MS1500E

Data Logger
(Version 1)

Metal Samples
A Division of Alabama Specialty Products, Inc.
152 Metal Samples Rd., Munford, AL 36268
Phone: (256) 358-4202 Fax: (256) 358-4515
E-mail: [email protected] Internet: www.metalsamples.com
Table of Contents
I. Introduction ..................................................................... 1
A. General Description ..................................................... 1
B. Ports and battery replacement ...................................... 3
C. Specifications ............................................................... 5

II. Operation .......................................................................... 7

A. Select probe ID ............................................................. 9
B. Make measurement ..................................................... 12
C. Compute MIL/MPY .................................................... 14
D. Recall readings ............................................................ 15
E. Delete readings ............................................................ 15
F. Communications .......................................................... 16
G. Set time and date ......................................................... 26
H. Test mode ................................................................... 26

III. Theory of Operation ....................................................... 27

A. Measurement theory .................................................... 27
B. ER sensing elements ..................................................... 28
C. ER element performance .............................................. 31
D. ER probe body design ................................................. 35
1. Fixed length ER probe ............................................ 36
2. Retractable ER probe ............................................. 37
3. High pressure retrievable ER probe ......................... 38

IV. Testing the MS1500E with the ER Meter Prover ........ 39

V. Returning an Instrument for Repair .............................. 41

VI. Warranty ......................................................................... 43

I. Introduction
A. General Description

The MS1500E is an intrinsically-safe, battery-powered, hand-held

corrosion meter that enables you to directly take measurements from an
electrical resistance probe, store the data, and upload directly to a
computer. The unit features an easy-to-use Main Menu that will permit
even an operator who is unfamiliar with the unit to take readings with
ease.

Corrosion rate measurements are made using the electrical resis-

tance method. The electrical resistance method has a wide range
of applications since it can be used in conductive or nonconductive
environments including oil and gas. The unit measures the change
in resistance of the probe element as metal loss occurs. The rate of
change is directly proportional to the corrosion rate.

After taking and storing a reading, the operator can display the
metal loss in mils and the corrosion rate in mils per year (mpy). All
measurements made with the unit are automatically time and date
stamped with the MS1500E internal real time clock. If the
MS1500E detects a probe with an internal leak or damaged ele-
ment, a CHECK FAILED message occurs. The unit can take up to
3,100 readings and can be used with up to 150 probes. All stored
readings are protected by a lithium back-up battery to prevent loss.

Data may be selectively deleted from memory to accommodate

additional information once the 3,100 reading capacity is reached.
Alternatively, information may be downloaded to a PC as a comma
delimited ASCII file for import into any of the standard data handling
and analysis programs (e.g., EXCEL).

1
The MS1500E may also be used as a data collection and transfer
terminal for the MS3500E remote data logger. Accumulated data
from several MS3500E field-based units may be locally down-
loaded to the MS1500E hand-held terminal, and then transferred to
a PC for further analysis.

The MS1500E offers seven operating modes:

Select Probe ID
Make Measurements
Compute
Recall
Delete Readings
Communicate
Set Time and Date

All electrical resistance probe types can be used with this unit, including
wire loop, tube loop, cylindrical element, surface strip, and flush mount
probes.

2
B. Ports and Battery Replacement

Use this cable to connect the MS1500E to a computer via serial port or
USB port.

COILED DATA CABLE

MS1500 SERIAL
PORT ADAPTER

TO
COMPUTER
SERIAL
PORT

SERIAL TO USB
ADAPTER (OPTIONAL)

TO
COMPUTER
USB
PORT

3
Use the port on top of the Top view of MS1500E
MS1500E for connecting to a
computer (with the cable
provided) or to the MS3500E
(with the Opti-link cable.)
See Communications (p. 16) for more information.

The battery compartment is accessed by removing the slip-fit cover

on the rear of the instrument. Three 1.5VDC, AA size, dry cell batter-
ies are placed in the spring loaded holders, following the plus/minus
orientation indicated on the battery holder as illustrated below.

FRONT BACK

"SLIP-FIT" BATTERY COVER

POWER SWITCH 3 X 'AA' ALKALINE BATTERIES

(DURACEL MN1500 OR PC1500
REQUIRED FOR INTRINSIC SAFETY.)

