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Metal Samples Company CorrTran MV MS2900L Operator's Manual

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Operator's Manual
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Metal Samples Company
A Division of Alabama Specialty Products, Inc.
152 Metal Samples Rd., Munford, AL 36268
Phone: (256) 358-4202 Fax: (256) 358-4515
E-mail: msc@alspi.com Internet: www.metalsamples.com
 

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Summary of Contents for Metal Samples Company CorrTran MV MS2900L

  • Page 1                         Metal Samples Company A Division of Alabama Specialty Products, Inc. 152 Metal Samples Rd., Munford, AL 36268 Phone: (256) 358-4202 Fax: (256) 358-4515 E-mail: msc@alspi.com Internet: www.metalsamples.com  ...

  • Page 2: Table Of Contents

    CorrTran MV Corrosion Monitor Contents SAFETY INSTRUCTIONS / DISCLAIMER ..............2 Designated use ....................2 Installation, commissioning, and operation ............2 Operational safety ....................2 Maintenance safety ....................2 Notes on safety conventions and symbols ............3 Disclaimer ......................3 IDENTIFICATION ......................

  • Page 3: Safety Instructions / Disclaimer

    CorrTran MV Corrosion Monitor SAFETY INSTRUCTIONS / DISCLAIMER 1.1 Designated use The CorrTran MV is a compact, 4-20 mA corrosion transmitter used to detect general corrosion, localized corrosion, and conductance in a wide range of industries. The transmitter measures the corrosion rate and pitting factor, giving the readout in mil/year or a 0-1 pitting factor, respectively.

  • Page 4: Notes On Safety Conventions And Symbols

    CorrTran MV Corrosion Monitor 1.5 Notes on safety conventions and symbols The following conventions are used to highlight safety-relevant or alternate operating procedures in this manual and are shown in the margin where appropriate. Safety conventions Symbol Meaning A warning highlights actions or procedures which, if not performed correctly, will lead to personal injury, a safety hazard, or destruction of the instrument.
  • Page 5 CorrTran MV Corrosion Monitor 2.1.2 Key to model number C M C M - - A 2 Insertion Length (fixed probes only) in inches, 5" … 28", in 0.2" increments 5.0" 5.2" … 27.8" 28.0" in mm, 130mm … 710mm, in 5mm increments 130mm 135mm …...

  • Page 6: Contents Of Delivery

    CorrTran MV Corrosion Monitor 2.2 Contents of delivery It is essential to follow the instructions concerning the unpacking, transport, and storage of this instrument given in section 2.3, “Incoming acceptance, transport, storage.” Attention The contents of delivery consist of: • Assembled instrument •...

  • Page 7: Installation And Mounting

    CorrTran MV Corrosion Monitor INSTALLATION AND MOUNTING 3.1 Dimensions 2.8 mm (1.1") Extended cable for remote mounting length 1.8 or 3.6 m (6 or 12 feet) Transmitter Transmitter 76 mm housing housing (3.0") (side view) (top view) 96 mm 96 mm (3.8") (3.8") ø...
  • Page 8 CorrTran MV Corrosion Monitor (1.6") Ø 60 mm Six pin connector cap (2.36") Six pin circular connector 26 mm (1.02") 29 mm (1.16") 20 mm (0.78") min. 50.8 mm Thread for direct (2.00") mount only (5.9") Thickness ANSI B 16.5 Packing gland assembly standard 1"...
  • Page 9 CorrTran MV Corrosion Monitor Six pin connector cap Six pin receptacle assembly 1/2" NPT ø5/8" fitting 8" Ø5/8 Insertion rod Blow out preventer (optional) Ø.7 Retrievable probe adapter, remote mount Adj. probe exten. adapter Heavy protective cover with 1/2" NPT Hollow plug assembly (3.88)

