Electrical Resistance (ER) Probes

MODEL 3500/3500HT  
 

Model 3501/3501HT  
Replacement Insert 

Features
 Cylindrical Element
 Mounting - 1" Full Port Valve Minimum
 Temp. Rating for Model 3500 - +425° F / + 218° C
 Temp. Rating for Model 3500HT - +1000° F / +520° C
 Pressure Rating for Model 3500 - 1500 PSI / 10.3 MPa
 Pressure Rating for Model 3500HT - 1000 PSI / 6.9 MPa
 Element Seal Material — All Welded
 Fill Material - Ceramic
 Probe Body Material – Carbon Steel, 316SS or Hastelloy C276***

Model  3500  Retractable  Process  electrical  resistance  of reference element. They are ideally suited to the more 

probes have a thin walled tubular sensing element made  aggressive  plant  conditions  and  may  be  used  in  very 
from  the  alloy  of  interest  welded  onto  a  body  of  the  aggressive organic or inorganic fluids over the entire pH 
same  material.  Mild  Steel  bodies  are  Teflon  coated.  No  range  0‐14,  subject  to  process  containment 
other  materials  contact  the  corrosive  process  fluid.  requirements.  
Materials  of  construction  are  carefully  matched  and   
welds  are  vacuum  annealed  during  assembly  to  avoid  These probes are standard in mild steel, 304 S.S. and 316 
preferential corrosion effects.  S.S. Certain other alloys can be provided on special order; 
  please  contact  the  factory  for  information.  The  useful 
Model  3500  ER  probes  provide  a  large  test  surface,  measuring lives of the T‐10 and T‐20 probe elements are 
excellent dynamic temperature response and protection  5  mils  (0.13mm)  and  10  mils  (0.25mm)  respectively.
MODEL 3500/3500HT

Element Availability
 
UNS  UNS 
Alloy  T10  T20  T50  Alloy  T10  T20  T50   
Number  Number 
 
Pipe Grade Carbon 
K03005        N08020  CARP 20‐Cb3         
Steel 
  
A106GRB  A106 Gr. B        S50400  9% Cr 1% Mo       
     
S30400  304 S.S.        N04400  Monel 400       
 
S30403  304L S.S.        N06600  Inconel 600         
S31600  316 S.S.        N06625  Inconel 625         
S31603  316L S.S.        N08825  Incoloy 825         
S31703  317 S.S.        N10276  Hastelloy C‐276         
S31803  2205 Duplex S.S.         A333GR6  A333GR. 6         
S32100  321 S.S.                   
S41000  410 Stainless Steel                   
502 S.S. (5% Cr 1/2%   
S50200                 
Mo)   
N08904  904L S.S.                   
Inches  .005  .010  .025    Inches  .005  .010  .010 
Useful Range (mm)  .127  .254  .635  Useful Range (mm)  .127  .254  .635 
Table 1 
Other element alloys or styles may be supplied subject to material availability. 

Dimensions

“A” Dimension is with probe fully inserted into packing gland

“B” Type Connector
 
Order  “A” Dimension  “B” Dimension 
Length  Inches  mm  Inches  mm 
18  14.4  366  22.25  565 
24  20.4  518  28.25  718 
30  26.4  670  34.25  870 
36  32.4  823   40.25  1022 
 MODEL 3500/3500HT

Ordering Information
Note: For high velocity process conditions it is recommended that Wake Frequency  
  Calculations be performed – please contact a Cosasco representative for further details.  
 
Model  Retractable ER Probes – Cylindrical Element Assembly 
3500  Complete Probe Assembly With Stuffing Box 
3500HT  Complete High Temperature Assembly *** 
3501  Model 3500 Replacement Insert 
3501HT  High Temperature Replacement Insert *** 
  Code  Element Form: See Table 1 for availability 
  T10  10 mil thickness (5 mil useful probe life) 
  T20  20 mil thickness (10 mil useful probe life) 
  T50  50 mil thickness (25 mil useful probe life)  
    Code  Element Alloy: See Table 1 for availability 
    XXXXXX  Enter UNS number 
      Code  Order Length 
      18  18 Inches 
      24  24 Inches 
      30  30 Inches 
      36  36 Inches 
        Code  Safety Clamp (Not an option for 3501 and 3501HT) 
        0  Not Included 
1  Safety Clamp Installed 
          Code  Shield 
          0  Not included (liquids 8 ft./sec, gases 25 ft./sec) 
          1  Standard (liquids 25 ft./sec, gases 75 ft./sec) 
          2  High Velocity/Erosion (liquids 50 ft./sec, gases 150 ft./sec) 
              3**  Coupon Holding (liquids 25 ft./sec, gases 75 ft./sec) 
            Code  Stuffing Box Material (Not an option for 3501 or 3501HT) 
            0  Stainless Steel/Carbon Steel* 
            1  Hastelloy C‐276 
            2  Same as element material 
               
3500  T10  K03005  18  1  1  0  Example 
3501  T10  K03005  18    1    Example 
3500HT  T20  K03005  18  1  1  0  Example 
3501HT  T20  K03005  18    1    Example 
 
*Carbon Steel for Carbon Steel Elements, Stainless Steel for all others. 
**Coupon holding tip will extend 2” beyond order length coupon holding shields use CI‐RS strip coupons. 
***For High‐Temp Carbon Steel Element Probes, the Probe Body will be 316L S.S. For other alloys the body will be Hastelloy C276. The Stuffing Box 
  and shields will be 316 S.S. 
 
Accessories
Part Numbers If Ordering Shield Separately: 
Model 3500 & 3501  Model 3500HT & 3501HT  Unit Weight: Probe Assembly with Safety          
Standard Shield #745006‐TXX‐XXXXXX  Standard Shield #745054‐XXXXXX         Clamp – 7 lbs. /3.18 kg 
High Velocity/Erosion Shield #745017‐TXX‐XXXXXX  High Velocity Shield #745017‐XXXXXX         Insert Only – 2.5 lbs./1.13 kg 
Coupon Holding Shield #745060‐XXXXXX  Coupon Holding Shield #745058‐XXXXXX 
“XXXXXX” is the UNS alloy number  “XXXXXX” is the UNS alloy number 
 
 
 
 
Cosasco 
  ©Rohrback Cosasco Systems, Inc. All rights reserved 
11841 Smith Avenue 
   
The contents of this publication are presented for information purposes only, and while effort has been made to ensure their accuracy, they 
Santa Fe Springs, CA 90670, USA 
  are not to be construed as warranties or guarantees, express or implied, regarding the products or services described wherein or their use or 
Tel: 1‐562‐949‐0123 
  applicability. We reserve the right to modify or improve the designs or specifications of our products at any time without notice. 
Email: [email protected]   
 
Web Site: www.cosasco.com 

3500‐DS rev‐B 
Rev. Date:  01/28/2019 
 ®
COSASCO MODEL 60 RETRACTABLE
1500 PSI SYSTEM RETRACTOR KIT
Work Instruction

11841 Smith Avenue

Santa Fe Springs, CA 90670 P / N: 613016revL
Tel: (562) 949-0123 • (800) 635-6898 www.cosasco.com
Fax: (562) 949-3065
Note: Please ensure you have the latest revision of this document by downloading it from our website or by contacting Cosasco Customer Service.
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Revision History Record

ECN Page Rev Date Description of Change Issue Reviewed Approved

No No.
ALL - 02/15/13 Initial Release KR ENG RA
6 A 04/11/13 Added Disclaimer Notes KR ENG RA
8, 10, 12 B 08/16/13 Updated Scope of Doc, Temp Rating, Pre Job KR ENG RA
Preparation
13 C 12/12/13 Added Warning – Deviation from Work KR ENG RA
Instruction
ALL D 01/28/14 Annual Review – No Changes KR ENG RA
14 E 05/28/14 Update page 14 step 6 KR ENG RA
ALL F 01/25/15 Annual Review KR ENG RA
ALL G 03/25/15 Added note on footer about latest revision KR ENG RA
ALL H 12/15/15 Annual Review/Update Cover and Name to KR ENG RA
Cosasco Throughout Document
ALL I 12/16/16 Annual Review MP ENG RA
All J 12/10/17 Change from RevI to RevJ JT JL DS
ALL K 27/11/17 Annual Review JL AA DS
21133 ALL L 23/11/18 Annual Review and insert ECN No JL MR DS

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Cosasco® is a registered trademark of Rohrback Cosasco Systems, Inc.

