmitted as real time to the control room receiver or SCADA unit.
DCI-Tx-d-ER unit uses Electrical Resistance principle method to determine metal loss from any a non-
conductive process stream, process stream where erosion-corrosion occurs, etc.
The transmitter electronics is mounted in an explosion proof enclosure. Data and power cable are protected
by signal & power barrier unit for isolation between DCI located in hazardous classified area to non-
hazardous PC or SCADA safe area.
Customer buying the DCI has the flexibility to choose the type of data transmission that will provide added
distance and still maintain real time sensitivity. With analog 4-20mA current loop transmitter, only
corrosion metal loss data can be transmitted.

Fig1. DCI–T x–d–ER–A (Al & SS316 enclosure)

2.2 Equipment List:

• DCI- T x –d–ER-A complete with 10 feet sensor cable (for indirect mounting).
• Communication and power cable (purchase separately).
• Mounting bracket assembly for mounted in 2” pipe support
• Operating Manual.
• Test Probe.

Upon receipt of the instrument, the user should verify that the above listed accessories are
included.
Any shortage should be reported immediately to:
E-mail : sales@korosispecindo.com
Http : //www.korosispecindo.com

KOROSI SPECINDO
Jl. Pangeran Jayakarta No.76, Jakarta 10730
Phone: 62-21 6267576 (Hunting) Fax: 62-21 6289919

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2.3 Technical Specification

Model
DCI-Tx-d-ER-A : Data Collection Instrument Transmitter ER version

Ph ysical Data
 Instrument W eight
 Instrument Dimensions
 Ambient Temperature
 Intrinsically Safety Certification
 Environment Safe
: 3 kg.
: Dia. 11.5 cm x H 10 cm
: -400C to +85 0C
: II 1 / 2 G Ex db ia IIC T4
: Explosion Proof (IP66 minimum), Aluminum / SS316

Performance Data
 Measurement type : ER measurement using any standard ER probe type
( F lush , Tubular, L oop, San d Probe)
 Resolution : 1 6 bit
 Accuracy : 0.1%

Electrical Data
 Power Requirement : Power Loop 24V for 4-20mA
 Typical Probe Cable Distance : 10 ft (other please consult)
 Data Communication : 4-20mA analog
 Cable Input size : NPT ¾” (Al), M20x1.5 (SS316 enclosure), others

2.4 Enclosure

DCI-Tx-D-ER-A is equipped with safety certification (Ex db ia IIC T4) for hazardous area operation and
housed in a NEMA 4X rated explosion- proof and explosion-proof enclosure. The probe cable is
connected through a tight cable gland, making it suitable to be applied in some outdoor
conditions.

3. INSTRUMENT INSTALLATION

The ER Transmitter operates on a ratio metric measurement principle, whereas such measurements are
made on exposed sample element (Rs) of the probe subjected to corrosion or erosion and a protected
reference element (Rr) inside the probe body. The recorded reading is a ratio of Rs/Rr.
The transmitter is powered by external-power 10-35VDC, measure program every minute of changes of
the probe resistance and send the data to control room via current loop 4-20mA.
The Transmitter also detects the Ratios of Rc/Rr, which are used to check the probe performance
under operating conditions. A constant CHECK reading indicates that probe internals have not been
subjected to corrosion (no intrusion by vessel pressure or media).

3.1. Preparation
1. Safety Procedure always ask for a person who will be in charged in the field, specifically an
Instrument, or Electrical, or c orrosion Engineer who will take responsibility in the field during
Installation of DCI-Tx-d-ER and other accessories.
2. If you plan to protect the wiring between the Corrosion Probe and the DCI-Tx-d-ER or any related
Instrumentation using Conduit for the first time or during your field survey, always prepare Sketch

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 Drawing or Draft on the notebook of every length, position, and angle of direction. Make sure that
the conduit accessories to be as efficient as possible, and be located closest to existing cable tray
on that level and location.
3. During wiring process, do not cut any cable in a hazardous area if you are not sure enough that the
correct lengths of all cable for Instrumentation are screened (armored) in overall length. So, you
should not extent or make any connection without Junction Box, except in Non Hazardous area. Any
extension or connection between two cables will result in unwanted noise affecting the sensitivity
of the signal and resulting in erroneous data or malfunctioning of the monitoring system.
4. Always Test all of your Equipment before you attempt to installed this in the field. Prepare any
tools such as, spare ER probe, extension probe, Probe Cable, Dummy Probe, etc.
5. Bring all Documentation and Manual Book along to the field for conducting Installation, setting
parameter and Troubleshooting.