PROBE CONNECTOR

4
C. Specifications
ER Probe Configurations
Wire Loop
Tube Loop
Cylindrical Loop
Flush Mount
Surface Strip

Battery: Three 1.5 Volt AA alkaline batteries

Battery Life: 8 hours of continuous use

Temperature Range: 32 to 120F (0 to 49C)

Operational
Humidity Range: 30% - 90%

Storage
Humidity Range: 5% - 95%

Memory Protection: 10-year battery, back-up life

Measurement/
Computations: Probe Life (0 - 100%)
Metal Loss (Mils)
Corrosion Rate (Mils/Year)

Display: 4 lines x 20 characters LCD panel

Maximum # of
probe storage files: 150

Maximum # of
stored readings: 3,100

5
Operating modes:
Select probe ID (select/enter/delete probe ID)
Make measurement
Compute (metal loss and corrosion rate)
Recall readings
Delete readings
Communicate (upload/download)
Set time and date

Communication port: RS-232 serial port

Dimensions: 7.5" length x 4.0" width x 2.0" depth

Weight: 1.5 lbs (5.2 lbs. with hardshell case)

Intrinsic Safety: Class I, Division 1

Groups A, B, C, and D
Temperature Code T3C
Class I, Zone 0
Group IIC, T3C
Conforms to ANSI/UL Std. 913

6
 II. Operation
The MS1500E allows you to mea-
sure metal loss and corrosion rate.
Review this section which describes
the functions that display on the
Storage capacity Main Menu:
The MS1500E allows a
maximum of 3,100 readings Select probe ID
with up to 150 probes. Make measurement
Compute MIL/MPY
To increase your free
storage, which displays in the Recall readings
start-up screen, select from Delete readings
the Main Menu: Communications
DELETE READINGS Set time & date
Test mode
or

SELECT PROBE ID
When you power up the MS1500E,
and then the start-up screen confirms these
DELETE PROBE checks:
or
ENTER NEW PROBE
the software version
currently running
free storage available (see
Storage capacity in
margin)
system test pass

The last display of the start-up

screen looks like this:

METAL SAMPLES
MS1500E VX.X
SYSTEM TEST : PASS

7
If you want to know how much
storage is currently available, care-
fully watch the start-up screen which
displays this information quickly
before SYSTEM TEST PASS; then
the Main Menu displays.

Screen 1 of the Main Menu looks

like this:

SELECT PROBE ID
MAKE MEASUREMENT
COMPUTE MIL/MPY
RECALL READINGS

Screen 2 of the Main Menu looks

like this:

DELETE READINGS
COMMUNICATIONS
SET TIME & DATE
TEST MODES

To run a function, select it by using

the up or down arrow and pressing
ENTER. While in the Main Menu,
pressing EXIT will return the selec-
tor icon to the first item of the Main
Menu.

8
 A. Select Probe ID

The SELECT PROBE ID function

allows you three options:

select a probe already in

memory for which you wish to
run any other feature of the
Select a probe before you MS1500E (Make Measure
run a function ment, Compute mil/mpy,
In order for you to make Recall Readings, or Delete
measurements, compute Readings);
mil/mpy or recall or delete enter into memory the identifi
readings, you must select cation of a new probe
a probe that is currently in delete from memory the
memory.
identification of a probe
The MS1500E provides
you with a list of probes in To run any of these three options,
memory; use the arrow choose SELECT PROBE ID from
key to select one and press the Main Menu.
enter. Now youre ready
to run any other function.
SELECT PROBE ID
MAKE MEASUREMENT
COMPUTE MIL/MPY
RECALL READINGS

The next screen allows you to choose

the functions to ENTER or DELETE
a probe ID or to select a probe ID
from those already in memory for
which you wish to make measure-
ments.

9
 To assist you with selecting a probe
ID, the screen displays a list of all
probe IDs currently in memory.

Select from the list of probes in

memory the probe for which you
wish to run a function (Make Mea-
Entering information
To enter a number, type it surement, Compute mil/mpy, Recall
using the keypad numbers. Readings, Delete Readings).

If you make an error,

press the down arrow - ENTER NEW PROBE
this allows you to type the DELETE PROBE
number again. 1234 WIRE 40
4567 FLUSH 20
Pressing the up arrow
retains the ID number you
typed in. 1. Press the arrow key to select a
probe ID.
Entering probe type 2. Press ENTER.
The MS1500E has a list of
probe types in memory.
Select one by pressing the To enter the ID of a new probe,
arrow keys. (See Appen- select ENTER NEW PROBE; the
dix B for a list of probe next screen allows you to enter the
types supported by the ID number and the type.
MS1500E.)

