corrtran-aqua; corrosion monitoring transmitter...

CORROSION MONITORING TRANSMITTER

PROCESS AUTOMATION

CorrTran® AQUA

Subject to modifications www.pepperl-fuchs.com

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CorrTran AQUA Corrosion Monitor

2

Contents

1 SAFETY INSTRUCTIONS / DISCLAIMER ................................................................... 3

1.1 Designateduse.................................................................................................... 3

1.2 Installation,commissioning,andoperation.......................................................... 3

1.3 Operationalsafety................................................................................................ 3

1.4 Notesonsafetyconventionsandsymbols............................................................ 3

1.5 Disclaimer............................................................................................................. 4

2 IDENTIFICATION ........................................................................................................... 4

2.1 Devicedesignation............................................................................................... 4

2.2 Contentsofdelivery.............................................................................................. 6

2.3 Incomingacceptance,transport,storage............................................................. 6

2.4 Certificatesandapprovals.................................................................................... 6

2.5 Registeredtrademarks......................................................................................... 6

2.6 Patents................................................................................................................. 6

3 INSTALLATION AND MOUNTING ............................................................................... 7

3.1 Dimensions............................................................................................................ 7

3.2 Mountingsafetyproceduresandhints................................................................. 8

3.3 Probespecifications........................................................................................... 12

3.4 Installationinstructions....................................................................................... 13

4 STARTUP AND WIRING ............................................................................................. 15

4.1 Quickwiringguide.............................................................................................. 15

4.2 HARTintroduction.............................................................................................. 15

4.3 WiringwithHART............................................................................................... 15

4.4 Post-installationcheck........................................................................................ 16

5 HART MODEM ............................................................................................................ 17

5.1 HARTmodemintroduction.................................................................................. 17

5.2 LoadingUS-HI-321devicedrivers..................................................................... 17

6 CONFIGURING THE DISPLAY .................................................................................. 20

CorrTranMV EVALUATION TOOL .................................................................................... 21

7.1 CorrTranMVEvaluationToolintroduction.......................................................... 21

7.2 EstablishingcommunicationwiththeCorrTranMVEvaluationTool................... 21

7.3 CorrTranMVEvaluationToolcapabilities........................................................... 23

8 TRANSFERING PROCESS DATA TO EXCEL .......................................................... 29

9 CHANGING OPERATING MODE TO REDUCE EXCITATION FREQUENCY ........... 32

10 REPLACEMENT PARTS AND ACCESSORIES ........................................................ 33

10.1 CorrTranAQUAparts......................................................................................... 33

10.2 Accessories........................................................................................................ 35

11 SYSTEM SPECS ......................................................................................................... 36

12 TROUBLESHOOTING ................................................................................................ 39

13 MEASURING PRINCIPLE ........................................................................................... 41

14 APPENDIX ................................................................................................................... 43


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1. SAFETY INSTRUCTIONS / DISCLAIMER 1.1 Designated use TheCorrTranAQUAisacompact,4-20mAcorrosiontransmitterusedtodetectgeneralcorrosion,localizedcorrosion,andconductanceinthewaterqualityindustry.Thetransmittermeasuresthecorrosionrateandpittingfactor,givingthereadoutinmil/yearora0-1pittingfactor,respectively.Italsoprovidesaconductancemeasurement.Thereadingsaretakeninrealtimeandareupdatedapproximatelyevery34minutes.

1.2 Installation, commissioning, and operation CorrTranAQUAhasbeendesignedtooperatesafelyinaccordancewithrelevanttechnicalandsafetystandards.Ifinstalledincorrectlyorusedforapplicationsforwhichitisnotintended,application-relateddangersmayarise.Forthisreason,theinstrumentmustbeinstalled,connected,operated,andmaintainedaccordingtotheinstructionsinthismanualbyappropriatelytrainedpersonnel.Thismanualmustberead,understood,andtheinstructionsmustbefollowed.Modificationsandrepairstothedevicearepermissibleonlywhentheyareexpresslyapprovedinthismanual.

1.3 Operational safety CorrTran AQUA cannot be used in a hazardous (classified) area.

1.4 Notes on safety conventions and symbols Thefollowingconventionsareusedtohighlightsafety-relevantoralternateoperatingproceduresinthismanualandareshowninthemarginwhereappropriate.

Safety conventions

Symbol Meaning

Warning

Awarningsymbolhighlightsactionsorproceduresthat,ifnotperformedcorrectly,willleadtopersonalinjury,asafetyhazard,ordestructionoftheinstrument.

Attention

Anattentionsymbolhighlightsactionsorproceduresthat,ifnotperformedcorrectly,mayleadtopersonalinjuryorincorrectfunctioningoftheinstrument.

Note

Anotesymbolhighlightsactionsorproceduresthat,ifnotperformedcorrectly,mayindirectlyaffectoperationormayleadtoaninstrumentresponsewhichisnotplanned.

Aterminalsymbolindicatesthataprotectivegrounding(earth)terminalmustbeconnectedtoearthgroundpriortomakinganyotherconnectiontotheequipment.


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1.5 Disclaimer Pepperl+Fuchs,Inc.(“P+F”)hasnopower,nordoesitundertaketopoliceorenforce,compliancewiththecontentsofthismanualorobservanceofthesafetyprecautionssetforthherein.P+Fdoesnotcertify,test,orinspecttheinstallationsofCorrTranAQUAforsafetyorotherpurposes.P+Fdisclaimsliabilityforanypersonalinjury,property,orotherdamagesofanynaturewhatsoever,whetherspecial,indirect,consequential,orcompensatory,directlyorindirectlyresultingfromthepublication,useof,orrelianceuponthismanual.P+Fmakesnoguarantyorwarranty,expressorimplied,astotheaccuracyorcompletenessofanyinformationpublishedinthismanual,anddisclaimsandmakesnowarrantythattheinformationinthismanualwillfulfillanyparticularpurposesorneeds.P+F’sonlywarrantyissetforthinthewrittenLimitedWarrantyspecificallyprovidedbyP+FinconnectionwiththepurchaseoftheCorrTranAQUA.

2. IDENTIFICATION2.1 Device designation 2.1.1 Nameplates


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2.1.2 Modelnumber

*Probe Mounting Guide and Electrode Material Guide can be found in the Appendix.

Model Number Description

CorrTranAQUA-912927 Kit,baseunitwithoutlocaldisplay,1018CSelectrodes,11”probe

CorrTranAQUAwithdisplay-912929 Kit,baseunitwithlocaldisplay,1018CSelectrodes,11”probe

Electrodes Electrodesotherthancarbonsteelmustbeorderedseparately


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2.2 Contents of delivery

Itisessentialtofollowtheinstructionsconcerningtheunpacking,transport,andstorageofthisinstrumentgiveninsection2.3,“Incomingacceptance,transport,storage.”

Unlessorderedascomponents,thecontentsofdeliveryconsistof:

• Assembledtransmitter

• Aprobe

• 3-electrodeelements(fingertelectrodesonly)

• 12’cable(forprobe)

• Accessories(ifanyareordered)

• Instructionmanual(thisdocument)

2.3 Incoming acceptance, transport, storage 2.3.1 IncomingacceptanceCheckthepackingandcontentsforanysignsofdamage.Checktheshipmenttoensurethatallpartshavebeenincludedandtoverifythattheshipmentmatchesyourorder.

Allprobesareshippedwiththeinsulatinggasketsinstalled.Uponremovingtheprotectivecap,ensurethattheO-ringsarenotloose.TheO-ringsaremadeofViton®(standard)orKalrez(onrequest).Iftheyarenotinstalled,theprobewillnotoperateproperly.PleaserefertoFigure14onpage14.