Note: Operator must concern to Local Safety Requirement, the safety requirements according to described
in operating and maintenance manual of equipment, the requirements of the relating explosion proof
standards as well as the requirements and instructions of EN 60079-10, EN 60079-14, EN 60079-17
latest standard.

3.2 Equipment or Special Tools Requirement

 Test Probe.
 Crow Spanner to open or to tighten the probe connector.
 Analog/Digital Multi-meter, soldering iron and electronic tools set.

3.3 Transmitter Connection

Analog 4-20 mA transmitter panel inside enclosure found selector switch for probe element type and
specific element thickness selected base to the Probe to be used in the field.

When any other electrically driven the sensor or measuring device is used in a potentially explosive
environment the measuring system must be installed in such a way that electrical energy (galvanic loops)
is either effectively isolated from the explosive environment (via explosive-proof containers, cable
conduits, etc.) or the amount of electrical energy produced in the hazardous area must be limited to an
intrinsically safe level.

Limiting electrical energy is the most practical method of protecting the DCI- TX-LPR-A m easuring
system when the Transmitter is installed in a hazardous area by the use of a repeater safety
barrier (or its equivalent) installed in the 4-20 mA current loop safety standard practice.
The safety barrier must be located in the safe area near the boundary between the safe and
hazardous areas. The safety barrier will repeat the signal current generated by the Transmitter and
will relay the signal to the data receiving station.

3.4 Incoming Inspection:

Check DCI-TX-ER-A Transmitter for mechanical damage when it is first received. Obvious damage to
shipping package should be brought to attention of the responsible carrier’s agent.
Open the transmitter cover, thus we can access to the 24V and data port by opening LCD, and make
below connection.

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 24V DATA

Power Supply +

24V -

Fig. 2. Incoming test of transmitter

Note:
 Use load resistor (100 – 250 Ω) in series with Data line
 Set Ampere meter in mA DC mode

With above connection, follow below procedure:

 Access keypad of transmitter for menu, and choose Test Loop
 Choose 4mA, and confirm that output in Ampere meter is 4 mA ± 5%
 Choose 20mA, and confirm that output in Ampere meter is 20 mA ± 5%
 Finish incoming inspection, and turn off the power and close the transmitter cover again

3.5 Instrument Connection:

Probe – DCI-Tx-D-ER-A
Fixed Transmitter must be installed at appropriate location and connected at probe d irectly or by probe
cable. It uses extension probe to connect from probe to DCI / DCI cable. And DCI enclosure is mounted
through bracket that can be placed at 2” pipe stanchion with U bolts. Please mind the vibration and also ease
of mounting when doing direct connection, as we need to adjust the probe insertion to let the transmitter face
to the front.

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 Fig.3. Connection between Probe and DCI-Dx-LPR-01(direct mounting & with cable)

Transmitter Wiring
When doing transmitter wiring after connected transmitter to probe, please follow local regulation for
cable and wiring specification. Wiring to the transmitter is going through cable gland, always keep the
transmitter IP rating by using sealant or bushing in cable gland.

LCD Display

Direct / with probe cable

Fig.4 . Transmitter Wiring

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4. Setup and Operation.
Soon after wiring is completed, the instrument will be ready to operate. This instrument is furnished with
display and keypad, so to configure the parameter, is performed by accessing the keypad of transmitter.
DCI-TX-ER-A Transmitter is a micro controller based unit and all its functions are firmware controlled.
These functions are accessed by issuing appropriate analog scale base to Industrial Standard 4 -20 mA
current loop signal in corrosion metal loss as engineering Unit.

4.1 Transmitter Integration

DCI-TX-ER-A comes with Probe Cable (6 wires, screened, PVC outer sheath). For incoming/function check,
use own Power and Signal cables witches have 1 core 3 wires minimum for function check as mention in
3.4.
Connect Power Cable to existing DC Power Supply set maximum 16 VDC. Connect Signal Cable to Ampere-
meter series with 100 Ohm as R-Load, select Ampere-meter to mA-DC; Using dummy probe ER injected to
Sensor Cable connector and set DCI- TX-ER-A for check the correct mA as indicated in Calibration Check
Sheet (appendix 2).