No part of this work instruction may be reproduced or transmitted in any form or by any
means, electronic or mechanical, including photocopying and recording, for any purpose,
without the express written permission of Rohrback Cosasco Systems, Inc.

Note: Please ensure you have the latest revision of this document by downloading it from our website or by contacting Cosasco Customer Service.
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CONTENTS
Page No

1 Important instructions ...................................................................................... 5

2 Disclaimer .......................................................................................................... 6

3 Safety warnings ................................................................................................. 7

4 Scope of Document ........................................................................................... 8

5 How the retractable System Works................................................................. 9

5.1 Retractable System Retractor Kit ............................................................................ 9
5.2 The Retractor Tool ................................................................................................ 10

1 6 Pre Job Preparation ..................................................................................... 11

6.1 Site Survey ............................................................................................................ 12
6.2 Documentation & Communication ......................................................................... 12
6.3 Worksite Checks ................................................................................................... 13

7 Retractable system construction & preparation .......................................... 13

8 Installation of monitoring device ................................................................... 14

8.1 Retraction of Monitoring Device............................................................................. 15

9 access valve & stuffing box installation ........................................................ 16

10 Cleaning and Maintenance of Retractor ........................................................ 17

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1 IMPORTANT INSTRUCTIONS

Cosasco is committed to providing the safest and highest quality products, services, and
training for the industries it serves. We are committed to ensuring that all users of our
equipment work safely and efficiently. Fully anticipating the infinite variety of conditions that
may be encountered in the field would be impossible, but we have designed this work
instruction to emphasize safe working practices, and as much as possible, to convey the full
benefit of our knowledge and collective experience in the use of the Coassco Model 60
Retractor and 1" Access Valve Assembly. This work instruction is not meant to be a sole
source of instruction or training guide. Because these tools are used in a broad range of
environments and applications, it is important that the owner and operation personnel have
been assessed, certified, and deemed competent in all safety, work management and
additional risk assessment requirements in the application of this procedure.

WARNING Installing, operating or maintaining a Cosasco low pressure retractor tool

improperly could lead to serious injuries. Comply with all information on
the product, in this work instruction, and in Cosasco System Safety
Awareness Training that apply to the product. Do not allow untrained or
inexperienced personnel to work with this product. Use Cosasco parts and
work procedures specified in this work instruction.

BE SURE ALL PERSONNEL READ AND FOLLOW THE INSTRUCTIONS

IN THIS WORK INSTRUCTION AND ALL PRODUCT WARNINGS.

Product Owners (Purchasers)

1. Use the correct product for the environment and pressures present. If you are
unsure, discuss your needs with your Cosasco representative.

2. Inform, educate, and train all personnel in the proper installation, operation, and
maintenance of this product.

3. To ensure proper performance, only competent, field experienced and trained

personnel should install, operate, repair and maintain this product.

4. Save this work instruction for future reference.

Product Operation Personnel (Personnel):

1. Read and understand all instructions and operating procedures for this product.

2. Follow all warnings, cautions, and notices marked on, and supplied with, this product.

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3. Follow all instructions during the installation, operation, and maintenance of this
product.

4. To prevent personal injury, ensure that all components are in place prior to and
during operation of the product.

5. If you do not understand an instruction, or do not feel comfortable following the

instructions, contact a Cosasco service technician for clarification or assistance.

6. If this work instruction is not correct for your Cosasco product, contact your regional
Cosasco office and Cosasco will provide you with the requested work instruction.

7. Use only replacement parts specified by Cosasco. Unauthorized parts and

procedures can affect this product’s performance, safety, and invalidate the warranty.
“Look-a-like” substitutions may result in improper operation and may result in serious
injury or death.

8. Save this work instruction for future reference.

2 DISCLAIMER

This disclaimer relates to the use of these work instructions by non-Cosasco persons and
entities.

Any person or organization utilizing this work instruction, for any purpose, does so at their
own risk. Rohrback Cosasco Systems, Inc., its affiliates and employees assume no liability
arising from the use of, or reliance on the information provided in any Cosasco work
instructions.

Information provided in this work instruction should not be considered as all-encompassing

or suitable for all situations, conditions or environments. Each individual and the
organization he or she represents are responsible for implementing their own program of
training and safety awareness in connection with this work instruction.

Application of information furnished by this work instruction does not guarantee that the
information furnished will meet applicable USA (including OSHA), United Kingdom, or any
other country’s health or safety standards or requirements or, that by implementing any of
the programs you or your company will comply with such rules and regulations. Always seek
the advice of your legal, medical or other advisors before using this information.

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3 SAFETY WARNINGS

WARNING It is imperative that the following safety warnings are taken into
important consideration before and during use of Retractable System
Equipment. Safety warnings are noted throughout this document to
ensure precautions are taken for all procedures where there are risks
involved. Failure to follow these warnings could result in serious injuries.

1. Do not use the Retractor equipment unless you have been properly trained in its safe
operation.

2. Safe operation requires a minimum of one trained operator.

3. If it has been longer than 90 days since your last operation, you should review this work
instruction and first practice on a dummy (no pressure) fitting.

4. Make sure you have complied with all plant safety requirements and environmental
regulations.

5. Identify the type of media, its pressure and temperature. Review material safety data
information of the media prior to operation.

6. Ensure you have all the required safety equipment for the given media, (i.e. hard hat,
safety glasses, protective clothing, safety gloves, respirator, spill safety equipment,
etc…).

7. Any actions which could vary system pressure such as surges caused by opening and
closing of valves and chokes should be delayed until completion of the retraction
operations.

8. Ensure you have enough clearance for safe operation. Note wind direction prior to
starting operations involving hazardous products.

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4 SCOPE OF DOCUMENT
This document details the procedure for the installation and retrieval of corrosion and
erosion monitoring devices or chemical injection equipment using the Cosasco Model 60
Retractable System Retractor Kit.

Caution must be used at all times when working with pressurised equipment and
before actual field work personnel must be trained in the safe use of the retractor.

This document is not to be used as a training manual in the use of the fore mentioned
equipment and is intended for use by Cosasco trained and qualified personnel or service
personnel of clients who have been assessed, certified, and deemed competent in all safety,
work management and additional risk assessment requirements in the application of this
procedure. The lead technician is responsible for strict adherence to this work instruction.