2.3.2 TransportProtectthetransmitterelectrodesfromdamage.Donotattempttocarrythetransmitterbyitselectrodes.

2.3.3 StorageAlwayspacktheinstrumentforstorageortransporttoprotectitagainstimpact.Theoriginalpackingmaterialprovidestheoptimumprotectionforthedevice.Thepermissiblestoragetemperatureis-40°Fto+176°F(-40°Cto+80°C).

2.4 Certificates and approvals TheCorrTranAQUAisdesignedtomeetrelevantsafetyrequirements.Ithasbeenfullytestedtoensurethatitisinsafeoperatingcondition.Theinstrumentcomplieswiththeapplicableregulationsinaccordancewithknownstandards.

2.5 Registered trademarks HART®RegisteredtrademarkofHARTCommunicationFoundation,Austin,USA

Viton®RegisteredtrademarkofthecompanyE.I.DuPontdeNemours&Co.,Wilmington,USA

2.6 Patents ThisinstrumentisprotectedbyoneormorepatentsregisteredintheUSPatentOffice.

Warning

Attention


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3. INSTALLATION AND MOUNTING 3.1 Dimensions

51 mm(2.00")

190 mm(7.50")

Ø 19 mm(0.75")

70 mm(2.78")

32 mm(1.25")

¾ NPTnyloncompressionthread

Adjustable epoxy glassprobe and electrode

Ø14.8

48.2

Ø10

Ø10

Ø10.8

M12x1external threads

Ø10.8

Ø14.8

45.3

M12x1internalthreads

Probecable

ProbeCableLength:3.6m(12’)


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Figure 1. CMC Probe Installation Figure 2. CMC Probe Installation

3.2 Mounting safety procedures and hints Theelectrodesselectedmustreflectthesamemetalpropertiesasthepipingorothercomponentssusceptibletocorrosion.Forexample,inapplicationswherethepipeismadeofstainlesssteelandthewaterpump’simpellerismadeofcarbonsteel,theimpellerwillcorrodefasterthanthepipe.Inthiscase,itisadvisabletoselectelectrodesthataremadeofthesamematerialasthepump’simpeller.

3.3.1 Mountingrequirements/scenarios

ThetransmittershouldnotbemountedinapipedropsincethecorrosiveliquidmaynotbeinfullcontactwiththeelectrodesasshowninFigure1.

CorrTranAQUAshouldbemountedintheriserofapipenearanelbowwherethevelocityisthehighest.Ingeneral,CorrTranAQUAshouldbemountedinpipesortanksatlocationsofhighestliquidvelocityandconstantimmersion,showninFigure2.Forvelocitiesgreaterthan20fps,theprotrudingfingerelectrodesmustbeprotected.Asnotedabove,highfluidvelocitiescanalsocauseunwantedturbulenceinthepipeduetotheextensionoftheprobe.

4 - 20 mA PROBE

Attention

Warning

4 - 20 mA PROBE

OK!

15 diameters downstream


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TheCorrTranAQUAprobecanbelocatedatanypointonthepipelinebutshouldalwaysbeimmersedinthecorrosivematerialasshowninFigure3.

Figure 3. Correct CorrTran AQUA Pipeline Position

Ateeinthecondensatereturnline(Figure4)isagoodlocationtomounttheCorrTranAQUAprobe

Figure 4. CorrTran AQUA Located in Tee

4 - 20 mA PROBE

4 - 20 mA PROBE

4 - 20 mA PROBE

Note: The line must be full at all times and electrodes must be located in the bottom half of the line. Electrodes must be covered at all times.


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TheCorrTranAQUAprobeshouldbelocateddownstreamofacontrolvalveforbestperformanceandcanalsobelocatedinthedeadlegportionofaby-pass.Notethattheprobelocatedintheby-passlegshouldbemountedinfrontofthevalveforbestperformance.SeeFigure5.Thisguaranteesthattheelectrodeswillalwaysbeimmersedinthecorrosivematerial.

Figure 5. CorrTran AQUA Located in Bypass Loop Top View

InstallingseparateCorrTranAQUAprobeswithdifferentelectrodematerialsonthesuctionsideofthepumpwillensuremonitoringofthepumpimpellerandthepipeasshowninFigure6.Thereshouldbeaminimumseparationdistanceof50cm(19.7”)betweenprobes.

Figure 6. CorrTran AQUA Probes Mounted With Different Electrodes

4 - 20 mA PROBE

4 - 20 mA PROBE

Note

15 diameters

Bypass Valve Bypass Valve

Control Valve

4 - 20 mA PROBE


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Inadditiontopipes,acondensateflashtank,showninFigure7,isalsoagoodapplication.

Figure 7. CorrTran AQUA Installed in a Condensate Flash Tank

TheCorrTranAQUAprobeshouldNOTbelocatedintheblowdownofaY-strainerasshowninFigure8.NorshoulditbelocatedinthedischargesideofthebasketstrainerasshowninFigure9.

4 - 20 mA PROBE

4 - 20 mA PROBE

4 - 20 mA

PRO

BE

Figure 8. Probe Mounted in Y-Strainer Figure 9. Probe Mounted in Basket Strainer

CorrTranAQUAmaybeimplementedinarackinplaceoftraditionalmetal-losscouponmonitoringandcanbeinstalledinanexistingcouponrack.Inthiscase,theCorrTranAQUAprobesshouldbeinsertedinplaceofthecouponholderportsasshowninFigure10.

Figure 10. CorrTran AQUA Mounted in a Coupon Rack

4 - 20 mA PROBE

Directionofflow


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Figure 11. CMP Epoxy Adjustable Probe

3.3 Probe specifications CMPepoxyadjustableprobeTheCMPepoxyadjustableprobe(Figure11)consistsofaglassepoxyprobewitha¾”NPTnyloncompressionfittingforinsertionintothesystem.Thestudsformountingtheelectrodesandthesix-pinconnectorareheldinplacebytheepoxyfillmaterial.Thisprobeisavailablein127mmand280mm(5”and11”)lengthsonly.Thisprobeisonlyavailablewiththeremotemountingoption.

Electrodesshowninthepictureareorderedseparately.

Specifications

ProbeBody Glassepoxy

EndcapSeal Epoxy

FillMaterial Epoxy

ProcessTemperature -50…65°C(-58…149°F)

PressureRating 7bar(100psi)

Mounting 3/4”NPTnylonfitting

StandardLengths 127,280mm(5,11”)

CustomLengths N/A

InsertionLength Adjustable,Max=probelength-89mm(3.5”)+EL

*EL=32mm(1.25”)forfingerand0mm(0”)forflushelectrodes


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3.4 Installation instructions 3.4.1 General

AtrainedspecialistmustperformthenecessaryinstallationandcommissioningofCorrTranAQUA.Recognizedrulesofthetechnologyandsetuprequirementsmustbemaintainedbothduringandafterinstallation.Safetyrequirementsmustbeobservedduringallinstallationsteps.

IfthepipeorvesselintowhichtheCorrTranAQUAistobeinsertedisunderpressureand/orcontainsanyhazardoussubstance,suchassteam,causticsolutions,acids,toxinsorothersubstancesspecifiedbyOSHAasphysicalorhealthhazards,thepipeorvesselmustfirstbedepressurized,anyhazardoussubstancepurgedtherefrom,andappropriatelockout/tagoutproceduresobservedinaccordancewithSection1910.147oftheOSHARegulations,beforeCorrTranAQUAcanbeinstalled.Failure to follow these procedures may result in serious injury or death.

CorrTranAQUAconsistsofthreebasiccomponents:

• Transmitter:Atransmitterhousingcontainstheelectronicsandprovidesthe4-20mAwithHARToutputsignal.