1. Enter the probe ID - use the

number keys (press the DOWN
arrow if you make an error).
2. Press the UP arrow when youve
entered the correct ID number.
3. Enter probe TYPE (see margin).
4. Press ENTER.

10
 PROBE ID: 5385
PROBE TYPE: WIRE 40

USE ARROW KEYS

It is occasionally necessary to re-

Deleting probes
move the ID of a probe from
Its necessary to delete a memory, for example:
probe when you replace
one. Note that when you when the memory bank is full
delete a probe, you also when a probe is no longer used
delete all the readings for
that probe.
To delete the ID of a probe in
You might want to transfer memory, select DELETE PROBE.
the readings to a com-
puter before deleting them DELETE PROBE
by using the PROBE ID:
COMMUNICATIONS
option in the Main Menu. UP ARROW WHEN DONE
(See Communications, p.
16.)

1. Enter the probe ID - use the

number keys (press the DOWN
arrow if you make an error).
2. Press the UP arrow when youve
entered the correct ID number.

The instrument will confirm your

choice of probe ID before deleting it
from memory.

11
 B. Make Measurement

To take measurements from probes

in memory, select MAKE MEA-
SUREMENT from the Main Menu:
Select a probe before you
run the function
SELECT PROBE ID
In order for you to run
MAKE MEASUREMENT
MAKE MEASUREMENT,
COMPUTE MIL/MPY
you must have already
RECALL READINGS
selected a probe from
memory.

See Select Probe ID from The next screen displays the Probe
the Main Menu (see page ID that you selected earlier from the
9).
Main Menu item
SELECT PROBE ID.

Set time and date

To ensure readings you PROBE ID: 1234
make are accurate, be sure
the time and date settings in
the MS1500E are correct PRESS ENTER TO START
(see page 26).

When you press ENTER, the

MS1500E checks the probe for
correct operation. The next screen
then displays the results of that check
as PASSED or FAILED.

12
 If the probe failed the test, this
screen displays:

PROBE ID: 1234

PROBE CHECK FAILED

PRESS EXIT
Check failed = bad probe
When a probe fails this
test and the screen Press EXIT to return to the Main
displays CHECK Menu.
FAILED, it means the
probe may have either a
damaged element or an If the probe passed, this screen
internal leak. displays:

Replace a probe that PROBE ID: 1234

results in a CHECK PROBE CHECK PASSED
FAILED.
PRESS ENTER TO READ

Press ENTER to view the reading:

PROBE ID: 1234

READING: 124

PRESS ENTER TO SAVE

Press ENTER to save the reading in

memory. Saved readings also
include the date.

Press EXIT to return to the Main

Menu.

13
 C. Compute MIL/MPY

Select COMPUTE MIL/MPY to

review data from the last reading on
Select a probe before you a probe. The MS1500E calculates
run a function
these data from a comparison be-
In order for you to run
COMPUTE MIL/MPY, tween the last reading and the first
RECALL READINGS or reading on the probe:
DELETE READINGS,
you must have already
selected a probe from 20/01/98 TO 20/02/98
memory. MET LOSS: 0.05 MIL
COR RATE: 0.59 MPY
See Select Probe ID from PRESS EXIT
the Main Menu (see page
9).
Press EXIT to return to the Main
Menu.

14
D. Recall Readings

Select RECALL READINGS to look

at data from different dates. Use the
arrow keys to choose the reading
number. Or press ENTER to type in
the number on the keypad.

READING #: 2
DATE: 20/02/98
READING: 124
DOWN/UP/EXIT/ENTER

Press EXIT to return to the Main

Menu.

E. Delete Readings

Select DELETE READINGS to

erase a reading from memory. Peri-
odically delete readings to create
more free storage area in memory.

DELETE READINGS
#1 20/01/98 125
#2 20/02/98 125
ENTER TO DELETE

Press EXIT to return to the Main

Menu.

15
F. Communications

The MS1500E Data Logger has the ability to store readings as they are
taken. These readings can later be transferred to your PC via serial
port or USB port. To transfer data to a PC it is necessary to install the
Corrosion Data Management Software.