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5 HOW THE RETRACTABLE SYSTEM WORKS

5.1 Retractable System Retractor Kit

The Retractable System consists of a retractor tool which clamps onto a stuffing box seal
assembly which is connected to a preinstalled ball valve via an NPT fitting. With the use of a
Retractor Tool, various probes, coupons or chemical injection equipment can be removed
and installed through the valve while the system is under pressure.

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5.2 The Retractor Tool

The Cosasco Retractor is a lightweight tool capable of retrieving corrosion monitoring

devices in pressurized systems up to 1500psi (103bar) and temperatures up to 535ºC
(995ºF).

The Retractor Tool comes in two sizes, 24” and 36”. The tool size determines the length of
device the tool can retrieve from the line.

Some useful tool specifications are included in the table below:

Ordering Length
Description
24" 36"
35” 47”
Retractor Overall Length
0.89m 1.2m
9.5” 9.5”
Minimum Working Radius
0.24m 0.24m
Maximum Device Size
24” 36”
Which Can Be Retracted.
19# 22#
Retractor Assembly Weight
8.64kg 9.98kg

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Retractor Reference Diagram

B A. Handle Nut
1 B. 1-1/2” Hex Nut
A Spanner
C. Retractor Shaft
D. Quick Release Pin
E. Hex Nut Plate
C F. Thrust Coupling
G. 1” Coupling Fitting
H. Lever Nut
I. Clamp Assembly

H I

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6 PRE JOB PREPARATION

The following three sections discuss the major steps required prior to starting any on-line
retrieval using the Retractor Kit. The lists in the following sections are prompts and are not
intended to replace client Risk Assessments or Job Safety Analysis which will also have to
be completed prior to work start.

6.1 Site Survey

It is necessary to perform a Job Step Analyses at each work location prior to work start, to
ensure the following variable information is known:

 Scaffolding or any additional access requirements to ensure safe access and egress
to work site
 Clearance for using the Retractor tool. See table in section 5.2 for guidance on
clearances required.
 Pipe line pressures & temperatures, so that operating pressure of tools is not
exceeded
 Any potential hazards around the worksites, such as slip, trip or fall hazards
 Emergency access & egress routes
 The pipe line media, which the equipment and operators will be exposed to
 Means of raising alarm in emergency situations

6.2 Documentation & Communication

Prior to work start the following documentation must be generated and reviewed:

 Permit to Work, as specified by the client

 Client specific Risk Assessment or Job Step Analyses, with Cosasco personnel input
 Critical Step Checklist
 SAFR Location Sheet
 Personnel competency certificates

A toolbox talk will be performed by the Cosasco Technician, including but not limited to the
following:

 The main steps involved in the job

 Equipment to be used
 Review of work permit and risk assessment
 PPE required
 Means of communication with Control Room personnel
 Actions to be taken in the event of an emergency
 Control room is aware of work party location
 All personnel involved with the work are aware of all control measures and are
competent to be involved in the work
 Work party are aware of any other work taking place in close proximity to worksite

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 Any additional hazards identified during this talk should be reviewed and control
measures implemented

6.3 Worksite Checks

Upon completion of the steps in section 6.1 & 6.2 final checks should be made at the
worksite prior to work starting, as follows:

Worksite
 Ensure any scaffolding to be worked on is certified
 Check previously identified escape routes are still clear
 Test means of communication with control room
 Double check PPE is in good condition and fit for purpose
 Identify any other work parties in proximity work location

All equipment including Retractor Kit, hand tools and corrosion monitoring equipment is to be
inspected pre-job to ensure it is fit for purpose and in good working order.

WARNING If a situation arises during the execution of this Work Instruction, which
requires a deviation, then an approved Job Step Analysis will be required
before continuing with the operations at the monitoring location concerned.
The JSA must be approved by Cosasco and by the Operator of the site before
proceeding with the deviation. Site specific work permit policies should be
followed to ensure site management are fully aware of the deviation to the
standard procedures. No further steps may be taken at the monitoring
location concerned until this is completed. Work may proceed as per the work
scope at the next applicable monitoring location whilst the JSA is reviewed
and issued for approval.

7 RETRACTABLE SYSTEM CONSTRUCTION & PREPARATION

1. An online access valve must be used with a minimum bore of .95” and a 1” NPT nipple
for mounting to the stuffing box. This nipple should be sized appropriately to
ensure clearance of the fully retracted probe when closing the access valve.

2. All probes/devices (here after referred to as ‘probes’) must have a mechanical stop
(velocity shield or stop ring) installed. The mechanical stop ensures that the probe
cannot be removed from the stuffing box while online (under pressure).

NOTE: A safety clamp kit assembly and retractor are required when pressures are in
excess of 150psi and/or above temperatures of 150ºF.

3. The 3/8” threaded rods on the safety clamp assembly must be sized prior to using
the retractor to allow sufficient mounting clearance. Any rod in excess of 1” past either
end of the safety clamp jam nuts, at position of desired insertion, must be cut off.

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8 INSTALLATION OF MONITORING DEVICE

1. NOTE: If probe is not already online refer to section 9 "Access Valve and Stuffing Box
Installation".

2. Assemble the two halves of the clamp assembly around the probe stuffing box such
that the cut out in the clamp aligns with the threaded rods (when present) and
ensuring that the safety cable is not crossed or interfering. Draw the clamp assembly
together and secure with the lever nut. Insert the quick release pin into the hole
provided on the right half of the clamp assembly.

3. Remove the dust cover or any instrumentation cabling connected from the connector
end of the probe and install the thrust coupling over the 1” NPT connector threads. If
the connector has other than 1” NPT threads a separate adaptor must be used.

4. Install the coupling fitting on the connector or the adapter. Rotate the handle until it
rests just above the thrust coupling.

5. Slowly open the access valve. The stuffing box is now pressurised; loosen the 1” hex
locking nut and the 1-1/2” hex stuffing nut, but do not remove. Should leakage occur
around the 1-1/2” hex stuffing nut, tighten as necessary. Do not tighten to the point
that it is difficult to push the probe through the stuffing box assembly.

Loosen the 1” hex locking nut and the 1-1/2” hex stuffing nut, but do
IMPORTANT! not remove.

6. Insert the probe by rotating the handle nut in a clockwise direction until the desired
insertion depth is obtained and orient the probe in the flow as required. Tighten the 1 ½”
hex stuffing box nut ½ turn past hand tight then tighten the 1” hex locking nut ¾ turn past
hand tight. When the probe has a safety clamp kit then reinstall the jam nuts onto the
threaded rods and push the safety flanges toward each other and tighten the inside
jam nuts flush with the inside of the inboard and outboard safety flanges. Check for
any leaks and tighten as necessary.

7. To remove the retractor from the probe first remove the coupling fitting from the
connector end of the probe then back off the handle nut counter clockwise and lift the
thrust coupling off and clear of the probe. Remove the quick release pin and loosen
the lever nut on the clamp assembly. Swing open the clamp assembly and remove
the retractor from the probe.

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8.1 Retraction of Monitoring Device

1. Install the retractor onto the stuffing box as per section 8. Do not remove the safety
clamp assembly or loosen the 1-1/2” hex stuffing box nut or 1” hex locking nut before
retractor is installed.

WARNING! Do not remove the safety clamp assembly or loosen the 1-1/2”
hex stuffing box nut or 1” hex locking nut before retractor is
installed.

2. Loosen and remove the top two 9/16” hex jam nuts from the top safety flange closest to
the probe end connector.

3. Loosen the 1” hex locking nut until it can be turned freely. Carefully loosen the 1-1/2”
hex stuffing nut until the probe can be retracted smoothly but no more than one full
turn. Should leakage occur around the 1-1/2” hex stuffing nut then tighten as
necessary.