  • Page 10: Probe Specifications

    CorrTran MV Corrosion Monitor 3.2 Probe specifications CMP epoxy adjustable probe The CMP epoxy adjustable probe (Figure 1) consists of a glass epoxy probe with a ¾” NPT nylon compression fitting for insertion into the system. The studs for mounting the electrodes and the six-pin connector are held in place by the epoxy fill material.
  • Page 11 CorrTran MV Corrosion Monitor CMP fixed probe The CMP fixed probe (Figure 3) is a fixed-length probe. The probe assembly consists of a ¾” NPT pipe plug that is welded in place, an insertion rod with a three-electrode end cap, a hermetically sealed connector, and a six-pin connector welded in place.
  • Page 12 CorrTran MV Corrosion Monitor CMP fixed flange probe The CMP fixed flange probe (Figure 4) is a fixed-length probe. The probe assembly consists of a specified flange that is welded in place, an insertion rod with a three-electrode end cap, a hermetically sealed connector, and a six-pin connector welded in place.
  • Page 13 CorrTran MV Corrosion Monitor CMP retractable probe The CMP retractable probe (Figure 5) is an adjustable-length probe. A specially designed packing gland is used with the probe for insertion into or retraction from a pressurized system without a process shutdown. The packing gland is designed to mount easily on a 1”...
  • Page 14 CorrTran MV Corrosion Monitor CMP retractable flange probe The CMP retractable flange probe (Figure 6) is an adjustable- length probe. A specially designed packing gland is used with the probe for insertion into or retraction from a pressurized system without a process shutdown. The packing gland is welded to a 1”...
  • Page 15 CorrTran MV Corrosion Monitor CMP retrievable probe The CMP retrievable probe (Figure 7) is a fixed-length probe. It is designed to be used with HPTM and MHTM high-pressure access systems. The probe assembly consists of an insertion rod with a hermetically sealed three-electrode end cap, a hollow plug nut, and a standard six-pin connector, which are all welded in place.

  • Page 16: Mounting Safety Procedures And Hints

    CorrTran MV Corrosion Monitor 3.3 Mounting safety procedures and hints The CorrTran MV must be installed in locations that are most susceptible to corrosion. In most cases, the highest levels of corrosion tend to occur where water is trapped or stagnant.
  • Page 17 CorrTran MV Corrosion Monitor CorrTran MV can be located at any point on the pipeline but should always be immersed in the corrosive material as shown in Figure 10. Figure 10. Correct CorrTran MV Pipeline Position A tee in the condensate return line (Figure 11) is a good location to mount CorrTran MV. Figure 11.
  • Page 18 CorrTran MV Corrosion Monitor CorrTran MV should be located downstream of a control valve for best performance and can also be located in the deadleg portion of a by-pass. Note that the transmitter located in the by-pass leg should be mounted in front of the valve for best performance. As shown in Figure 12.
  • Page 19 CorrTran MV Corrosion Monitor In addition to pipes, a condensate flash tank, shown in Figure 14, is also a good application. Figure 14. CorrTran MV Installed in a Condensate Flash Tank The CorrTran MV transmitter is shown in the blow down of a Y-strainer in Figure 15, and the discharge side of the basket strainer is shown in Figure 16.