• Probe:Theremotemountprobeissuppliedwitha12’cable.

• Electrodes:Eitherfingerelectrodesorelectrodesflushtotheprobeendareused.Correctlychosenelectrodeswillcorrodeinthesamemannerasthemetalbeinginvestigated.Foraccuratemeasurements,theelectrodesmustreflectthesamemetalpropertiesasthemetalbeinginvestigated.

3.4.2 ElectrodeinstallationTheelectrodesareshippedlooseandmustbeinstalledhand-tight.Ensurethatthe

Viton(standard)orKalrez(onrequest)gasketsareinplacepriortoinstallingtheelectrodes.SeeFigure12fortheelectrodeinstallationdrawing.

Typically,carbonsteelelectrodesareinspectedevery90to180daysandyellowmetalelectrodes(copperandcopperalloy)areinspectedevery180to360days.It’snotjustthegeneralcorrosionrate,it’salsofoulingorbridgingthatoccursthatmayresultinfalsereadings.Wheninstalledincorrosioncouponracks,theprobesshouldbeinspectedwheneveracorrosioncouponisremovedandreplaced.Iftheelectrodesarefouled,theyshouldeitherbecarefullycleanedorreplaced.

Figure 12. Electrodes and Viton Gaskets

Pepperl+Fuchsrecommendsthatthepersoninstallingtheelectrodeswearaplasticgloveofthetypeusedinmedicalofficesorthetypeusedbyfoodpreparers.Or,carefullyusethecorrosionbarrierpaperthatispackedintheelectrodeenvelopeandwitheachcorrosioncouponItisimportantnottotouchtheelectrodeswithyourbarehands.

Warning

Electrodes VitonGaskets

Note


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3.4.3 ProbeinstallationCMP adjustable and fixed probes

1)Inserttheprobeintothepipe

2)Adjusttodesireddepth

3)Apply1-1/4turnsfromhand-tighttoprovidethesealasshowninFigure13.

Figure 13. CMP Adjustable and Fixed Probe Mounting

Forfixedtypeprobes(withoutthecompressionfitting)onlythe1-1/16”hexnutneedstobetightened.Note

4 - 20 mA PROBE


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4. STARTUP AND WIRING4.1 StartupThemeasurementcycleofCorrTranAQUAis34minutes.Whenpowerisfirstappliedtotheunit,theoutputwillread4mAfor34minutes.Afterthefirstreading,theoutputshouldgotohigherthan4mA,dependingonthecorrosionrate.

4.1.1 QuickwiringguideFieldinstallableV1-Gconnector(117051),Figure14.

Figure 14. Transmitter Wiring

4.2 HART introduction Pepperl+Fuchs’CorrTranAQUAprobesupportstheHARTcommunicationprotocol.HARTisanacronymforHighwayAddressableRemoteTransducer.TheHARTprotocolmakesuseoftheBell202FSKstandardtosuperimposedigitalsignalsatalowlevelontopofthe4-20mAsignal.Thisenablestwo-waycommunicationandmakesitpossibleforadditionalinformationbeyondjustthenormalprocessvariabletobecommunicatedtoandfromasmartfieldinstrument.

4.3 Wiring with HART IfyouareusingCorrTranMVwithanon-HARTcompatibleI/Oofdatacollectiondevice,theKFD2-HLC-Ex1.D,HARTLoopConverter,canintegratethethreeCorrTranAQUAvariablesintoseparate,independent4-20mAoutputs.


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Pleaseobservethefollowingguidelines:

• Alwaysuseagroundedpowersupply(ontheACside).

• EnsurethattheI/Ocardisisolatedfromground.

Figure 15. Connecting to analog auxiliary port on controller

Figure 16. Connecting with a HART modem or handheld

4.4 Post-installation check Afterwiringthetransmitterandconnectingtheprobes,performthefollowingchecks:

• Istheprobesecureandtightenedtospecifiedtorque?(Seesection3.4.3.)

• Havetheelectrodesbeencleaned?(Seesection3.4.2.)

• Istheterminalassignmentcorrect?(Seesection4.1.)

• Isthehousingcoverscrewedtight?

4-20 mA

Controller

4-20 mA

HART handheld

PACTware

250 Ω

HART modem

DC power supply unit

or Controller


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5. THE HART MODEM 5.1 HART modem introduction AnyHARTModemcanbeusedtocommunicatebetweentheCorrTranAQUAandtheCorrTranMVEvaluationTool.Pepperl+FuchsrecommendtheUS-HI-321HARTModem.

5.2 Loading US-HI-321 device drivers IfyouareusingadifferentHARTmodemyoushouldensurethatyouhavesuccessfullyistalleditsassociatedsoftware/devicedriversbeforemovingontosection3.

IfyouareusingtheUS-HI-321HARTmodemfollowthesestepstoinstallitsdevicedriver.Ifyouhavealreadyinstalledthedevicedriverthenmoveontosection3.

• InsertSmarResearchProductCDthataccompaniestheUS-HI-321intoyourcomputerCD-ROM.TheCDwillautomaticallyopentothewindowseeninFigure17.

Figure 17. SmarResearch Product DC Launch Screen


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• Byselecting‘English’thescreenshouldappearasshowninFigure18.

Figure 18. SmarResearch Product DC

• Select‘ProductDrivers’toaccesstheUS-HI-321productdriverasseeninFigure19.

Figure 19. Product Drivers


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• Select‘InstallHI321Drivers’toinstalltheUS-HI-321drivers.ThescreenseeninFigure20willappear.IftheUS-HI-321driverhasbeensuccessfullyinstalled,itwillaskyoutopressanykeytocontinue.

Figure 20. US-HI-321 Driver Installation Screen

• TheUS-HI-321DriverhasnowbeensuccessfullyinstalledandtheSmarResearchProductCDcanbeejectedfromthecomputer.


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Texmate, Inc. Tel. (760) 598-9899 • www.texmate.comPage 2 September 8, 2003 SD-50X Data Sheet (SD02)

Controls and Indicators Dip Switch Settings

Two Point Digital Scaling and Calibration - Quick Reference Guide

Digit/Descriptor Display Lock/Frequency

Default SettingWhen set to ON

displays [Lock] whenany button is pressed

Effect on Display

F

C

12

12

12

12

ON

ON

ON

ON

Dummy Zero

12

ONOFF50

ON60

Display Lock

Rejection Filter (Hz)

DefaultSetting

When set to ONdisplays [Lock] whenany button is pressed

F

CDummyZero

OFF50

ON60

Display Lock

RejectionFilter (Hz)

Rear View of the MeterUP ARROW

BUTTON

DOWN ARROWBUTTON

PROGRAM BUTTON: This button is used to move from oneprogram step to the next.When pressed simultaneously with theUP ARROW button, the Programming Mode is entered.UP ARROW BUTTON: Increases the value of the displayedparameter.DOWN ARROW BUTTON: Decreases the value of the dis-played parameter.NOTE: When the display lock switch is on and any button ispressed, the display will show only [Lock] momentarily asshown above and then return to the normal operational display.

PROGRAMBUTTON P

Enter theCalibration Mode Enter the

Calibration Mode

Operational Display

Operational Display

Operational Display

Select [cAL on]

TEXMATE

Prog.

Set DIP switchto lock OFF

TEXMATE

Prog.

Set the LOW input valueand enter the HIGH Input

[hi in] Mode

Apply the 4 mALOW inputcalibration signalto the meter.

TEXMATE

Prog.

Enter the LOW Input[Lo in] Mode

If display shows [cALErr] the calibration has been canceledand the previously calibrated scale

factors are retained in memory.(See page 2, para 5)

TEXMATE

Prog.

TEXMATE

Prog.