4. Remove the probe by rotating the handle nut counter clockwise, allowing system
pressure to drive the probe out until it is fully retracted (safety cable will become
fully taut) which will allow closing of the access valve assembly.

5. Close the access valve and bleed off the pressure in the nipple by loosening the
stuffing box body. Once a l l t h e pressure is bled off then remove the stuffing box
assembly from the nipple.

NOTE: The retractor lower 2-1/4” hex nut (across flats) is provided on the threaded
shaft in the event that system pressure is not sufficient to drive the probe. If required,
rotate nut counter clockwise (with 2-1/4” wrench) until it makes contact with the bottom
surface of the thrust coupling. Locate the handle nut so that no more than two
threads are visible between the handle nut and the thrust coupling. This will provide a
stopper in the event of sudden movement. Rotate the 2-1/4” hex nut counter clockwise
while keeping the handle nut two threads above the thrust coupling.

Only after the probe has been retracted and the access valve
WARNING! closed and the pressure in the nipple between the access valve
and the probe body has been bled off (by loosening the stuffing
box body threads) can the probe and retractor be safely
removed from the system.

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Cosasco® 1500psi Model 60 Retractable System Retractor Kit P/N: 613016revL
Work Instruction

Page: 16 of 18
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9 ACCESS VALVE & STUFFING BOX INSTALLATION

1. Assemble the access valve and nipples (if not already online). A 1” female NPT
connection is provided on the stuffing box body to mate with the thread on the
access valve outlet nipple.

2. Close the access valve. The vessel may now be pressurised.

3. If a safety clamp kit assembly has been installed remove the outer two jam nuts
closest to the probe connector end.

4. Loosen the 1” hex locking nut and the 1-1/2” hex stuffing nut but do not
remove.

Loosen the 1” hex locking nut and the 1-1/2” hex stuffing nut, but do
IMPORTANT! not remove.

5. Slip the stuffing box assembly as far forward (toward the shield/measuring element,
quill, or coupon end) as possible.

6. Apply thread sealing compound or PTFE tape to the threads of the access valve and
outlet nipple.

7. Mount the stuffing box assembly onto the access valve outlet nipple and tighten 2-3/4 to
3-1/4 full turns past hand tight. (Normal thread engagement to make a tight joint is
0.66”.)

8. Tighten the 1-1/2” hex stuffing nut HAND TIGHT.

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Cosasco® 1500psi Model 60 Retractable System Retractor Kit P/N: 613016revL
Work Instruction

Page: 17 of 18
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10 CLEANING AND MAINTENANCE OF RETRACTOR

The retractor should be kept clean and free of dirt, sand and foreign material that
could hamper the operation of the retractor. The threaded shaft should be kept lightly
lubricated with a high quality and waterproof grease.

Note: Please ensure you have the latest revision of this document by downloading it from our website or by contacting Cosasco Customer Service.
Cosasco  [email protected]  www.cosasco.com
COSASCO® RETRACTABLE SYSTEM
(LOW PRESSURE) BY HAND
Work Instruction

11841 Smith Avenue P/N: 741060revH

Santa Fe Springs, CA 90670
Tel: (562) 949-0123 • (800) 635-6898
www.cosasco.com
Fax: (562) 949-3065

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 Cosasco® Retractable System (Low Pressure) by Hand Work Instruction P/N: 741060revH
Page: 2 of 17
Scheduled Review Date: July 2019 Date: 10/08/18

Revision History Record

ECN Page Rev Date Description of Change Issued Reviewed Approved

No. No.
- - 12/12/13 Initial Release KR ENG DS
ALL A 01/29/13 Annual Review KR ENG RA
13,10,9 B 08//18/14 Update – Installation of monitoring device KR ENG RB
ALL C 03/30/15 Annual Review / Note on footer about revision KR ENG RA
ALL D 12/15/15 Annual Review/Update Cover and Name to KR ENG RA
Cosasco Throughout Document.
14 E 05/05/16 Updated Section 10 KR ENG RA
ALL F 01/26/17 Annual Review MP ENG RA
ALL G 28/11/17 Annual Review JL AA DS
21022 7 H 10/08/18 Add Step 9 JL MR DS
13 Add new Step 5
Reword Step 9
14 Add new Step 2
Reword Step 3 & 4
Added Warning between Steps 3 & 4
2 Add ECN Number

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Cosasco® Retractable System (Low Pressure) by Hand Work Instruction P/N: 741060revH
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COSASCO® is a registered trademark of Rohrback Cosasco Systems, Inc.

No part of this work instruction may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopying and recording, for any purpose, without the
express written permission of Rohrback Cosasco Systems, Inc.

Note: Please ensure you have the latest revision of this document by downloading it from our website or by contacting Cosasco Customer Service.
Cosasco® Retractable System (Low Pressure) by Hand Work Instruction P/N: 741060revH
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CONTENTS
Page No

1 Important Instructions ...................................................................................... 5

2 Disclaimer .......................................................................................................... 6

3 Safety Warnings ................................................................................................ 7

4 Scope of Document ........................................................................................... 8

5 How the Retractable System Works ................................................................ 9

5.1 Retractable System Retractor Kit ............................................................................ 9
5.2 The Retractor Tool ................................................................................................ 10

6 Pre Job Preparation ........................................................................................ 11

6.1 Site Survey ............................................................................................................ 11
6.2 Documentation & Communication ......................................................................... 11
6.3 Worksite Checks ................................................................................................... 12

7 Retractable System Construction & Preparation .......................................... 12

8 Installation Of Monitoring Device................................................................... 13

9 Retraction of Monitoring Device .................................................................... 14

10 Replacement of Stuffing Box Seals ............................................................... 14

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Cosasco® Retractable System (Low Pressure) by Hand Work Instruction P/N: 741060revH
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1 IMPORTANT INSTRUCTIONS

Cosasco is committed to providing the safest and highest quality products, services, and
training for the industries it serves. We are committed to ensuring that all users of our
equipment work safely and efficiently. Fully anticipating the infinite variety of conditions that
may be encountered in the field would be impossible, but we have designed this work
instruction to emphasize safe working practices, and as much as possible, to convey the full
benefit of our knowledge and collective experience in the use of the Cosasco Retractable
System by Hand. This work instruction is not meant to be a sole source of instruction or training
guide. Because these tools are used in a broad range of environments and applications, it is
important that the owner and operation personnel have been assessed, certified, and deemed
competent in all safety, work management and additional risk assessment requirements in the
application of this procedure.

WARNING Installing, operating or maintaining a Cosasco Retractable System by

Hand improperly could lead to serious injuries. Comply with all information
on the product, in this work instruction, and in Cosasco System Safety
Awareness Training that apply to the product. Do not allow untrained or
inexperienced personnel to work with this product. Use Cosasco parts and
work procedures specified in this work instruction.

BE SURE ALL PERSONNEL READ AND FOLLOW THE INSTRUCTIONS

IN THIS WORK INSTRUCTION AND ALL PRODUCT WARNINGS.

Product Owners (Purchasers)

1. Use the correct product for the environment and pressures present. If you are unsure,
discuss your needs with your Cosasco representative.

2. Inform, educate, and train all personnel in the proper installation, operation, and
maintenance of this product.

3. To ensure proper performance, only competent, field experienced and trained personnel
should install, operate, repair and maintain this product.