  • Page 20: Installation Instructions

    CorrTran MV Corrosion Monitor 3.4 Installation instructions 3.4.1 General A trained specialist must perform the necessary installation and commissioning of CorrTran MV. Recognized rules of the technology and setup requirements must be maintained both during and after installation. Safety requirements must be observed during all installation steps.
  • Page 21 CorrTran MV Corrosion Monitor Metal Samples recommends cleaning the electrodes with rubbing alcohol or with another similar solution prior to operation to establish a reliable baseline for the transmitter electronics. Note 3.4.3 Probe installation CMP adjustable and fixed probes 1) Insert the probe into the pipe 2) Adjust to desired depth 3) Apply 1-1/4 turns from hand-tight to provide the seal as shown in Figure 18.
  • Page 22 CorrTran MV Corrosion Monitor CorrTran MV safety bracket assembly and installation See Figure 19 for detailed drawings. 1) Screw nut (2) on to threaded rod (3). 2) Screw threaded rod (3) in to base plate (1). 3) Tighten nut (2) to lock threaded rod (3) in place. 4) Slide top plate (4) on to threaded rods (3).
  • Page 23 CorrTran MV Corrosion Monitor CMP fixed flange probes Insert the probe into the pipe, and tighten to flange specifications. CMP retractable and retractable flange probes The packing must be adjusted prior to mounting the packing gland to the process. See Figure 20 for packing design details. Note 1) Loosen the locking nut.
  • Page 24 CorrTran MV Corrosion Monitor Compression Washer Jam Nut Ferrule Retainer Insertion Rod Packing Body Grafoil or V-Ring Packing Locking Nut Figure 20. Retractable Probe Packing Design If the system is greater than 10.3 bar (150 psi) the use of an “Easy Tool Retracting System”...

  • Page 25: Wiring

    CorrTran MV Corrosion Monitor PIPE & WALL MOUNT CMC-PMB-01 P/N 905775 Figure 21. CorrTran MV Mounting Bracket Assembly and Installation WIRING 4.1 Quick wiring guide Before connection, please note the following: • The power supply must be identical to the data on the nameplate. • Switch off power supply before connecting the device. • C onnect equipotential bonding to transmitter ground terminal before connecting the device. Connect CorrTran MV as follows: 1) Unscrew housing cover.

  • Page 26: Hart Introduction

    CorrTran MV Corrosion Monitor + – – 3 mm (1/8 in) Figure 22. Transmitter Wiring 4.2 HART introduction Metal Samples’ CorrTran MV probe supports the HART communication protocol. HART is an acronym for Highway Addressable Remote Transducer. The HART protocol makes use of the Bell 202 FSK standard to superimpose digital signals at a low level on top of the 4-20 mA signal.

  • Page 27: Post-Installation Check

    CorrTran MV Corrosion Monitor DC power supply unit 4-20 mA PACTware HART handheld HART modem Figure 23. Connecting a HART Modem or a Handheld Device 4-20 mA KFD2-STC4-Ex1 HART handheld HART modem Figure 24. Wiring with IS Barrier or Signal Conditioner 4-20 mA KFD2-HLC-Ex1.D HART handheld...

  • Page 28: Configuration And Commissioning

    CorrTran MV Corrosion Monitor CONFIGURATION AND COMMISSIONING 5.1 PACTware introduction PACTware is the latest generation of configuration software that makes it easy to program our equipment. PACTware also interfaces with HART-capable field instruments as well as bus systems such as PROFIBUS, Modbus and ControlNet. PACTware offers many features that allow users to simplify plant documentation, generate trend curves, and monitor signals using HART data.
  • Page 29 CorrTran MV Corrosion Monitor Figure 27 . ‘HART Communication’ FDT 5.2.2 CorrTran MV connection To establish a connection with your CorrTran MV unit(s): • Highlight the HART Communicator. • R ight click and select ‘Device’ > ‘Add device’ from the toolbar and add the ‘CorrTran MV’ DTM. Your screen should appear as shown in Figure 28. Figure 28. ‘CorrTran MV’ DTM...
  • Page 30 CorrTran MV Corrosion Monitor 5.2.3 Assigning the HART modem to the correct com port When loaded into PACTware, the HART modem defaults to Com 3 and will very likely need to be changed when using RS-232 or USB port modems. USB connections will show up as com ports in the PACTWare environment.
  • Page 31 CorrTran MV Corrosion Monitor Figure 30. HART Modem USB Connected to a Different COM Port 5.2.4 Connection to the CorrTran MV unit. • Highlight the ‘CORRTRAN’ to the left of the screen. • R ight click and select ‘Connect’ from the toolbar. Wait several seconds and the COM Parameter tab will display a ‘#’ symbol, and a green check mark will appear in the bottom left indicating that the CorrTran MV has established communication with PACTware, as seen in Figure 31.