Installing the Software

To run the Corrosion Data Management Software, you need a PC that
meets the following requirements:

Pentium class processor

Windows 95 or higher operating system
16 MB of RAM
10 MB of available hard-disk space
VGA monitor with 800 600 or greater resolution
Mouse or pointing device recommended
Available 9-pin serial port or USB port
CD-ROM drive for software installation

To install the Corrosion Data Management Software:

1. Insert the setup disk provided in your accessory kit.

2. You will be prompted to close any open programs. After you

have done so, click OK to continue.

16
3. Click the install button to begin installation. Note, it is recommended
that you install the software in the default directory.

4. After clicking the install button, the software will be installed on your
PC.

5. When the software installation is complete you should remove the

setup disk, then reboot your computer.

17
Instrument Download Center

The Instrument Download Center is a simple tool for retrieving data

from Metal Samples ER and LPR data logger instruments.

To download data from an instrument:

Connect the instrument to an available PC serial port or USB

port (see page 3.)
Turn the MS1500E on.
Run the Corrosion Data Management Software
Open the Instrument Download Center
Select the serial port and instrument
Click the Download button (ensure that Part Status toggles to
On).
From the main menu of the instrument, go to the Select Probe
I.D. menu and select the probe data you wish to download.
From the main menu of the instrument, go to the Communica-
tions menu and select Computer Upload.

Data will begin to transfer from the instrument to the PC, and will
appear in the data window of the Instrument Download Center as
shown above. If the data appears garbled, the wrong instrument type
has been selected. Select another instrument type and try again. If data
does not appear in the data window at all, verify that:

18
 The instrument is connected to a valid serial or USB port
All cables are securely connected
The message Port Status: On appears in the status bar
There are no errors on the instrument
If using a USB adapter, ensure that the device drivers have
been installed.

Selecting a Serial Port

Use the Serial Port selection box to select the port to which the
instrument is connected. If the COM port number is unknown, it can
be found in Windows Device Manager under Ports (COM & LPT).

Selecting an Instrument
Use the Instrument option box to select the model of Metal Samples
instrument being downloaded. This sets the appropriate communication
parameters, which will be displayed in the status bar at the bottom of
the window (9600,N,8,1 for an MS1500, 2400,N,8,1 for an
MS3500).

Downloading Data
To toggle the selected port on and off, click the Download button.
Toggling the port on and off will also clear the data window.

Once a valid serial port and instrument have been selected, click the
Download button to turn the port on and enable the computer to
receive data. If a valid serial port has been selected, the status bar at
the bottom of the window will display the message Port Status: On.
If an invalid serial port has been selected, an error message will appear,
and the status bar will display the message Port Status: Off. If this
happens, another serial port should be selected.

19
Saving Data
To save the data in the data window, click the Save button. The data is
comma-delimited ASCII text. It can be saved to a standard text (.txt)
file, or it can be saved to a comma-separated values (.csv) file, which
greatly simplifies the process of importing the data into some spread-
sheet programs such as Excel or Quattro Pro.

Printing Data
To print the contents of the data window, click the Print button. A print
dialog box will be displayed to allow printer selection and setup.

Charting Data
To chart the contents of the data window, click the Chart Data button.
If the data has not yet been saved, the user will be prompted to do so
before the charting process begins. For more information on charting
data, see the Data Analysis section.

Data Analysis

The Data Analysis utility is a convenient tool for charting data from
Metal Samples ER and LPR data logger instruments. The Data Analy-
sis utility can be opened from the Main Menu, or it can be opened
directly from the Instrument Download Center.

If the Data Analysis utility is opened from the Instrument Download

Center, the contents of the data window will be loaded into the chart.
However, if the Data Analysis utility is opened directly from the Main
Menu, a valid data file must be loaded. The Select File box will open
to allow selection of a data file.

20
Loading a Data File
After selecting a data file (or clicking the Chart Data button from the
Instrument Download Center) a status window will display the progress
of the file being opened, along with the Instrument Type, Probe Type,
and Probe ID for the data file.

Data Table
After a file has been successfully loaded, the data will be displayed in
the Data Table for review. By default, all data points will be included in
the chart. However, data points can be turned off, or excluded, from
the chart. If the Excluded flag appears in the status column for a data
point, that data point will not appear in the chart. To toggle the exclude/
include status of a data point, double-click the data point, or select the
data point and click Exclude/Include in the Options menu.

Printing Data
The data table can be printed by clicking Print in the Options menu. A
print dialog box will be displayed to allow printer selection and setup.