4. Save this work instruction for future reference.

Product Operation Personnel (Personnel):

1. Read and understand all instructions and operating procedures for this product.

2. Follow all warnings, cautions, and notices marked on, and supplied with, this product.

3. Follow all instructions during the installation, operation, and maintenance of this product.

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Cosasco® Retractable System (Low Pressure) by Hand Work Instruction P/N: 741060revH
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4. To prevent personal injury, ensure that all components are in place prior to and during
operation of the product.

5. If you do not understand an instruction, or do not feel comfortable following the

instructions, contact a Cosasco service technician for clarification or assistance.

6. If this work instruction is not correct for your Cosasco product, contact your regional
Cosasco office and Cosasco will provide you with the requested work instruction.

7. Use only replacement parts specified by Cosasco. Unauthorized parts and procedures
can affect this product’s performance, safety, and invalidate the warranty. “Look-a-like”
substitutions may result in improper operation and may result in serious injury or death.

8. Save this work instruction for future reference.

2 DISCLAIMER

This disclaimer relates to the use of these work instructions by non-Cosasco persons and
entities.

Any person or organization utilizing this work instruction, for any purpose, does so at their own
risk. Rohrback Cosasco Systems, Inc., its affiliates and employees assume no liability arising
from the use of, or reliance on the information provided in any Cosasco work instructions.

Information provided in this work instruction should not be considered as all-encompassing or

suitable for all situations, conditions or environments. Each individual and the organization he
or she represents are responsible for implementing their own program of training and safety
awareness in connection with this work instruction.

Application of information furnished by this work instruction does not guarantee that the
information furnished will meet applicable USA (including OSHA), United Kingdom, or any other
country’s health or safety standards or requirements or, that by implementing any of the
programs you or your company will comply with such rules and regulations. Always seek the
advice of your legal, medical or other advisors before using this information.

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Cosasco® Retractable System (Low Pressure) by Hand Work Instruction P/N: 741060revH
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3 SAFETY WARNINGS

WARNING It is imperative that the following safety warnings are taken into
important consideration before and during use the Cosasco Retractable
System by Hand. Safety warnings are noted throughout this document
to ensure precautions are taken for all procedures where there are risks
involved. Failure to follow these warnings could result in serious injuries.

1. Do not use the Cosasco Retractable System by Hand unless you have been properly
trained in its safe operation.

2. Safe operation requires a minimum of one trained operator.

3. If it has been longer than 90 days since your last operation, you should review this work
instruction and first practice on a dummy (no pressure) fitting.

4. Make sure you have complied with all plant safety requirements and environmental
regulations.

5. Identify the type of media, its pressure and temperature. Review material safety data
information of the media prior to operation.

6. Ensure you have all the required safety equipment for the given media, (i.e. hard hat, safety
glasses, protective clothing, safety gloves, respirator, spill safety equipment, etc…).

7. Any actions which could vary system pressure such as surges caused by opening and
closing of valves and chokes should be delayed until completion of the retraction operations.

8. Ensure you have enough clearance for safe operation. Note wind direction prior to starting
operations involving hazardous products.
9. To prevent personal injury always keep your head and body out of the line of fire above the
end of the monitoring device.

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Cosasco® Retractable System (Low Pressure) by Hand Work Instruction P/N: 741060revH
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4 SCOPE OF DOCUMENT

This document details the procedure for the installation and removal of corrosion/erosion
monitoring devices or chemical injection equipment with the Rohrback Cosasco 1’’ Retractable
System.

The low pressure Retractor system is designed for maximum 1500 psi working pressure.

This document covers the manual insertion by hand and extraction of probes or quills under 150
psi line pressure.

Caution must be used at all times when working with pressurised equipment and before actual
field work, personnel must be trained in the safe use of the equipment.

If pressures are 150 psi or greater then a Retractor Tool must be used.

This document is not to be used as a training manual in the use of the fore mentioned
equipment and is intended for use by Cosasco trained and qualified personnel who have been
assessed, certified, and deemed competent in all safety, work management and additional risk
assessment requirements in the application of this procedure. The lead technician is
responsible for the strict adherence to this work instruction.

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Cosasco® Retractable System (Low Pressure) by Hand Work Instruction P/N: 741060revH
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5 HOW THE RETRACTABLE SYSTEM WORKS

5.1 Retractable System Retractor Kit

The Retractable System consists of a retractor tool which clamps onto a stuffing box seal
assembly which is connected to a pre-installed ball valve via an NPT fitting. With the use of a
Retractor Tool, (for pressure up to 1500 PSI) or by hand (for pressure up to 150 PSI), various
probes, coupons or chemical injection equipment can be removed and installed through the
valve while the system is under pressure.

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Cosasco® Retractable System (Low Pressure) by Hand Work Instruction P/N: 741060revH
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5.2 The Retractor Tool

The Cosasco Retractor is a lightweight tool capable of retrieving corrosion monitoring devices
in pressurised systems up to 1500psi (103bar) and temperatures up to 260ºC (500ºF).

The Retractor Tool comes in two sizes, 24” and 36”. The tool size determines the length of
device the tool can retract from the line.

Some useful tool specifications are included in the table below:

Ordering Length
Description
24 36

35” 47”
Retractor Overall Length
0.89m 1.2m
9.5” 9.5”
Minimum Working Radius
0.24m 0.24m
Maximum Device Size
24” 36”
Which Can Be Retracted.
19# 22#
Retractor Assembly Weight
8.64kg 9.98kg

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Cosasco® Retractable System (Low Pressure) by Hand Work Instruction P/N: 741060revH
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6 PRE JOB PREPARATION

The following three sections discuss the major steps required prior to starting any job. The lists
in the following sections are prompts and are not intended to replace client risk assessments or
Job Safety Analysis which will also have to be completed prior to work start.

6.1 Site Survey

It is necessary to perform a Job Step Analysis at each work location prior to work start, to
ensure the following variable information is known:

 Scaffolding or any additional access requirements to ensure safe access and egress to
work site
 Any potential hazards around the worksites, such as slip, trip or fall hazards
 Emergency access & egress routes
 The pipe line media, which the equipment and operators will be exposed to
 Means of raising alarm in emergency situations

6.2 Documentation & Communication

Prior to work start the following documentation must be generated and reviewed:

 Permit to Work, as specified by the client

 Client specific Risk Assessment or Job Step Analysis, with Cosasco personnel input
 SAFR Location Sheet
 Personnel competency certificates

A toolbox talk will be performed by the Cosasco Technician, including but not limited to the
following:

 The main steps involved in the job

 Equipment to be used
 Review of work permit and risk assessment
 PPE required
 Means of communication with Control Room personnel
 Actions to be taken in the event of an emergency
 Control room is aware of work party location
 All personnel involved with the work are aware of all control measures and are
competent to be involved in the work
 Work party are aware of any other work taking place in close proximity to worksite
 Any additional hazards identified during this talk should be reviewed and control
measures implemented

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Cosasco® Retractable System (Low Pressure) by Hand Work Instruction P/N: 741060revH
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6.3 Worksite Checks

Upon completion of the steps in section 6.1 & 6.2 final checks should be made at the worksite
prior to work starting, as follows:

Worksite
 Ensure any scaffolding to be worked on is certified
 Check previously identified escape routes are still clear
 Test means of communication with control room
 Double check PPE is in good condition and fit for purpose
 Identify any other work parties in proximity work location

All equipment including Retractor Kit, hand tools and corrosion monitoring equipment is to be
inspected pre-job to ensure it is fit for purpose and in good working order.