4.2. Installation
Please refer to Safety Installation or any equivalent safety barrier rules and regulation.
Warning:
Installation in hazardous area must conform to safety mounting and electrical wiring procedure.
Note:
Operator must concern to Local Safety Requirement, the safety requirements according to described in
operating and maintenance manual of equipment, the requirements of the relating explosion proof
standards as well as the requirements and instructions of MSZ EN 60079-10:2003, MSZ EN 60079-
14:2003, MSZ EN 60079-17:2003 standard.

Purpose the current loop cable is to connect DCI-TX-ER-A Transmitter to power source input and signal
output, normally using communication cable contain 4 core shielded and twisted pair size 22 AWG. Polarity
is critical when attaching the cable to the transmitter loop connection terminals. All cable access to the
transmitter box must be wired through the proper conduit.
Caution:
Do not connect shielding of power and signal cable to the Transmitter ground. The shield must remain
floating at the transmitter (Only the Sensor Cable shield connected to Transmitter Ground).
Power Barrier and Signal Isolation installed only in Non Hazardous Area, maximum cable length from
transmitter to the barrier is 1,000 meter.
Dummy probe ER is a Sensor Simulator and has been calibrated based on manufacturer's
climate local condition and will vary depending on local destination’s ambient temperature and
humidity. Interpolation data must be introduced into SCADA system based on their own local
condition, and tolerance is close to ± 5%, with typical value of Rs/Rr = 1.025 and check = 0.295, or with
the value that’s written in Dummy Probe ER. SCADA programming engineer must declare to the system
every range and engineering unit to be use in the system.

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 Metal loss Sample Flush Tubular Sand Probe
Value F10 F2 F40 T10 T20 T40 T80 F40 F80 F120
Min 1.020 0.196 0
0.392 0.784 0.190 0.368 0.688 1.182 0.784 1.569 2.353
Sample 1.025 0.244 0.488 0.976 0.236 0.458 0.856 1.472 0.976 1.951 2.927
Max 1.030 0.291 0.583 1.165 0.282 0.547 1.023 1.759 1.165 2.330 3.495

Table 1. ER Dummy probe metal loss reading with variant of probe type

DCI-TX-ER-A is factory-calibrated before shipment and there should not be any drift against time unless
mechanically damaged. Check the accuracy of the whole system by setting Selector Switch on the front
panel to 4 mA then 20 mA and check the Corrosion Meter, adjust zero or span as required.
Every Corrosion Sensor has range of thickness and effective life in Mils.
If Metric System unit must be used, please declare to the SCADA system with conversion of 1 mils =
0.0254 mm.

4.3. Probe Selection

Open enclosure cover, in the internal panel find selector push button most difference type of probe
Select Probe as below thickness and effective life description:

Thickness Effective Life

No Element Type
Mils Mils mm
10 5.00 0.13
1 Flush 20 10.00 0.25
40 20.00 0.51
10 5.00 0.13
20 10.00 0.25
2 Tubular
40 20.00 0.51
80 40.00 1.01
4 2.00 0.05
3 Tube Loop
8 4.00 0.10
40 10.00 0.25
4 Wire Loop
80 20.00 0.51
40 20.00 0.51
5 Sand Probe 80 40.00 1.01
120 60.00 2.02
Table 2. ER Probe selection and its effective life

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 LCD display
Keypad   >  for selecting Menu

Fig. 5. Keypad button

The Transmitter DCI-TX-d-ER-A has 4 - 20 mA current range which is translated into division of 1000
equivalent of probe life. Probe life is equivalent to the amount of metal that the measuring element can
lose during the useful life of the probe.

When a specific element type & thickness has been selected in the menu, it’s also subsequently selected
the effective life range that has been stored in the internal Firmware as the true representation of the life
span of the Sensor (Table 2). As a result, now proceed to select the step increment between zero-span and
engineering unit on the SCADA Programming.

Transmitter output is Linear. Initial transmitter current output begins at 4 mA and increases to maximum of
20 mA. The maximum output of 20 mA indicates that measuring element lost its reading integrity and the
probe must be replaced.