TEXMATE

Prog.

Pass Calibration Modeand enter Decimal Point

Setting Mode

12

ON

Set DIP Switchto Lock On

12

ON

Set DIP switchto lock ON

12

ON

Set DIP switchto lock OFF

12

ON

OR

TEXMATE

Prog.

ORPress

1

TEXMATE

Prog.

Set the HIGH input value andreturn to Operational Display

Apply the 20 mAHIGH inputcalibration signalto the meter.

Press1

TEXMATE

Prog.

Press1

Press1

TEXMATE

Prog.

Adjust the decimal pointto the desired position

Press1

Step 1

Two Point Calibration and ScalingExample: 4 to 20 mA input to read 0 to 20,000

Decimal Point Setting

Step 2

Step 3

Step 4

Step 5

Step 7

Step 2

Step 3

Step 4

Set the decimal point positionand return to Operational Display

Pressat same

timePress

at sametime

Operational DisplayTEXMATE

Prog.

Step 1

Pressat same

time

Pressat same

time

TEXMATE

Prog.

Adjust display to thedesired reading for

HIGH input

TEXMATE

Prog.

OR

Any value between-19,999 and 30,000may be selected. Reverse scaling

is accepted.

TEXMATE

Prog.

TEXMATE

Prog.

Adjust display to desiredreading for LOW input

OR

Step 6

Max differencebetween [hi in] &

[Lo in] displayvalues selectedcannot exceed32,000 counts.

If the input signal is dis-connected after Step 5, the

[Lo in] values are saved, andthe meter automatically

returns to the [hi in] mode whensignal power is re-applied.

Maximum positive reading is30,000 & maximum negativereading is -19,999. Maximumdisplay span is 50,000 counts.

6. CONFIGURING THE DISPLAY (if equipped)


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7. CorrTranMV EVALUATION TOOL7.1 CorrTranMV Evaluation Tool introductionCorrTranMVEvaluationToolissuppliedwitheveryCorrTranAQUA.(**TheCorrTranMVEvaluationToolisfunctionallyequivalenttotheCorrTranAQUA.)Itprovidesaneasy-to-usesetupfeatureforCorrTranAQUAplustheabilitytostoreAQUAdatainASCIIfilesthatcanbeimportedintoyourfavoriteanalysispackage.

TheunitmayalsobeprogrammedusingPepperl+Fuchs’PACTwareprogrammingenvironment.PleasecontactthefactoryformoreinformationonPACTware

7.2 Establishing communication with the CorrTranMV Evaluation Tool• ToestablishcommunicationbetweenyourCorrTranAQUAusingtheCorrTranMV

EvaluationTool,youmustfirstensurethatyourCorrTranAQUAandHARTmodemareconnectedasshowninsection4.3,thedevicedriversforyourHARTmodemhavebeensuccessfullyinstalled,andyouhavetheCorrTranMVEvaluationToolsoftwareinstalledonyoucomputer.

• OpenCorrTranMVEvaluationTool.Figure21showsthemain(default)screenyouwillseewhenopeningtheprogram.

Figure 21. CorrTranMV Evaluation Tool Main (default) Screen

7.2.1 AssigningtheHARTmodemtothecorrectcomportWhenfirstlaunched,theCorrTranMVEvaluationTooldefaultstoCom1andwillverylikelyneedtobechangedunlessyouareusingaRS232HARTmodem.

USBconnectionswillshowupascomportsintheCorrTranMVEvaluationToolenvironment.Ifyouarenotsurewhatcomportyourmodemisusing,gotoyourcomputer’sdevicemanagerbyopeningthefollowingwindows:

• ‘Controlpanel’>‘System’>‘Hardware’>‘DeviceManager’

• Expandthe‘Ports(COM&LPT)’tofindoutwhichcomportisbeingusedbytheUSBmodem,asseeninFigure22.


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Figure 22. Device Manager Ports (COM & LPT)

NowthatyouknowtheappropriateComPortforyourHARTmodem:

• Select‘Communication’>‘ComPort’fromthetoolbarandselecttheComPortthathasbeenassignedtoyourHARTModem.

7.2.2 ConnectiontotheCorrTranAQUA• Select‘Communication’>‘Open”fromthetool.The‘Connect’buttonwillbecome

availableasseeninFigure23.

• Pressthe‘Connect’buttontoestablishcommunicationbetweentheCorrTranAQUAandCorrTranMVEvaluationTool.IfeverythinghasbeendoneproperlyallthefieldswillbepopulatedasseeninFigure24.

Figure 23. After Communication Opened


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Figure 24. After Successfully Connected

Atthetopofthescreenthefollowingreadonlyinformationisdisplayed:

• Devicerevision• DeviceID• Hardwarerevision• Softwarerevision

7.3 CorrTran MV Evaluation Tool capabilities Onceaconnectionhasbeenestablished,informationfromtheCorrTranAQUAtransmittercanbegathered.

7.3.1 ProcessdatatabsTheprocessdatatab,seeninFigures23and24,allowsyoutoviewthemostrecentoutputsfromtheCorrTranAQUA.

• Cycle:NumberofcorrosionmeasurementcyclescompletedonCorrTranAQUAtransmittersincethedevicewaslastreset.SeeSection7.3.4forinformationonresettingthenumberofcycles.

• Update–PressingthisbuttonpopulatesallcategoriesontheprocessdatatabwiththecurrentCorrTranAQUAoutputvalues.

• Cyclic–PressingthisbuttonenablestheCorrTranMVEvaluationTooltoupdatethevaluesontheprocessdatatabeverymeasurementcycle.Whenthisbuttonisengagedthetimeremaininginthecurrentcycleisdisplayedatthebottomofthescreen.

• LogOn/Off–WhencheckeditenablesthedataloggingcapabilitiesoftheCorrTranMVEvaluationTool.Youwillneedtoplaceacheckmarkbyeachdatapointyouwishtolog.Figure27providesdataloggingofeverypossibledatapointinacyclicalmanner.FormoreinformationontheloggingcapabilitiesoftheCorrTranMVEvaluationToolseesection7.3.4.


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Adatasetcanbemanuallyaddedtothelogfilebyclickingtheupdatebutton,orloggingcanbemadeautomaticforeverymeasurementcyclebyhavingcyclicselected.

• Gen.Corr.:Currentgeneralcorrosionreadinganditsmeasurementunits.

• Loc.Corr.:Currentlocalizedcorrosionreading.

• LC.Avg:Theaveragelocalizedcorrosionvalue.ThisvalueisaverageduntiltheCycles/AvgisresetortheCorrTranAQUAisresettofactorydefault.SeeSection7.3.4forinformationonCycles/Avgresetandresettingtofactorydefault.

• Sol.Cond.:CurrentsolutionconductancemeasureinSiemens(S)

• B-Value:CurrentmeasuredStern-Gearyvalue(Bharm)

• LpCurrent:Currentloopcurrent

Figure 25. Log On For All Data Points, Cyclic Mode

7.3.2 Onlineparameters:processvariablesThedeviceSettingtab,seeninFigure26,allowsyoutoconfigurethefollowingparameters:

• PVPreferences:AllowsyoutoconfigurethePrimaryVariable(PV)aseithergeneralorlocalizedcorrosion.

Note

IfgeneralcorrosionisselectedasthePrimaryVariablethenlocalizedcorrosionbecomesthesecondary.IflocalizedcorrosionisselectedasthePrimaryVariablethengeneralcorrosionbecomestheSecondaryVariable.TheTertiaryVariable(TV)isalwaysconductanceandcannotbechanged.