WARNING If a situation arises during the execution of this Work Instruction, which
requires a deviation, then an approved Job Step Analysis will be required
before continuing with the operations at the monitoring location concerned.
The JSA must be approved by Cosasco and by the Operator of the site before
proceeding with the deviation. Site specific work permit policies should be
followed to ensure site management are fully aware of the deviation to the
standard procedures. No further steps may be taken at the monitoring
location concerned until this is completed. Work may proceed as per the work
scope at the next applicable monitoring location whilst the JSA is reviewed
and issued for approval.

7 RETRACTABLE SYSTEM CONSTRUCTION & PREPARATION

1. A 1’’ minimum full port access valve must be used with a minimum bore of 0.95” and a 1”
NPT nipple for mounting to the stuffing box. This nipple should be sized appropriately to
ensure clearance of the fully retracted probe when closing the access valve.
2. All probes/devices (here after referred to as ‘probes’) must have a mechanical stop
(velocity shield or stop ring) installed. The mechanical stop ensures that the probe
cannot be removed from the stuffing box while online (under pressure).

NOTE:
A safety clamp kit assembly and retractor are required when pressures are in excess of 150psi
and/or above temperatures of 150ºF.
The 3/8” threaded rods on the safety clamp assembly must be sized prior to using the retractor
tool to allow sufficient mounting clearance.

In the event of the Retractor Tool being used any threaded rod in excess of 1’’ past either
end of the safety clamp jam nuts, at the position of desired insertion, must be cut off.

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Cosasco® Retractable System (Low Pressure) by Hand Work Instruction P/N: 741060revH
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8 INSTALLATION OF MONITORING DEVICE

ACCESS VALVE & STUFFING BOX INSTALLATION

1. Assemble the access valve and nipples (if not already installed). A 1’’ female NPT
connection is provided on the stuffing box body to mate with the thread on the access
valve outlet nipple.

2. The Access Valve should be closed.

3. If a safety clamp kit assembly has been installed. Remove the outer two jam nuts closest
to the probe connector end.

4. Loosen the 1’’ hex locking nut and the 1-1/2’’ hex stuffing nut BUT DO NOT REMOVE.

5. To prevent personal injury always keep your head and body out of the line of fire above the
end of the monitoring device.

6. Slip the stuffing box assembly as far forward as possible (towards the shielding/measuring
element, quill or coupon end) to fully retract the device.

7. Apply thread sealing compound or PTFE tape to the threads of the access valve outer
nipple.

8. Mount the stuffing box assembly onto the access valve outer nipple and tighten 2-3/4 to 3-
1/4 turns past hand tight. (Normal thread engagement to make a tight joint is 0.66’’)

9. Tighten the 1-1/2’’ hex stuffing nut HAND TIGHT.

10. To insert the device, ensure the access valve is fully open. If any pressure is leaking pass
the packing up the device shaft, tighten the 1-1/2” hex stuffing nut until the leak stops. Be
sure to only tighten until leak stops. Over tightening at this time will prevent you from
inserting your device. The 1’’ hex locking nut should be loose at this point. Slightly back off
1-1/2’’ hex stuffing nut (if necessary) until the device can be gently pushed by hand to
desired position. Once in the required position, tighten up 1-1/2’’ hex stuffing nut and lastly
tighten up 1’’ hex locking nut.

11. Install the safety clamp kit assembly.

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Cosasco® Retractable System (Low Pressure) by Hand Work Instruction P/N: 741060revH
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9 RETRACTION OF MONITORING DEVICE

1. If a safety a clamp is fitted loosen and remove the top two 9/16’’ hex nuts from the safety
clamp closest to the probe end connector then remove the safety clamp stud opposite
the safety cable to allow access to 1-1/2’’ & 1’’ nuts.
2. Apply hand pressure to the top of the device but keep your head and body out of the line
of fire above the end of the monitoring device.
3. Loosen the 1’’ hex locking nut until it can be turned freely. Loosen the 1-1/2’’ hex
stuffing nut until the probe can be retracted smoothly through the access valve till the
mechanical stop (on device end) reaches the stuffing box or the safety cable on the
safety clamp is completely extended. When this has been achieved then the valve can
be closed.

WARNING Do not loosen the 1-1/2” hex stuffing box nut or 1” hex locking nut until
you apply slight hand pressure on top of the monitoring device. Be sure
to keep your head and body out of the line of fire above the end of the
monitoring device. Always wear gloves and proper PPE during this
operation.

4. Remove the device by turning the stuffing box counter clockwise with a 2-3/8’’ wrench.
Slight pressure bleed off may be experienced at this point.

10 REPLACEMENT OF STUFFING BOX SEALS

1. If a safety clamp is fitted then remove 9/16 nuts and bolts.

2. Remove top safety clamp plate by turning plate anticlockwise over threaded (probe /inj.
tube/coupon holder end.
3. Slacken off hex locking nut then slacken off hex stuffing nut.
4. Unscrew the stuffing body completely off the stuffing nut exposing the Teflon seals.
Remove the circlip off the probe w/ S type connector/inj. tube/coupon holder shaft end.
For probes w/ A or B type connectors remove the shield or stop ring on element end.
5. Remove packing assembly.
6. The seals can now be installed/replaced.
7. When replacing new glass filled Teflon seals ensure that the new seals are replaced in
same order and direction as the seals that have been removed.

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Cosasco® Retractable System (Low Pressure) by Hand Work Instruction P/N: 741060revH
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8. After seals have been replaced, re-assemble stuffing box and probe/inj. tube/coupon
holder in the reverse order. Be sure to re-install all parts prior to putting back in service.

Note: Please ensure you have the latest revision of this document by downloading it from our website or by contacting Cosasco Customer Service.
NOTES
Cosasco  [email protected]  www.cosasco.com
CHECKMATETM
Reference Manual

Cosasco
11841 Smith Avenue
Santa Fe Springs, CA 90670
Tel: (562) 949-0123 P/N 723600-Manual Rev C
Fax: +1 (562) 949-3065 www.cosasco.com
 © 2005 Rohrback Cosasco Systems, Inc. All rights reserved.

CHECKMATE™ is a trademark of Rohrback Cosasco Systems, Inc.

CORROSOMETER® and CORRDATA® are registered trademarks of Rohrback

Cosasco Systems, Inc.

Windows® is a registered trademark of Microsoft Corporation.

No part of this manual may be reproduced or transmitted in any form or by any

means, electronic or mechanical, including photocopying and recording, for any
purpose, without the express written permission of Rohrback Cosasco Systems,
Inc.