As an example, select probe type Wire loop 40, so the range will be selected from 0 (zero) to 10
mils or from 0 to 0.25 mm sensor thickness, see diagram below:

Therefore, the result in Corrosion Meter will be 0 mils for 4 mA and 10 mils for 20 mA; or will be 0 mm
for 4 mA and 0.25 mm for 20 mA.
But step increment of measurement base to capability of Corrosion Meter, if it has 1000 division, that
will be 0.01 mils per division.

x-4
Value = x 1000
16

Floating Point becomes 1000.

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4.3. Corrosion Rate Calculation
Transmitter generates Corrosion Rate data by calculating Metal Loss against current time as compare
to Metal Loss in previous time.
The following formula is used to determine the corrosion rate occurring at the installed probe:

∆Probe Reading (mA) Effective Life (mils) 365 (days)

Corrosion Rate = X X
(mpy)
16 (mA) ∆ Time (days)

There is optional for Corrosion Rate calculation in the transmitter that can be displayed by the following
steps:
 Select the Output Mode Menu on the transmitter, choose Corrosion rate
 Choose either Corrosion Rate span 10 or Corrosion Rate 100, then confirm.

Note:
 This option is not recommended for line that haven’t had previously known corrosion rate value/ standard
or has fluctuating process fluid condition
 Due to limitation in transmitter memory, it needs to reset the calculation at maximum 3-years application
(by set the probe to other, then set again to appropriate probe type)
 Stable condition will be reached after minimum 2-weeks calculation.

5. Maintenance
 Ensure that the probe is operational and is not completely corroded.
 Examine all electrical connection for proper electrical connections, check sign of corrosion to ensure
that the connections are environmentally protected.
 Contact Korosi Specindo for technical assistance if the Transmitter continues to malfunction.

Note: Operator must concern to Local Safety Requirement, the safety requirements according to described
in operating and maintenance manual of equipment, the requirements of the relating explosion proof
standards as well as the requirements and instructions of EN 60079-10, EN 60079-14, EN 60079-
17 latest standard.

5.1 Self Calibration

DCI is equipped with Dummy test probe to check its reading integrity. Its sample and check value
mentioned in dummy test probe can be used to confirm if there is a problem in the transmitter. Use TPKS-
ER and connected to the probe insert port in end coupling, then with specified probe type, confirm that the
value of metal loss is within the value in Table 1.

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If the value is not within the range, there is problem in the equipment and contact Korosi Specindo for
assistant, since it could problem from connectivity, wiring, etc.

5.2 Probe Life

When the probe has reach its lifetime, it’s indicated by metal loss value has reached maximum effective
probe life in Table 2. Also confirmed that the check value is within specification (can be seen check value in
screen or cross confirmed with KSHHU-ER to see its Check value).
If this value has been reached, it is strongly recommended to change the probe, as the probe integrity might
be effected and its reading can be erroneous and cannot be used for corrosion rate calculation.

5.3 Firmware
DCI-Tx-d-ER is a micro controller based unit and all its functions are firmware controlled. These functions
are accessed by issuing appropriate commands as per the command set.

6. Special Condition for Safe Use (X)

 The cleaning of the enclosure of the DCI unit must be done only with damped clothes because of the
danger of the electrostatic charging
 Always turn off the transmitter when trying to do wiring or accesing the PCB.
 In operation the local safety requirements, the safety requirements according to described in operating-
and maintenance manual of equipment, the requirements of the relating explosionproof standards as well
as the requirements and instructions of EN 60079-10:2003, EN 60079-14:2003, and EN 60079-
17:2003 standards must be kept

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Appendix 1. Probe Code

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Appendix 2. Sample of Inspection Checklist

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Appendix 3. Checklist for DCI-Tx-d-ER-01 Ex d LCD Display (Transmitter check)

No. Description OK Not

OK
1 Connect battery 24V to DCI-Tx-d-ER- 01 Ex d LCD Display
2 Select 4mA by pressing Up button or Down button then press Enter (Display m ust
show
4m A)
3 Select 20mA by pressing Up button or Down button then press Enter (Display must
show
20mA)
4 Connect to dumm y probe, then select probe type using Up button or Down button
display
will show metal loss (see table below)
Appendix 4. Other wiring option with Corrosion meter
Appendix 5. Other wiring with 24V Power Loop DCS

P/N : DCI-Tx-d-ER-A
II 1 / 2 G Ex db ia IIC T4 Ga/Gb