Note


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• PVUnits,LRV,URV:allowsyoutoconfigurethePVunitsandrange,whengeneralcorrosionisassignedasthePV.ThedefaultvaluesontheCorrTranAQUAareinunitsofmpywitharangeof0…40mpy.ThefullrangeofCorrTranAQUAis0…1000mpy(0…25mmpy).

Note

WhenlocalizedcorrosionisassignedasthePV,nounitsorrangeareselectablebecauselocalizedcorrosionisunitlessandisonascalefrom0to1,with0beingnolocalizedcorrosionand1beingveryhigh.)

• Alarm Mode:ControlsthesettingsforanalarmthatactivateswhenthePVcorrosionrategoesbeyondtheURV.ThedefaultisAuto,andtheoptionsareasfollows:

• Auto–Outputgoesto22.5mAandresetsautomatically

• Manual–Outputgoesto22.5mAandresetsmanually

• Off–Alarmisturnedoff

• B value:ReferstotheBvalueorStern-Gearyvoltage,whichisdefaultedto25.6mV.BUserisonlyrelevantinLPRonlymode.Thisvaluedoesnotnormallyneedtobechanged.

• A Elect Area:Allowsyoutochangetheelectrodearea,whichisrequiredforthecorrosioncalculation.Thesurfaceareaisdefaultedto4.75cm2forthefingertypeelectrodes.Flushmountelectrodesaredefaultedto0.316cm2.

• K Probe Const:referstotheKprobeconstant,orcorrosionconstantK.Thisvalueisdependentonthepipe’smetalpropertiesandisrequiredforthecalculationprocess.

Thedefaultis11597.63 mm * cm2

year * cm2

K= 3270.22 * (atomic mass of metal in grams)(# of electrons in the corrosion reaction) * (density in g/cm2)

SeeElectrodeMaterialGuideTableintheAppendixforfactorycalculatedKvaluesofcommonelectrodematerials.

• Measurement Mode:Certaincorrosionmeasurementscanbeturnedofftogiveafasterresponseifnotrequiredforthecalculation.Thetwovariablesthatcanbeswitchedoffaregeneralcorrosion(GC)andlocalizedcorrosion(LC).Conductanceisrequiredforbothcorrosiontypesandcannotbeturnedoff.Ifallthreeareused,thedefaultisGC+LC+Cond.Thethreepossibleconfigurationsandcycletimesare:

• GC+LC+Con–General,Localized,Conductivity:21min.cycle

• GC+Con–General,Conductivity:4min.cycle

• LC+Con–Localized,Conductivity:17min.cycle


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• Device Mode:ThisdeterminesthewaythegeneralcorrosioncalculationisperformedbytheCorrTranAQUA.

• Normal(HDA/LPR)–Aprocess-specificStern-Gearyvoltage(Bharm)iscalculatedwitheverymeasurementcyclethroughHDA.ThisvalueisthenimplementedintheLPRcorrosionratecalculation.Thisisthedefaultsettingandshouldbeleftintacttomaintainthebestaccuracy.

• LPRonly–AuserdefinedStern-Gearyvoltage(‘BUser’)isspecifiedandusedforallLPRcorrosionratecalculations.ThisishowCorrTranAQUAisconfigured.

• Device Settings Tab Buttons:ThesebuttonsarefoundatthebottomoftheDeviceStatusTabpage.

• ResetAlarm-ThisbuttonisusedtoresetthealarmwhenoperatingtheCorrTranAQUAinManualAlarmMode.

• ReadValues-PressingthisbuttonpopulatesallcategoriesonthedevicesettingstabwiththecurrentvaluesprogrammedontheCorrTranAQUAtransmitter.

• WriteValues-PressingthisbuttonprogramstheCorrTranAQUAtransmittertoallsettingscurrentlydisplayedontheDeviceSettingsTab.

Figure 26. Device Setting Tab


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7.3.3 DevicestatustabTheDeviceStatustab,seeninFigure27,allowsyoutoviewanysystemerrorsorfaultstheCorrTranAQUAmaybeexperiencing.Errorsorfaultsappearascheckmarksnexttotheirdescriptor.

Figure 27. Device Status Tab Device

ThecauseofeacherrororfaultisdescribedinSection12,Troubleshooting,Table2.

• DeviceSettingstabbuttons:ThesebuttonsarefoundatthebottomoftheDeviceStatustabpage

• Resetconfigchangedflag:Clearsachecknexttoconfigurationchanged

• UpdateStatus:Updatesthedevicestatustabwiththemostrecentsystemerrorsorfaults

7.3.4 ToolstabTheToolstab,seeninFigure28,allowsyoutologcorrosiondata,extractpreviouslycollectedcorrosiondata,andaccesstheresettingfeaturesofCorrTranAQUA.


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Figure 28. Tools Tab

• Data Logging:TheSelectFilebuttonallowsyoutosetthelocationforandthenameoftheLogFilewheredataisstoredwhentheLogfunctionisenabledontheProcessDatatab,seesection6.3.1.Dataissavedinoneoftwoways:

• Append–Dataisaddedtopreviouslyloggeddata• Overwrite–Datareplacespreviouslyloggeddata

• History File: TheSelectFilebuttonallowsyoutosetthelocationforandthenameoftheHistoryFilewheredataisstoredwhenGetHistorybuttonispressed.Dataisretrievedandsavedinoneoftwoways:

• Append–Dataisaddedtopreviouslyretrieveddata• Overwrite–Datareplacespreviouslyretrieveddata

• View Files: ClickingtheLogFilebuttonortheHistoryFilebuttonwillopentheirrespectivefiles.

• Initial Bavg-Value:ThedefaultsettingisActualAverageandresultsaretypicallybestifleftasis.

• Num of Cycles to read:TheCorrTranAQUAstoresdatafromitslast300cyclesinitsinternalmemory.BypressingtheGetHistorybuttontheCorrTranAQUAEvaluationToolextractsthedataforauserdefinednumberofcycles(1to300)andappendsoroverwritesittotheHistoryFile.

• Loop Current:WhenusingHARTcommunicationfordatacollection,the4-20mAsignalisnolongerimportant.Youcanchoosetosettheloopcurrenttoaconstantfixedvalue.IfyougetanerrorforElectrodeBalanceoutofRangeontheDeviceStatustab,settingtheloopcurrenttoahighmAfixedvalueshouldclearthis.Ifyouwanttheloopcurrenttochangebetween4-20mAastheprimaryvariablechangesselectActualPVValue(normal)whichisthedefaultsetting.

• Special Features:

• ResetCycles/Avg–Resetsthenumberofcyclesto0,clearstheinternalmemoryofitshistoricdata,andresetstheLC.Avg.calculation.

• ResetDevice–CyclespowertotheCorrTranAQUA.• FactoryDefault–HasthesamefunctionsoftheResetCycles/Avgbutton,and

resetsallsettingstothefactorydefault.


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8. TRANSFERING PROCESS DATA TO EXCELTheCorrTranMVEvaluationToolallowsyoutoviewCorrTranAQUAprocessdataintwoways.Youcanusetheloggingfunctiontosetuparunninglogfilethatwillrecordthecorrosionvaluesyouselect.Thesecondmethodinvolvesretrievingdatafromtheinternalmemory,whichstoresdatafromthelast300cyclescreatingahistoryfile.BoththeLogFileandHistoryFilearesavedas.txtdocuments.TotransferthisdataintoExcel,clickontheviewlogfileorhistoryfilebuttononthetoolstabandtheappropriate.txtfilewillopenasseeninFigure29(forthisexample,thelogfileisused).

Figure 29. CorrTran MV Log File

• Select‘Edit’>‘SelectAll’fromthetoolbartoselectallthedatainthelogfile.

• Select‘Edit’>‘Copy’fromthetoolbartocopyallthedatainthelogfile.