Page No. Rev Date Description of Change Issue Reviewed Approved

- - 20.Jan.06 Initial Release - - -

- A 18.Nov.08 Re-drawn & updating Manual K.C D.P D.P

- B 27.Apr.15 Update manual format & images K.R D.P D.P

- C 19.Mar.19 Updated format, removed appendix A B K.R D.P D.P

 TABLE OF CONTENTS i

Table of Contents
Chapter 1 Introduction ................................................................................1

Chapter 2 Specifications ............................................................................3

Chapter 3 Installation ..................................................................................5

Chapter 4 System Configuration ................................................................9

Chapter 5 Reading Probes ........................................................................13

Chapter 6 Custom Probe Configuration ..................................................25

Chapter 7 Displaying Data ........................................................................29

Chapter 8 Transfering Data to the PC ......................................................31

Chapter 9 Quick Troubleshooting Guide .................................................33

ii CHECKMATE™

Figures and Tables

Figure Page
1.1 CHECKMATE™ Instrument .................................................2

3.1 CHECKMATE™ Battery Cover..............................................7

4.1 CHECKMATE™ Function Keys .............................................9

Table
5.1 Electrical Resistance Probe Types and Spans....................23
 INTRODUCTION 1

Introduction CHAPTER 1

The CheckMate™ is the next evolution in handheld corrosion monitoring instruments. It

is capable of reading all Corrosometer® (electrical resistance) corrosion probes with an
enhanced resolution of 0.1 probe divisions (0.01% probe span). The CheckMate™ also
features a reduced measurement cycle while still maintaining high accuracy. As with its
predecessors, this portable unit has built-in memory that stores readings for later retrieval,
however the CheckMate™ can store readings for up to 204 individual probes, with 10
readings per probe. Furthermore, the CheckMate™ makes transferring its stored data to
a PC a much simpler process than before, using the included Corrdata® CSV program.
2 CHECKMATE™

4.3” 2.0”

3.00”

7.75”

3.1”

20” MIN
80” MIN

Figure 1.1 CheckMate™ Instrument

 SPECIFICATIONS 3

Specifications CHAPTER 2

CheckMate™ Instrument

Physical
 Dimensions: 7.75”H x 4.30”W x 2”D ( 196.8 mm x 109.2 mm x 50.8 mm )
 Weight: 1.5 lb. ( 0.68 kg )
 Temperature range:
Operating - 0oF to 122oF ( -18oC to 50oC )
Storage - 0oF to 150oF ( -18oC to 70oC )
 Splash-proof enclosure with sealed membrane keyboard

Electrical
 Compatible with all ER probes
 Measurement resolution: 0.1 probe divisions
(0.01% of probe span)
 Measurement repeatability: ± 1 division
(0.1% of probe span)
 Rapid measurement cycle of 30 seconds
 Memory for up to 204 probes (with 10 readings per probe)
 Reads probes on extension cable of up to 200ft (61m)

 Power Supply: 6 AA Alkaline cells

 Battery Life: 900 probe readings (typical)
4 CHECKMATE™

 Automatic power shutoff in 2 minutes after reading or non-use

 Four Line Liquid Crystal Display (LCD)
 Supplied with:
 ER test probe
 6 AA batteries
 CheckMate™ to computer cable (including DB25 to DB9 adapter)
 CD-ROM with Corrdata® CSV PC software and manual
 INSTALLATION 5

Installation CHAPTER 3

NOTE: Each CheckMate™ instrument is carefully tested, inspected and

packaged prior to shipment. Before unpacking the instrument, please
inspect the packaged materials for shipping damage and retain all damaged
packaged materials to support any claim against your freight carrier should
this become necessary.

Unpacking

Carefully remove the instrument from its package. Included in the package you
should find:

CheckMate™ Instrument

 Handheld CheckMate™ instrument

 ER test probe
 6 AA batteries
 CheckMate™ to computer cable (including DB25 to DB9 adapter)
 USB with software and manual
6 CHECKMATE™

Battery Installation

The CheckMate™ is supplied with a set of six 1.5 Volt AA alkaline batteries.
To install these batteries, remove the access panel on the back of the unit
(see Figure 3.1) with the provided Allen Key and install the batteries with the
polarities as indicated on the unit.
 INSTALLATION 7

Battery Cover

Figure 3.1 Battery Cover of CheckMate™ Instrument

A secondary, back up battery for stored readings in the CheckMate™ is

provided by lithium batteries mounted internally within the unit. These
batteries should provide 7-10 years of back up capacity. Replacement of
these batteries requires the unit to be returned to Cosasco or an authorized
dealer.
8 CHECKMATE™

To check that the unit is operational, press the ON button. The screen should appear as
shown below:

If the batteries are low or in need of replacement, a warning screen will appear as
follows:

If batteries are good, the instrument will sequence directly to the Standby display as
below:

The battery is tested both at initial switch on, and during probe measurement.
 SYSTEM CONFIGURATION AND SETUP 9

System Configuration and Setup CHAPTER 4

CheckMate™ Keypad

The CheckMate™ features a 34-key keypad, with keys for the alphabet A through Z and
numerals 0 through 9. The numerals are shared with letters F through P and S. Switch
between these letters and the numbers using the “Alpha/Numeric” key. There are also
four soft keys, F1 through F4 (as shown below). The soft keys are multi-function keys
used to make on-screen selections.

Figure 4.1 CheckMate™ Function Keys

Setting the Time and Date on the CheckMate™

The CheckMate™ has its own clock so that individual probe readings are automatically
time and date stamped.

To set the internal clock for Time and Date:

From the Standby display, press SetUp (F4) to go to the Mate Configuration display:
10 CHECKMATE™

Press Set Mate (F3) to go to the Mate Settings display:

Press Set Time (F2) to go to the Mate Clock Set To display:

Press Set (F2) to go to the Set Mate Date & Time display:

From the keyboard, enter the last two digits of the year followed by the number of the
month followed by the date followed by the time in hours followed by the time in minutes
followed by 00. When the time is set correctly, press Enter to start the clock. To update
the clock on the Mate Clock Set To display, press Read (F1). Press Exit to go to the
Mate Settings screen. Press Exit again to return to the Mate Configuration screen.
Press Exit again to return to the Standby screen.

NOTE: The hour is set on the military 24 hour clock, where 00:00
hours is midnight at the start of the day, and 12:00 is mid-day.
 SYSTEM CONFIGURATION AND SETUP 11

Setting the Engineering Units

To set the Engineering Units:

From the Standby display, press SetUp (F4) to go to the Mate Configuration display:

Press Set Mate (F3) to go to the Mate Settings display:

Press Set Units (F1) to go to the Set Metal Loss Units display:

Select and press Mils (F1) for mils (0.001”) and mils/year or press mm (F2) for millimeters
and mm/year or um (F3) for micrometers and um/year.

After the selection is made and correctly displayed on the display, press Exit to set the
units and return to the Mate Settings display. Press Exit again to return to the Mate
Configuration display. Press Exit again to return to the Standby display.
12 CHECKMATE™

Clearing Memory on CheckMate™

Normally it will not be necessary to clear the memory on the CheckMate™

unless extraneous entries have been made, for example, when initially
experimenting with the system. Alternatively, if the equipment is to be
transferred to a new location, then it is recommended to clear the memory
to avoid confusion with any previously collected data. To clear the memory,
proceed as follows.

From the Standby display, press SetUp (F4) to go to the Mate Configuration display:

Mate Configuration

Man Set _
Conf Mate Exit

Press Set Mate (F3) to go to the Mate Settings display:

Mate Settings

Set Set Clr

Units Time Mem Exit

Press Clr Mem (F3) to go to the clear memory confirmation screen:

WARNING!

This will ERASE all

Of the Mates Data!

Clear Abort

Press Clear (F1) to clear all memory.

Note: this will clear readings stored in internal memory.

 READING ER PROBES 13

Reading Electrical Resistance Probes CHAPTER 5

Electrical Resistance probes can be read using three different procedures: Quick, ID and
New.

The Quick reading allows the user to read a probe and view the result in approximately 30
seconds. The result of a Quick read can also be saved for future reference, calculation
of corrosion rate and/or downloading to a PC.