  • Page 32: Corrtran Mv Online Variables And Parameters

    CorrTran MV Corrosion Monitor 5.3 CorrTran MV online variables and parameters Once a connection has been established, information from the CorrTran MV transmitter can be gathered. 5.3.1 Connection to online parameters To get online parameters: • Highlight the ‘CORRTRAN’ to the left of the screen. • R ight click and select ‘Parameters’ > ‘Online Parameterization’ from the toolbar. Your screen should appear as shown in Figure 32.
  • Page 33 CorrTran MV Corrosion Monitor Figure 33. Process Variables – Primary Variable (read only) 5.3.3 Online variables: diag/service The ‘Device Variables’ screen, as shown in figure 34, provides an overview of all three process variables. This screen is read only. Figure 34. Device Variables (read only)
  • Page 34 CorrTran MV Corrosion Monitor 5.3.4 Online variables: device variables The Diagnostics/Service feature is password protected by default. To utilize this feature, you must enable the password as seen in Figure 35. The default password is ‘managers’ , and can be changed after the password has been enabled. After the password is enabled, you will see the screen shown in Figure 36. Figure 35.
  • Page 35 CorrTran MV Corrosion Monitor From the ‘Diag/Service’ menu, you have access to the following features: • ‘Loop test’: allows you to impress a current signal on the output of the transmitter. If the transmitter is being used for control, then it should be disabled. The Current selected for output will be imposed onto the loop. Attention • ‘Reset Device’: recycles power. • ‘Reset Fact Default’: resets parameter and passwords to factory default settings. • ‘ Reset Counter Average’: resets sample count and average to zero and the PV and SV are set to zero.
  • Page 36 CorrTran MV Corrosion Monitor 5.3.5 Online variables: basic setup The ‘Basic Setup’ windows allow basic configuration for the following parameters: The password must be enabled in order to configure the CorrTran MV. Note • ‘ Device Information’: allows you to enter information about your CorrTran MV. Some of the fields, such as model and manufacturer, are read only. Figure 38. Basic Setup – Device Information • ‘...
  • Page 37 CorrTran MV Corrosion Monitor Figure 39. Basic Setup – Device Variable Assignment • ‘ Range and Units’: allows you to configure the PV units and range, when general corrosion is assigned as the PV. Figure 39 displays the ‘Range and Units’ window. When localized corrosion is assigned as the PV, no units or range are selectable because localized corrosion is unitless and is on a scale from 0 to 1, with 0 being no localized corrosion and 1 being very high.) Note Figure 40.
  • Page 38 CorrTran MV Corrosion Monitor • ‘ Damping’ and ‘Poll addr’: are listed as two menu items, but actually appear on one screen. Damping is defaulted to 0.01 seconds, but does not affect the readings because the measurement cycle can range from 4 to 21 minutes. 5.3.6 Online variables: detailed setup The data needed to complete the ‘detailed setup’ window is entered at the factory before the CorrTran MV is shipped, but you may need to reenter or change information in this window if the electrodes are changed to a different material or general or localized corrosion are eliminated from the measurement for faster update times.
  • Page 39 CorrTran MV Corrosion Monitor See Table 5 in the Appendix for factory calculated K values of common electrode materials. Note • ‘ Alarm Config’: This screen controls the settings for an alarm that activates when the PV corrosion rate goes above or bellow the URV or LRV. The default is High/Auto, and the options are as follows: • No Alarm – Alarm is turned off • High/Auto – Output goes to 22.5 mA and resets automatically.
  • Page 40 CorrTran MV Corrosion Monitor Figure 42. Review (read only) 5.3.8 Additional functions: process trend To get ‘Process Trend’: • Highlight the ‘CORRTRAN’ to the left of the screen. • R ight click and select ‘Additional Functions’ > ‘Process Trend’ from the toolbar. Your screen should appear as shown in Figure 42. ‘Process Trend’ allows you to plot all three variables (general corrosion, localized corrosion, and conductance) on the same graph over a user defined period of time. Figure 43.