21
Creating A Chart
To chart the selected data, click the Chart Data button, or select
Chart Data from the Options menu. The chart will be displayed in a
new window.

Printing a Chart
A chart can be printed using the Print Chart option in the File menu.
A print dialog box will be displayed to allow printer selection and setup.

Exporting a Chart
A chart can be exported to other applications using the Copy Chart
option in the File menu. This will copy both the chart and the raw data
to the Windows Clipboard. The chart can then be inserted into other
applications using the Paste function. Note: In some applications,
using the Paste function will insert the raw data instead of the chart. In
this case, use the Paste Special function, then select Picture to insert
the chart.

Chart Tools
Statistical Data
The Statistical Data tab at the bottom of the Data Chart window
will display a page with statistical information about the chart data.
If the Statistical Data page is visible, this information can be printed
by clicking Print Statistical Data in the File menu.

22
 Finding A Data Points Value
While viewing the chart, the value of any data point can be
determined by simply clicking it. The value will be displayed in the
charts tool-tip box (a small text box that is displayed near the
mouse pointer). If the tool-tip box does not appear immediately
after clicking the data point, hold the mouse pointer stationary over
the chart background for a moment.

The Tools Menu

The Tools menu contains a collection of utilities for viewing and
manipulating the chart. The Tools menu can be accessed by
clicking Tools on the menu bar, or by right-clicking anywhere on the
chart.

o Data Markers
Show Data Markers toggles the data markers on and off.

o Mean Value
Show Mean Value toggles the mean value line on and off.

o Trend Line
Show Trend Line toggles the trend line on and off.
23
o Title/Footnote Setup
Title/Footnote Setup displays a window that allows the
chart title and footnotes to be toggled on and off, and to be
modified.

o Plot Setup
Plot Setup displays a window that allows configuration of
Y-axis scaling, and of the chart type.

The Y-axis can be scaled to default values by checking the

Auto Scaling option box. The Y-axis can be scaled to
manual values by un-checking the Auto Scaling box, then
entering the desired values in the Minimum and Maximum
fields.

The chart type can be set to Line Chart, Bar Chart, or

Area Chart by selecting the appropriate button in the
Chart Type box. The default chart type is Line Chart.

o Data Series Color

Data Series Color displays a color selection box, which
allows the user to select the brush color for the plot line.
The default color for the plot line is Blue.

o Zoom In
Zoom In allows a region of the chart to be enlarged so that
it may be viewed in greater detail. To enlarge a region of
the chart, click on the two data points that define the left
and right boundaries of the region.

In zoom mode, the mouse pointer will change to a cross-

hair. When zoom mode ends, the mouse pointer will return
to its normal state.

To cancel zoom mode, click Cancel Zoom In from the

Tools menu, or simply press the Esc key.

24
o Zoom Out
Zoom Out restores the initial view of the chart, which
displays the full data set.

o Calculate Corrosion Rate

If the chart contains ER data, the Calculate Corrosion
Rate option will become available under the Tools menu.
This option allows the corrosion rate to be calculated
between any two data points on the chart. To calculate the
corrosion rate click Calculate Corrosion Rate, then click
two data points. The corrosion rate between those two
data points will be displayed.
In calculate mode, the mouse pointer will change to an
arrow/question mark. When calculate mode ends, the
mouse pointer will return to its normal state.

To cancel a calculation, click Cancel Calculate from the

Tools menu, or simply press the Esc key.

25
 G. Set Time and Date
When you need to set the internal
clock, select SET TIME & DATE.
Caution In order for information in memory
The time and date are set to be useful and accurate, be sure the
at the factory, but may
need to be adjusted to your time and date are accurate.
time zone.
SET TIME & DATE
Also, if you try to change 11:46 AM 20/02/98
the date or time and it
conflicts with stored ENTER TO ACCEPT
information, the MS1500E
will display N/A.
Use the numbers on the keypad and the
arrow keys to make changes to the time
and date.

Note: The MS1500E uses the interna-

tional date format (DD/MM/YY). Be
Sure to enter the date in this format to
prevent errors in data handling and
calculations.

Press ENTER to confirm your changes

and to return to the Main Menu, or
press EXIT to discard your changes.

H. Test Mode
This function of the instrument is
used by authorized factory personnel
for servicing or upgrading the
MS1500E.