• OpenanewExcelworkbookandselectcellA1.

• Select‘Edit’>‘Paste’fromtheExceltoolbartotransferallthelogdatatoExcel.AtthispointthedataisallincolumnAasatextformatandwillappearasseeninFigure30.


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Figure 30. CorrTran MV Log File

• SelectallofcolumnAasseeninFigure30,Select‘Data’>‘TexttoColumns…’fromthetoolbarandthescreeninFigure31willappear.

Figure 31. Text to Columns

• SelectFixedwidthasseeninFigure31andthenpressFinish.ThetextdatahasnowbeentransposedtothepropercolumnswiththeproperheadingsasseeninFigure32.Adjustthecolumnsizestoaccommodatethedataasneeded.


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Figure 32. Properly Sorted Data

• Youcannowtrendandanalyzethelogdataasneeded.Figure33isanexampleofhowyoucanplotgeneralcorrosion,localizedcorrosion,andconductanceovertime.

Figure 33. Example Log Data Graph


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9. CHANGING CORRTRAN AQUA OPERATING MODE TO REDUCE THE EXCITATION FREQUENCY (Factory Default Setting for CorrTran AQUA)

ThefunctionalityhereisthatundercertainconditionstheCorrTrancanreadvaluesthatare,typically,muchhigherthanexpected.Thismaybeduetoahigh-capacitanceeffectontheelectrodescausedbyfilminginhibitors.

Toseeifthiseffectispresent,itisnecessarytoreducethesinewavefrequencyinordertoeliminatethecapacitanceeffect.OperatingtheunitinEnhancedMode1or2facilitatesthelowerfrequencysinewave.Iftheeffectisnotpresent,therewillbelittlechangebetweenstandardandenhancedmodes.Ifthereisabigreductioninthecorrosionrate,thenthecapacitanceeffectisrealandEnhancedMode1or2shouldbesetpermanentlyforthatapplication.DeterminingwhichEnhancedModetooperateinisdeterminedempirically.

Figure 34 is for the CorrTran EC. It is identical on the CorrTran MV or CorrTran AQUA. Note: CorrTran AQUA is shipped from the factory defaulted to this setting.

1. ConnecttheCorrTranEvaluationTool.EstablishCommunication.

2.OntheToolsTab,underLPR/HDAPerformanceselectEnhancedMode1.PresstheSetbuttontosendthesetuptotheunit.Ifthecorrosionratedoesnotchangeafter1-2hoursofoperation,thereisnocapacitanceeffect.ReturntheunittoStandardMode.

3. Ifthereisareductionincorrosionrate,tryEnhancedMode2.Ifareductionincorrosionrateisstillproduced,useEnhancedMode2otherwisereturnsettingtoEnhancedMode1.

Figure 34. Enhanced Mode

DisconnecttheEvaluationToolandreconnectyourDCA.Note:Theevaluationtimeforacompletecyclechangesfrom21minutesinStandardModetoapproximately37minuteswhenrunningEnhancedMode2.ItisbetweenthetwoforEnhancedMode1.ThisisthereasontobackdowntoEnhancedMode1ifEnhancedMode2doesnotproduceanadditionalreductionincorrosionrate.


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10. REPLACEMENT PARTS AND ACCESSORIES 10.1 CorrTran AQUA parts PleasesubmittheserialtagnumberonthenameplatewhenorderingreplacementpartsforCorrTranAQUA.

IfthepipeorvesselintowhichtheCorrTranAQUAistobeinsertedisunderpressureand/orcontainsanyhazardoussubstance,suchassteam,causticsolutions,acids,toxinsorothersubstancesspecifiedbyOSHAasphysicalorhealthhazards,thepipeorvesselmustfirstbedepressurizedandanyhazardoussubstancepurgedtherefrom,andappropriatelockout/tagoutproceduresobservedinaccordancewithSection1910.147oftheOSHARegulations,beforeCorrTranAQUAcanberemovedortheelectrodesreplaced.Failure to follow these procedures may result in serious injury or death.

10.1.1Transmitterreplacement

C M T A - A 4 I H 3 - - G P

CertificatesDisplay/No DisplayB No DisplayD LCD, Loop Powered Display

Remote Probe Cable3 12' Cable

Electrical OutputIH 4-20 mA, HART

HousingA1 ABS Housing, Nema 4x, Cable Gland EntryA4 ABS Housing, Nema 4x, V1 (M12) connector

Corrosion TypeA CorrTran AQUA, Multivariable

Warning


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C M P - - /

Insertion Length (fixed probes only)in inches, 5" … 28", in 0.2" increments

Electrode Material0A… see electrode material guide*only needs to be specified for flush mounted electrodes

Probe Length050* 5", 3/4" NPT080 8", 3/4" NPT110* 11", 3/4" NPT120 12", 3/4" NPT or Flange180 18", 3/4" NPT or Flange240 24", 1" NPT, 3/4" NPT, or Flange300 30", 1" NPT, 3/4" NPT, or Flange754* 127 mm, 3/4" NPT756 204 mm, 3/4" NPT280* 280 mm, 3/4" NPT305 305 mm, 3/4" NPT or Flange457 457 mm, 3/4" NPT or Flange610 610 mm, 1" NPT, 3/4" NPT, or Flange762 762 mm, 1" NPT, 3/4" NPT, or Flange*epoxy probe only

Probe MountingSee probe mounting guide

Measurement Unit, Probe MaterialCB inches, 1.4435, 316LCF inches, epoxy glassDB mm, 1.4435, 316LDF mm, epoxy glass

Process ConnectionN21 3/4" NPT, ANSI B 1.20.1, 1.4435/316LN2P 3/4" NPT, ANSI B 1.20.1, adj. thread, nylonN31 1" NPTN51 1-1/2" NPTXXX Special Version

10.1.2Probereplacement*ProbeMountingGuideandElectrodeMaterialGuidecanbefoundintheAppendix


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10.1.3Electrodereplacement–fingerelectrodes

Electrodesaresoldinapackof3.

10.2 Accessories

Forinstallationsrequiringmorethenonetransmitter,P+FoffersawidevarietyofHARTmultiplexersandterminationboardsforwiringtoaPLCorDCSsystem.Themultiplexersareavailablein16and32channeloptions.

• KFD2-HMM-16 16-channelMUXmaster• KFD0-HMS-16 16-channelslave

PleasecontactP+Fforterminationboardselection.

Additional Accessories

Note

Accessories

US-HI-321 HART modem, HART to USB interfaceFor direct connection to your PC

KFD2-HLC-Ex1.D HART Loop ConverterConverts HART signal to 3 separate 4 ... 20 mA outputs

KFD2-HLC-Ex1.D.2W HART Loop ConverterConverts HART signal to 3 separate 4 ... 20 mA outputs

KFD2-HLC-Ex1.D.4S HART Loop ConverterConverts HART signal to 3 separate 4 ... 20 mA outputs


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11. SYSTEM SPECSApplicationTheCorrTranAQUAperformscontinuous(electro-chemical)corrosionmeasurementofliquidsandgasses.Probesareavailableinseveraldifferentmaterialsandprocessconnections:

• Epoxyglassprobe:3/4”NPTadjustablenylonfitting

• Adjustableprobe:3/4”NPTfitting,availablein316LSS

• Fixedprobe:3/4”NPTfittingandflangesstartingat1”ANSIB16.5150lbs,availablein316LSS

FunctionandSystemDesignMeasuringPrinciple:TheCorrTranAQUAutilizesstate-of-the-artalgorithmsanddataanalysistechniquestoaccuratelymeasuregeneralcorrosionrateandpitting.ToimprovetheperformanceoftheindustryacceptedLinearPolarizationResistance(LPR)techniquetheHarmonicDistortionAnalysis(HDA)isusedtocalculateandupdateaprocessspecificStern-Gearyvariable(Bharm)everymeasurementcycle.Tofurtherenhancetheperformance,anapplication-specificStern-Gearyvariable(B-value)iscalculatedandupdatedeverymeasuringcycle.ThereisnoneedtomanuallyupdatetheB-valuebecauseofprocesschanges.Duringthemeasurementcycle,CorrTranAQUAalsoperformsanautomatedElectrochemicalNoise(ECN)measurementwhichprovidesalocalizedcorrosion(pitting)measurement.Atthecompletionofeachmeasurementcycle,therespectivecorrosionrateandpittingvalueintheformofa4-20mA/HARTsignalisproducedandmadeavailabletoplantpersonnel.