  • Page 41: Corrtran Mv Test Probe: Cmp-Tester

    CorrTran MV Corrosion Monitor 5.4 CorrTran MV test probe: CMP-TESTER Note: Using the CMP-TESTER is optional and not required for configuring and commissioning the CorrTran MV Note: The CMP-TESTER is designed as a tool to verify proper functionality of the CorrTranMV. It is not a calibration device, and can not be used to scale the Note corrosion process data.

  • Page 42: Replacement Parts And Accessories

    CorrTran MV Corrosion Monitor REPLACEMENT PARTS AND ACCESSORIES 6.1 CorrTran MV parts Please submit the serial tag number on the nameplate when ordering replacement parts for CorrTran MV. If the pipe or vessel into which the CorrTran MV is to be inserted is under pressure and/or contains any hazardous substance, such as steam, caustic solutions, acids, toxins or other substances specified by OSHA as physical Warning...
  • Page 43 CorrTran MV Corrosion Monitor 6.1.2 Probe replacement C M P - Insertion Length (fixed probes only) in inches, 5" … 28", in 0.2" increments 5.0" 5.2" … 27.8" 28.0" in mm, 130mm … 710mm, in 5mm increments 130mm 135mm … 705mm 710mm Electrode Material...
  • Page 44 CorrTran MV Corrosion Monitor 6.1.3 Electrode replacement – finger electrodes C M C - Electrode Material 0A… see electrode material guide *Electrode Material Guide can be found in the Appendix Electrodes are sold in a pack of 3. Note 6.1.4 Remote mount cable replacement C M C - R / 0 2 - Cable Length remote mount with 1.8m (6') cable...

  • Page 45: Hart Accessories

    CorrTran MV Corrosion Monitor 6.2 HART accessories For installations requiring more then one transmitter, we offer a wide variety of HART multiplexers and termination boards for wiring to a PLC or DCS system. The multiplexers are available in 16 and 32 channel options. Model Description KFD2-HMM-16...

  • Page 46: Additional Accessories

    CorrTran MV Corrosion Monitor 6.4 Additional accessories Model Description 905820 Safety label US-HI-321 USB HART modem CMC-SCD-01 Safety bracket for direct mount probes CMC-SCR-01 Safety bracket for remote mount probes CMC-PMB-01 Wall or pipe mounting bracket for remote mounted transmitters CMD-DL-Ex1 Safe area mountable data logger CMD-DR2-Ex1...

  • Page 47: Technical Data

    CorrTran MV Corrosion Monitor Technical data Input Measured Variable • G eneral corrosion: Electro-chemical corrosion that proceeds more or less uniformly over the surface of the material exposed to the corrosive environment. • L ocalized corrosion (pitting): Electro-chemical corrosion that occurs at discrete sites on the material exposed to the corrosive environment. • C onductance: The reciprocal of the solution resistance. It is a measure of how easily electricity flows along a certain path through an electrical element.
  • Page 48 CorrTran MV Corrosion Monitor Technical data (continued) Operating Conditions Operating Conditions Installation Instructions See page 20, Section 3.4 Installation Instructions Environment Ambient Temperature Ambient temperature for the transmitter: Range • GP, NI, IS version: -50 °C to +70 °C (-58 °F to +158 °F) • EX version: -40 °C to +70 °C (-40 °F to +158 °F) Storage Temperature -40 °C to +70 °C (-40 °F to +158 °F) Degree of Protection • Housing: IP66, NEMA 4X Vibration Resistance...
  • Page 49 CorrTran MV Corrosion Monitor Technical data (continued) Ex Approval LCIE 05 ATEX 6097X, II 1G EEx ia IIC T4 CSA Approval cCSAus certified for US and Canada; Certificate #1563164: • IS: Cl. I, II, III; Div. 1, 2; Groups A…G • NI: Cl. I, II, III; Div. 2: Groups A…G • EX: Cl. I; Div. 1,2; Groups A…D IEC Approval Patents U.S. patents: 7,239,156; 7,245,132; 7,265,559; 7,282,928 Ordering Information Metal Samples can provide detailed ordering information and Ordering Information information on the order codes on request Accessories...