E 2939 O153R1364 O151

G57 RATIO 0.4641
READING: 122 #105
PROBE: 1234-WIRE 40

26
III. Theory of Operation

A. Measurement Theory

The reduction in cross-sectional area of an element of metal or

alloy as it corrodes is accompanied by a corresponding increase in
the electrical resistance of the element.
The relationship is given by

R= x L/A .............................(1)

R = element resistance
= specific resistivity of the element alloy
A = element cross-sectional area
L = element length

Consequently, periodic resistance measurements of a metal/alloy

element that is continuously exposed to a corrosive environment,
will provide data on the rate and extent of corrosion for that alloy/
environment combination.

In practice, resistance is also a function of temperature. Therefore,

electrical resistance corrosion sensors need some means to com-
pensate for the effects of temperature change. This is achieved by
constructing the sensors such that the sensing element has an
exposed portion that freely corrodes and a protected portion that is
within the body of the sensor and not subject to corrosion. Such a
construction is illustrated in Figure 1.

Figure 1: Temperature compensated element

27
The resistance of both the exposed (RE) and protected (RT) portions
of the sensors are equally influenced by temperature. Conse-
quently, the resistance ratio of the exposed to protected elements is
a function only of the loss in metal thickness on the exposed
element, and therefore of corrosion.

This resistance ratio (RE/RT) is measured either periodically with a

portable instrument, or continuously with a variety of continuous,
automatic recording/data logging instruments and read as percent-
age thickness loss. Thus, total metal loss versus time is directly
available, and corrosion rate is indirectly available as the slope of
the line for metal loss versus time.

Figure 2: Typical data

28
B. ER Sensing Elements

Electrical resistance probe elements are offered in a variety of

thicknesses and geometries. The most common are illustrated
below:

Wire Loop Cylindrical Tube Loop Flush

Figure 3: Element styles

Tubular loop elements are constructed from thin-walled tubing.
Their small cross-section allows fast response at low corrosion
rates.

Wire loop elements, constructed of solid wire, provide a good compro-

mise between sensitivity and long life. They are typically used for
systems exhibiting moderate corrosion rates (5-20 mpy).

Cylindrical elements are made from hollow cylinders and are

extremely robust. They are widely used in high temperatures and
high flow rate conditions. They tend to be sensitive to noise and
somewhat sluggish in response. Consequently, they are only
recommended for moderate to high corrosion rates (20-50 mpy).

Flush elements are designed to be located flush with the corroding

surface of the vessel/pipe, consequently, most closely simulating
true corrosion rates. The flush element is useful in high flow
regimens and operating conditions where internal obstructions are
not permissible, e.g. pigged pipelines.

The mechanism for sealing elements into probe bodies varies. For
example, the cylindrical type elements are sealed with an all metal
weld, whereas flush elements are sealed with an epoxy seal.
29
The sealing mechanism of the element is a primary factor in determining
the temperature and pressure rating of an ER probe.

Table 1 provides a guide to temperature and pressure limitations for

various element designs.

Ele me nt Pre s s ure Te mpe rature

Form Thickne s s Ele me nt ID Rating PSI Rating F / C
tubular loop 4 mil TU04 1500 500 / 260
glass sealed 8 mil TU08
wire loop 40 mil WR40 1500 500 / 260
glass sealed 80 mil WR80
cylindrical element 10 mil CT10 1500 500 / 260
all metal 20 mil CT20
flush element 5 mil FM5 1500 400 / 204
epoxy seal 10 mil FM10

Table 1: Element temperature and pressure ratings

The temperature and pressure limitations given above may be

subject to modification according to the probe body design. This is
discussed later in this manual.

A final issue with respect to sensing elements is material of con-

struction. Generally, this should be selected to most nearly match
that of the plant or equipment under consideration.

Almost any geometric configuration and thickness of element can

be made in any commercially available alloy. However, some
alloys, particularly in the glass sealed loop version, may be costly
and have a considerable delivery time.

30
C. ER Element Performance

The basic ER measurement gives percentage of metal thickness

loss and is a function of the original element thickness. Essen-
tially, total metal loss and corrosion rate are given by the following
functions:

X x K ........................................ (2)
ML =
1000

(X2 - X1) x K x 365

CR = ................... (3)
1000 t

ML = METAL LOSS IN MILS

X = INSTRUMENT READING AT ANY GIVEN TIME
X2 = INSTRUMENT READING AT TIME t2
X1 = INSTRUMENT READING AT TIME t1
t = TIME LAPSE (DAYS) BETWEEN READINGS X1 AND X2
CR = CORROSION RATE IN MILS PER YEAR
K = PROBE CONSTANT

31
The probe constant K is a function of the element thickness and
geometry. Table 2 lists the K factors for various common elements.