EquipmentArchitectureSeeSection4.3WiringwithHART.


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Technical dataInput

MeasuredVariable •Generalcorrosion:Electro-chemicalcorrosionthatproceedsmoreorlessuniformlyoverthesurfaceofthematerialexposedtothecorrosiveenvironment.

•Localizedcorrosion(pitting):Electro-chemicalcorrosionthatoccursatdiscretesitesonthematerialexposedtothecorrosiveenvironment.

•Conductance:Thereciprocalofthesolutionresistance.Itisameasureofhoweasilyelectricityflowsalongacertainpaththroughanelectricalelement.

MeasuringRange •Generalcorrosion:0...1000mpy(0...25mmpy),0...40mpy(0...1mmpy)defaultvalue

•Localizedcorrosion(pitting):Unitlessnumberfrom0...1,with0beingnolocalizedcorrosionand1beingveryhigh.

•Conductance:Notadjustable.MeasuredinSiemens.

Output

OutputSignal 4-20mAwithHARTprotocol,2-wire

SignalonAlarm Errorinformationcanbeaccessedviathefollowinginterfaces:•Currentoutput,22.5mA•Digitalinterface

Auxiliary Energy

LoadHART MinimumloadforHARTcommunication:250Ω

CableEntry IndustrystandardV1(M12connector)

SupplyVoltage 11-30VDCwitoutdisplay15-30VDCwithoptionaldisplay

RatedOperatingVoltage 11VDCminatmaxloopcurrent

ConnectableLoad Max.loadat24VDC:575Ωwithalarm/650Ωwithoutalarm

B-Value(Start-up) 25.6mV

Performance Characteristics

ReferenceOperatingConditions

•Temperature:-40°Cto+70°C(-40°Fto+158°F)

•Pressure:6.8bar(100psi)

•Solutionconductance:Min4μS

•Generalcorrosionrate:0...1000mpy(0...25mmpy)

Accuracy •Voltagemeasurementandelectrodeexcitation:<0.02%

•Currentmeasurement:<0.1%


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Technical data (continued)Operating Conditions

OperatingConditions

InstallationInstructions SeeSection3.4InstallationInstructions

Environment

AmbientTemperatureRange

Ambienttemperatureforthetransmitter:

•Withdisplay:-10°Cto+50°C(-14°Fto+58°F)

•Withoutdisplay:-40°Cto+70°C(-40°Fto+158°F)

StorageTemperature -40°Cto+70°C(-40°Fto+158°F)

DegreeofProtection Housing:IP66,NEMA4X

CleaningoftheProbeandElectrodes

SeeSection3.4.2ElectrodeInstallation

Process Conditions

ProcessTemperatureLimits

Seetechnicalspecificationsforyourprobe,Section3.3ProbeSpecifications

ProcessPressureLimits Seetechnicalspecificationsforyourprobe,Section3.3ProbeSpecifications

ProcessFlowRateLimits •Fingerelectrodes:Max6.1mps(20fps)

•Flushelectrodes:None.

Mechanical Construction

Design,Dimensions SeeSection3.1Dimensions

Weight Approx.500g(16.1oz),transmitterhousing

Material •Housing:ABS

•ProcessConnections:1.4401/316LSSorNylon

•Probe:1.4401/316LSSorepoxyglass;fillmaterial:epoxy

•Endcapseal:Glass(standard)orepoxy(onrequest)

•Electrode:SeeElectrodeMaterialGuide

•O-ring:Viton(standard)orKalrez(onrequest)

ProcessConnection SeeSection2.1.2KeytoModelNumber

Human Interface

OperationConcept SeeSection4.3WiringwithHART.SeeSection5ConfigurationandCommissioning

Certificates and Approvals

Patents U.S.patents:7,239,156;7,245,132;7,265,559;7,282,928


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12. TROUBLESHOOTING IfyouencounterproblemsconfiguringorusingyourCorrTranAQUA,consultthefollowingtroubleshootingtable.Ifyoucontinuetohaveproblems,pleasecontactyourP+Frepresentativeforfurtherassistance.

Symptom Cause/Procedures Solution

No4-20mAoutput Checkvoltageandcompareitwiththespecificationsonthenameplate. Connectthecorrectvoltage

Measuringcorrectvoltagebutunitdoesnotrespond

Checkpolarityontheterminals. Seesection4.1:QuickWiringGuide

HARTcommunicationdoesnotfunction

Thecommunicationresistorisnotinstalledproperly. Seechapter4.3:WiringwithHART

Table 1. CorrTran AQUA Basic Troubleshooting Guide

Device Status Codes

Description Troubleshooting

PVoutoflimits TheprimaryvariablehasexceededeithertheLRVorURV.

ThiscanonlyhappenifGeneralCorrosionisassignedtothePVandtherangesarenotsetproperly.Extendtherangevaluestoincludecurrentdatapoint.Seesection6.3formoreinformation.

SVorTVoutoflimits

ThesecondaryortertiaryvariablehasexceededeithertheLRVorURV

ThiscanonlyhappenifGeneralCorrosionisassignedtotheSVandtherangesarenotsetproperly.Extendtherangevaluestoincludecurrentdatapoint.Seesection6.3formoreinformation.TheTVcannotbeoutoflimitsbecauseithasnolimits.

Analogoutputsaturated

Theanalogoutputhasreachedeitheritsminimumormaximum

ThiscanonlyhappenifthealarmmodeisoffandthePVexceedsitsLRVorURV.

Analogoutputfixed

TheanalogoutputsignalhasbeensettoafixedmAvalue.

ThisisaresultofsettingtheLoopCurrenttoafixedvalueonthetoolstab.Seesection6.3formoreinformation.

Morestatusavailable

ThisflagindicatesthatoneormoreoftheflagsintheMoreFieldDeviceStatussectionareset

Informationonly.

Coldstart Thisflagissetafterpowerhasbeenrecycledforonecommunicationtransaction.

Informationonly.

Configurationchanged

AchangehasbeenmadetotheCorrTranAQUAconfiguration.

ThiscanberesetbypressingtheResetConfigChangedFlagonthedevicestatustab.Seesection6.3formoreinformation.

Devicemalfunction

ThisflagindicatesthatoneormoreoftheflagsintheDeviceMalfunctionsectionareset.

Informationonly.

Table 2. Device Status Codes Troubleshooting Guide (continued on next page)


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Device Status Codes

Description Troubleshooting

Highlocalizedcorrosiondetected

Thelocalizedcorrosionrateisabove0.3.

Informationonly.

Conductanceoutofrange

Themeasuredsolutionconductanceislowerthan4μS.Thisequalsaconductivityofapproximately1μS/cmforfingerelectrodes.

TheCorrTranAQUAneedsatleast4μSofsolutionconductanceorsolutionconductivityof1μS/cmforfullaccuracy.Thiscanalsobeanindicationthatthereistoomuchbuilduponthesurfaceoftheelectrodesandtheymayneedtobecleanedortheymaynotbefullyimmersedintheprocessfluid.