  • Page 50: Troubleshooting

    CorrTran MV Corrosion Monitor TROUBLESHOOTING If you encounter problems configuring or using your CorrTran MV, consult the following troubleshooting table. If you continue to have problems, please contact your Metal Samples representative for further assistance. Symptom Cause/Procedures Solution Check voltage and compare it with the No 4-20 mA output Connect the correct voltage specifications on the nameplate.
  • Page 51 CorrTran MV Corrosion Monitor Device Status Description Troubleshooting Codes LPR only mode The CorrTran MV has been configured Device mode is by default Normal to operate in LPR mode for its general (HDA/LPR) and should be left that way corrosion calculation. to maintain the best accuracy for all process variables.

  • Page 52: Measuring Principle

    CorrTran MV Corrosion Monitor MEASURING PRINCIPLE Anodic site corr Cathodic site Figure 44. CorrTran MV Corrosion Cell General corrosion Linear Polarization Resistance (LPR) is based on the fact that in a corroding electrode the relationship between i and the polarization resistance is give by the following equation: corr ∆E , where R...
  • Page 53 CorrTran MV Corrosion Monitor Conductance Solution resistance is a measure of how easily electricity flows along a certain path through an electrical element. The reciprocal of the solution resistance is solution conductance. The CorrTran MV measures solution resistance in order to more accurately calculate the general corrosion rates.

  • Page 54: Appendix A

    CorrTran MV Corrosion Monitor 10 APPENDIX A CorrTran electrode materials Electrode Material K-Value UNS Number Model Number Aluminum 1100 10940.96 A91100 CME-0N 2024 11400.51 A92024 CME-0O 7075 A97075 CME-1O Carbon Steel & Alloys 1010 11486.66 G10100 CME-0S 1018 11597.63 G10180 CME-0A 1020 11401.49...
  • Page 55 CorrTran MV Corrosion Monitor Probe mounting guide Transmitter O-ring Key # Probe Style* Process Connection Electrode Style Mounting Material Fixed NPT, flange Direct Standard finger Viton Fixed NPT, flange Remote Standard finger Viton Adjustable Direct Standard finger Viton Adjustable Remote Standard finger Viton Retractable...
  • Page 56 CorrTran MV Corrosion Monitor Default settings Figure 45. CorrTran MV default settings Figure 46. CorrTran pinout diagram...

  • Page 57: Appendix B: Corrtran Ec Startup

    CorrTran MV Corrosion Monitor 11 APPENDIX B: CorrTran EC Startup Insert the batteries as shown in the photo below: Figure 47 . Note battery orientation for proper polarity Press the reset button and hold it down until the LED flashes GREEN. CorrTran EC is now running.
  • Page 58 CorrTran MV Corrosion Monitor data internally to the CorrTran EC and then retrieve this data on a memory stick. 11.1.2 Device Settings Tab Figure 49. Device settings tab From the Device Settings Menu you can make the initial settings on the CorrTran EC and save them to the nonvolatile memory in the unit.
  • Page 59 CorrTran MV Corrosion Monitor On the Corrosion Parameter panel, you may enter your own Stearn-Geary value for B value. Figure 50. Corrosion parameter panel A Elect Area: This parameter is the electrode area, it should remain 4.75 cm for standard finger electrodes and XXX cm for flush electrodes.

  • Page 60: Hints On Extending Battery Life

    CorrTran MV Corrosion Monitor 11.2 Hints on Extending Battery Life By comparison to CorrTran itself, the memory stick is a huge consumer of battery power and life. Your demo unit is shipped with very high-density, 3.6 V, Li-SOCl2 batteries. These batteries will operate CorrTran for months under typical use and allow retrieval of data on several occasions.

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