ELEMENT GEOMETRY K FACTOR

TU04 2
TU08 4
WR40 10
WR80 20
CT10 5
CT20 10
FM5 2.5
FM10 5
FM20 10
FM40 20

Table 2: K factors

Some of the newer instruments, the MS1500E in particular, per-

form metal loss and corrosion rate calculations automatically and
display these as a direct reading.

Two key performance characteristics for a particular element style

are element life and response time. The element life is directly
proportional to its thickness, whereas response time, which is the
time required to obtain a significant reading change at a given
corrosion rate, is inversely proportional to element thickness.
Thus, the user must make some compromise between life and
response time when selecting a sensing element. Figures 4 and 5
provide a general guide for selecting optimum life and response
time combinations.
32
Figure 4: Element selection guide (element life)

33
Figure 5: Element selection guide (response time)

34
The other major performance characteristic related to element
geometry is measurement reproducibility. Under ideal circum-
stances the measurement reproducibility will match the instrument
resolution, which is 0.1% for most commercially available units.
However, low resistance elements (i.e., CT20, WR80) in systems
exhibiting frequent (30-60 minute cycle), and comparatively large
(10-15F), temperature fluctuation may only achieve a reproduc-
ibility of 0.5%. Such low resistance elements should be avoided
when temperature instability is anticipated, unless high corrosion
rates are expected (20+ mpy).

D. ER Probe Body Design

ER probe bodies may be made in almost any design and material.

Metal Samples frequently supplies custom probe designs for atypical
applications. However, a standard range of designs are available that
will cover the majority of uses. These standard designs are discussed in
the following paragraphs.

35
1. Fixed Length ER Probe

The fixed length probe, which has a body constructed in 316L

stainless steel, is a general purpose probe construction. The probe
is comprised of a NPT pipe plug entry or welded flange on a
cylindrical shaft. The probe is available in a variety of insertion
lengths, although no length adjustment is available; hence the
name fixed-length probe.

This probe is available in all element styles. The wire loop and
cylindrical elements can use threaded ports as small as 3/4" NPT.
The flush mount elements require at least a 1 NPT opening.
Pressure and temperature ratings are 3000PSI and 500F for pipe
plug entries, whereas flanged entries are controlled by the flange
rating. The major limitation of this design is that the system needs
depressurization prior to insertion or removal of the probe.

Wire, Tube or Strip

Loop Element

Figure 6: Fixed Length ER Probe

36
2. Retractable ER Probes

Retractable probes are the industry standard in refinery and petro-

chemical plants. The probe body is constructed in 316L stainless steel
and compromises a one inch FNPT packing gland with a cylindrical
probe shaft. Four basic probe lengths are available: 18", 24", 30", and
36".

However, the insertion is adjustable through the packing gland to

provide any desired insertion. The retractable probe is inserted into the
system through a customer supplied ball valve and can be inserted or
removed from pressurized systems without shutdown.

Retractable probes can be

operated at pressures to
1500 psi and 500F. Metal Safety Chain
Samples Easy Tool is
recommended for probe
Packing Gland
insertion or retraction in Assembly
systems with pressure over Nipple
150 pounds. Retractable
ER Probe Bleed Valve

1 Full Port
Valve
All element configurations
are available for retractable
Velocity Shield Safety Nut
probes and most can be (Optional)
accommodated through a
1" full-port valve. Flush
element probes, however,
require a 1 full-port
valve.

Figure 7: Retractable ER Probe

37
3. High Pressure Retrievable ER Probe

The high pressure retrievable probe is widely used in the oil and
gas production and transmission industry and is part of a specially
designed insertion/retraction system. The probe is mounted on a
specially designed plug and inserted through a welded or flanged
access fitting as shown in Figure 8.

The retrievable probe, which is normally constructed in AISI316L

stainless steel, can be inserted and removed from systems operat-
ing up to 3600 psi without system shutdown. This is achieved by
using a portable valve and retrieval tool that can be moved from
probe location to probe location as insertion or removal is required.