Celloffsetvoltageoverflow

TheCorrTranAQUAhasdetectedavoltagedifferencebetweenthethreeelectrodeswhichistoohightocompensate.

Typicallythisisanindicationthatthereistoomuchbuilduponthesurfaceoftheelectrodesandtheyneedtobecleanedorthattheyhaveexceededtheirusefullifeandshouldbereplaced.

Corrosionratecalculationnotpossible

TheCorrTranAQUAwasnotabletogetanyusefuldata.

Checktheelectrodesfordebris,checkforotherflags,andmakesurethattheelectrodesarefullyimmersed.

Electrodebalanceoutofrange

Duetoanextremelyhighunbalancedpotential(voltagedifference)oftheelectrodes,theCorrTranAQUAisdrawingmorepowerfromtheloopthanavailable.

Onewaytodealwiththisproblemistosettheloopcurrenttoafixedvalue(maxis20mA).Thisshouldonlyoccurunderveryrarecircumstances,wherethecorrosionrateisverysmall(loopcurrentisapprox.4mA)butatthesametimethereisahugepotentialdifferencebetweentheelectrodes.Thiscanindicatecontaminationofoneormoreelectrodes,corrosionmaskingeffectsofbuildup,orthatoneelectrodeisbentormissingfromtheprobe.

Internalfailure Hardwarefailuredetected Replacetransmitter

ADCfailure ADCfailuredetected Replacetransmitter

Memoryfailure Memoryfailuredetected Replacetransmitter

Table 3. Device Status Codes Troubleshooting Guide (continued from previous page)


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13. MEASURING PRINCIPLE

Figure 35. CorrTran AQUA Corrosion Cell

GeneralcorrosionLinearPolarizationResistance(LPR)isbasedonthefactthatinacorrodingelectrodetherelationshipbetweenicorrandthepolarizationresistanceisgivebythefollowingequation:

icorr = BRp

,where Rp = ∆E∆I

with∆Ebeingtheappliedvoltageand∆Itheresultingcurrent.

HarmonicDistortionAnalysis(HDA)allowsCorrTranAQUAtodetermineicorrwithoutusingtheTafelslopes(ba,bc).Thisistypicallydonebyapplyingalowfrequencysinusoidalvoltageanddeterminingthedistanceoftheresultingcurrent.

CorrTranAQUAaccuratelymeasuresthegeneralcorrosionratebyimplementingHarmonicDistortionAnalysis(HDA)toimprovetheperformanceofLinearPolarizationResistance(LPR).Aprocess-specificStern-Gearyvoltage(Bharm)iscalculatedwitheverymeasurementcyclethroughHDA.ThisvalueisthenimplementedintheLPRcorrosionratecalculationresultinginahighlyaccurateselfadjusting,processspecificcorrosionratecalculation.CorrTranAQUAcanmeasurethegeneralcorrosionratefrom0…1000mpy(0…25mmpy).

LocalizedCorrosion(Pitting)ElectrochemicalNoise(ECN)isthemethodofmonitoringspontaneousfluctuationsgeneratedattheinterfaceofthecorrodingmetalandprocesssolution.Aslocalizedcorrosionoccurs,thesefluctuationsincrease.

TheCorrTranAQUAmonitorsforthesefluctuationsontheelectrodesurfacesfor17minutes.Itthenperformsastatisticalanalysisresultinginaunitlesspittingfactorvaluebetween0and1.Apittingfactorofnearly0representsnolocalizedcorrosionactivityandapittingfactorof1representshighlocalizedcorrosionactivity.Independentstudieshaverevealedthatasustainedpittingfactorofgreaterthan0.3iscauseforconcernandyoushouldinvestigatethesourceoftheelevatedLocalizedCorrosionrate.Formoreinformationontheinterpretationoflocalizedcorrosionpleasereviewourwhitepaper:“DetectingandInterpretingLocalizedCorrosionUsingCorrTranAQUA.”

Fe

Anodicsite

Cathodicsite

Fe2+

2H+

H2

Icorr 2e-

4 - 20 mA PROBE


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ConductanceSolutionresistanceisameasureofhoweasilyelectricityflowsalongacertainpaththroughanelectricalelement.Thereciprocalofthesolutionresistanceissolutionconductance.

TheCorrTranAQUAmeasuressolutionresistanceinordertomoreaccuratelycalculatethegeneralcorrosionrates.AsanaddedfeatureCorrTranAQUAprovidesyouwiththesolutionconductanceinunitsofSiemensasthetertiaryvariablethatisnotscalable.CorrTranAQUArequiresaminimumsolutionconductanceof4μSinordertoprovidereliablecorrosiondata.

ThesolutionconductancevaluethatCorrTranAQUAprovidescanbeusedtoapproximatesolutionconductivitybythisrelationship:

Conductivity ( Scm ) ≈ Conductance (S)

19

Solutionconductivityisafunctionofdistance.Astheelectrodescorrode,theirsizesandgeometrychangecausingthiscorrelationtodeteriorate.TheCorrTranAQUAshouldnotbeconsideredasareplacementforstandardconductivitymeters.

Note


USA: +1 330 486 0002 Singapore: +65 6779 9091


Germany: +49 621 776 2222


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14. APPENDIX

Electrode material guide

Other materials are available on request.

Electrode material Key number K value UNS numberAluminum1100 0N 10940.96 A91100 2024 0O 11400.51 A920246061 0T — A960617075 1O — A97075Carbon & steel alloys1010 0S — G101001018 0A 11597.63 G101801020 1T 11401.49 G10200C4130 1R 11283.76 G41300Stainless steel1.4301 / 304 0C 11334.57 S304001.4307 / 304L 0D 11342.80 S30403 1.4401 / 316 0E 11513.39 S316001.4404 / 316L 0F 11519.53 S31603 1.4571 / 316Ti 1M 11382.15 S316351.4438 / 317L 1G 11400.62 S317031.4939 / 904L 1K 11287.19 N08904Copper alloysCDA110ETP (99.9 Cu) 0J 11686.71 C11000CDA220 (bronze) 0P 8644.02 R50400CDA443 (ARS AD. brass) 0M 12324.74 C44300CDA687 (Aluminium brass) 0L 12411.53 C68700CDA706 (Cu/Ni 90/10 0K 11513.44 C70610CDA715 (Cu/Ni 70/30) 0I 11337.86 C71500

Probe mounting guide

* Please consult Pepperl+Fuchs.

Key number Probe type Mounting Process connectionB Standard Remote mount fixedD Standard Remote mount adjustableE retractable* Remote mount adjustable* retrievable* Remote mount fixed


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Germany: +49 621 776 2222


44

Model Number Description

CorrTranAQUA-912927 Kit,baseunitwithoutlocaldisplay,1018CSelectrodes,11”probe

CorrTranAQUAwithdisplay-912929 Kit,baseunitwithlocaldisplay,1018CSelectrodes,11”probe

Electrodes Electrodesotherthancarbonsteelmustbeorderedseparately

CorrTran AQUA Model Numbers


USA: +1 330 486 0002 Singapore: +65 6779 9091


Germany: +49 621 776 2222


45

NOTES


USA: +1 330 486 0002 Singapore: +65 6779 9091


Germany: +49 621 776 2222


46

NOTES


USA: +1 330 486 0002 Singapore: +65 6779 9091


Germany: +49 621 776 2222


47

NOTES

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Subject to modifications • © 2010 PEPPERL+FUCHS, INC. • Printed in USA • Part No. 913039 • Drawing No. TDOCT-B069_USA 5/10

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corrtran-aqua; corrosion monitoring transmitter...

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