Probe Adapter

Cover

HP Hollow Plug
Assembly

HP Access Fitting
Retrievable ER Probe
(Shown with Velocity
Shield)

Figure 8:Retrievable ER Probe

38
IV. Testing the MS1500E with the ER
Meter Prover
An ER Meter Prover is provided to allow routine checks of the
MS1500E instrument. The ER Meter Prover simulates a Wire Loop
type ER probe at a fixed value which is printed on the Meter Prover
label (as shown below.)

To test the MS1500E with the Meter Prover:

1) Enter a new Probe ID in the MS1500E menu

with the probe type Wire 40 (see ENTER
NEW PROBE on page 10.) This Probe ID
can be used for future checks with the Meter
Prover.

2) Connect the ER Meter Prover to the

MS1500E probe connector as shown to the
right.

3) Perform a measurement by selecting MAKE

MEASUREMENT from the main menu (see
page 12.)

4) Allow the measurement to finish. The

measured value should be close the value
printed on the ER Meter Prover label (+/- 10
probe units is typical, but may vary more
depending on ambient conditions at the time.)
If the reading shows a significant difference
compared to the Meter Prover value, further
troubleshooting may be required.
39
It is important to note that the ER Meter Prover is only a check probe
used to verify general instrument operation. It is not a calibration
standard. The measured value may differ from the listed value as
explained in step 3 above.

It is also important to note that each ER Meter Prover is serialized to

match the instrument it is shipped with, and its measured value may
differ if it is used with another meter. If it is necessary to use an ER
Meter Prover with another meter, it is recommended that you establish
a baseline value for the ER Meter Prover with the other meter.

40
V. Returning an Instrument for Repair
If it is necessary to return any Metal Samples instrument for repair, the
following procedure is recommended to ensure the fastest possible
repair and return cycle. You may contact Metal Samples to verify that
returning the instrument is necessary.

1. If possible, pack the instrument in the original shipping

carton. If the original carton is not available, pack the
instrument in a rigid cardboard or wood carton. Surround
the instrument with a minimum of three inches of resilient
packing material such as foam rubber or shredded
newspaper.

2. Ship the instrument prepaid via air freight or air express to:

Metal Samples
152 Metal Samples Rd
Munford, AL 36268

3. Contact Metal Samples by telephone (256) 358-4202,

fax (256) 358-4515, or e-mail [email protected] and tell them:

a. the name of the airline carrying the instrument

b. the flight number

c. the estimated time of arrival

d. the waybill number and delivery instructions

4. When the instrument is packed, include a copy of the form

on the next page, filled in as required to expedite the repairs.

41
Copy this form when you need to return an instrument. Send a copy of this form
filled in as completely as possible.

1. Check one:
Repair this instrument under warranty.
Repair this instrument regardless of problem or cost of
repair.
Inspect this instrument and advise customer of approximate
cost of repairs if instrument is not covered under warranty
(Note: This may delay return of instrument to customer.)

2. Instrument Model #
Serial #
Date of purchase
Customers original purchase order #

3. Return this instrument to:

Company
City/State/Zip

Telephone Fax

4. Describe problem fully - this may shorten repair time.

5. Urgency of repairs

42
VI. Warranty
Metal Samples warrants that any part of Metal Samples corrosion rate
instruments and accessories which proves to be defective in material
or workmanship within one year of the date of original shipment to
Purchaser will be repaired or replaced, at the option of Metal Samples,
free of charge. This warranty does not cover (1) probe assemblies, (2)
items expendable in nature, or (3) items subject to damage from normal
wear, misuse or abuse, or failure to follow use and care instructions.

All damaged items are to be shipped at Purchasers expense to and

from Metal Samples. Metal Samples shall have the right to final deter-
mination as to the existence and cause of the defect.

The foregoing shall constitute the sole and exclusive remedy of

any purchaser of Metal Samples products for breach of warranty and is
exclusive and in lieu of all other warranties, expressed, implied or
statutory, including the implied warranties or merchantability and fitness.
In no event shall Metal Samples be liable for special or consequential
damages or for any delay in the performance of this warranty due to
causes beyond its control.

Orders or requests for additional information should be addressed to:

Metal Samples
152 Metal Samples Rd
Munford, AL 36268
Phone: (256) 358-4202
Fax: (256) 358-4515
E-mail: [email protected]

The technical information and suggestions contained herein are believed

to be reliable, but they are not to be construed as warranties since
conditions of use are beyond our control.

43