To do a Quick read-

From the Standby screen, press Read (F1) to go to the What To Read? Display:

Press Probe (F1) to go to the Read Probe By display:

14 CHECKMATE™

Press Quick (F2) to go to the Select Probe Type display:

Select and press A (F1) for Wire Loop type probes or press B/C (F2) for Tube Loop/
Strip Loop type probes or D (F3) for Cylindrical type probes or G (F4) for Model 610
Atmospheric Probes only. If you are unsure of the element type, this information can be
found on the probe packaging, etched on the probe body adjacent to the connector or in
Table 5.1 Probe Type Identification.

Immediately after pressing the key for the probe type selection the instrument will
automatically go to the “Measure” mode and display:

A series of > symbols will accumulate from left to right across the display to indicate
the progression of the measurement function At the conclusion of the measurement
function (approximately 30 seconds) the CheckMate™ will display the probe reading and
the check reading in divisions. A typical displayed reading is shown below:

The Div: reading is the cumulative metal loss (corrosion) of the probe element on a scale
of 1,000 divisions. In the example above 214.7/1000 (two-hundred fourteen point seven
one-thousandths of the element has been consumed by corrosion. In engineering units
this metal loss would be expressed as 214.7/1000 or 0.2147 times the probe span.
 READING ER PROBES 15

The Chk: reading is a measure of probe functionality or integrity. The initial value for
ER probes is 800 ±50 divisions. It is recommended that a CHECK reading be taken
and recorded immediately after unpacking a probe as it will be the value to which all
subsequent CHECK readings will be compared. The general rule is that the CHECK
reading should not vary by more than 1% (±10 divisions) from the initial value. If there is
more than a 1% change, it is an indication of a loss in probe integrity and replacement is
required.

To reread the probe, press the Read (F1) key and another reading will be taken and
displayed.

If the reading is to be saved in memory for later viewing, for corrosion rate calculation or
for downloading to a PC the following procedure should be followed:

Press the Save key to go to the Enter Probe Span display:

From the keypad, enter the span of the probe element in mils. The span in mils is shown
on the probe packaging or it can be found in Table 5.1. Note: If Type G for the Model 610
Atmospheric Probes is selected, the span is entered in Angs (Angstroms).

Pressing Clear (F2) will clear the value previously set so that a new span can be entered.
Pressing BkSp (F3) backs up one space each time it is pressed so that a change can be
made. Pressing Exit (F4) returns to the Read Probe By display.

Press Enter to go to the Enter Probe ID display:

16 CHECKMATE™

The instrument will automatically assign the next free ID number. If this is not acceptable
you may press Clr (F2) and manually assign an ID from the keypad. Pressing BkSp (F3)
backs up one space for each time it is pressed so that a change can be made. Pressing
Exit (F4) returns to the Read Probe By display.

Press Enter (F1) to go to the Enter Probe Tag display

Note: If an invalid ID has been selected, the Invalid ID display appears:

Press Try Again (F1) to return to the Enter Probe ID display. Pressing Exit (F4) returns
to the Read Probe By display.

Note: If the ID selected has already been configured, the This ID Already Configured
display appears:

Press Cont (F1) to continue to the Enter Probe Tag display if you want to continue to
use this ID number.

Press Try Again (F1) to return to the Enter Probe ID display. Pressing Exit (F4) returns
to the Read Probe By display.

Enter Clr BkSp Exit

 READING ER PROBES 17

The Enter Probe Tag display allows the user to enter up to twelve (12) alpha or numeric
characters to uniquely identify the monitoring location. This can be a Tag No., location or
process name.

Pressing Clr (F2) clears a previously entered ID. Pressing BkSp (F3) backs up one
space for each time it is pressed so that a change can be made.

Pressing Exit (F4) returns to the Read Probe By display.

Press Enter (F1) to go to the Enter Probe Alloy display:

The Enter Probe Alloy display allows the user to enter up to eight (8) alpha or numeric
characters to identify the alloy of the probe element for reference purposes only. It does
not affect the calculation of corrosion rates.

Pressing Clr (F2) clears a previously entered ID. Pressing BkSp (F3) backs up one
space for each time it is pressed so that a change can be made. Pressing Exit (F4)
returns to the Read Probe By display.

Press Enter to go to the Probe Reading Saved display:

Where XXX is the ID of the location and XXXXXXXXXXXXXX is the Probe Tag.

Press Exit to return to the Read Probe By display.

18 CHECKMATE™

To read a probe by ID-

Press ID (F1) to go to the Enter ID> < 51-255 display:

Enter the ID number of the probe and press Enter (F1)

The CheckMate™ will check the ID number to determine its validity. If the ID is valid, the
Connect To Probe display will appear. If the ID is found to be invalid, the ID Not Found
message will appear and the Exit key should be pressed to return to the Taking Probe
Reading display.

After connecting the CheckMate™ to the probe, press the Start key to begin the
measurement function and the Taking Probe Reading screen will appear

Pressing the Exit key will return to the Read Probe By screen:
 READING ER PROBES 19

A series of > symbols will accumulate from left to right across the screen to indicate the
progression of the measurement function At the conclusion of the measurement function
(approximately 30 seconds) the CheckMate™ will display the probe reading, the current
check reading and the initial check reading in divisions. The initial check reading in
divisions will be shown in parenthesis (). A typical display is shown below:

where 273.4 is the Metal Loss reading in divisions, 812 is the present Check reading in
divisions and (813) is the initial Check reading in divisions.

Pressing the Read (F1) key will return to the Taking Probe Reading display and
automatically start a new measurement cycle. Press the Save (F3) to go to a display that
allows the user to save the readings by pressing the Yes (F1) key which will go directly to
the Probe Reading Saved display which is explained below or pressing the No key will
discard the reading and return to the Read Probe By display. Press the More (F2) key
to go to the MLoss and Rate display:

The cumulative metal loss, MLoss, in the engineering units originally selected will be
displayed and the corrosion rate between the previous probe reading and the present
probe reading will be automatically calculated. The corrosion rate, Rate, will be displayed
in the engineering units originally selected per year.

Example: A T10 ER probe (span 5 mils) was installed in a refinery overhead system on
March 1, 2004. The initial probe reading of 97.3 divisions and check reading of 813 was
made on March 1, 2004. On March 30, 2004, the probe was again read and the results
were as shown in the typical display above, i.e. Div: 273.4 and Check: 812. The corro-
sion rate calculated between these two measurements would be equal to 10.7 mpy (mils
per year).
20 CHECKMATE™

The display for the example above would show:

Press Save to go to the Probe Reading Saved display:

The present probe reading will be saved with the ID number and Tag Number as displayed.
Pressing the Exit key will return to the Read Probe By display for reading of other probes.

To read a New probe

Press New to go to the Select Probe Type display

The probe type selections are W80 WIRE, W65 WIRE, W45 WIRE, W40 WIRE, TF50,
TF5, T50 CYLINDRICAL, T20 CYLINDRICAL, T10 CYLINDRICAL, T8 TUBE LOOP, T4
TUBE LOOP, S50 FLUSH, S40 FLUSH, S20 FLUSH, S10 FLUSH, S8 STRIP LOOP, S8
FLUSH, S4 STRIP LOOP, S4 FLUSH, S4 ATMOSPHERIC, OTHER and TEST PROBE
CO. You may scroll up through the list by repeatedly pressing the Up (F2) key or down
through the list by repeatedly pressing the Down (F3) key. When the probe element
selection is displayed, press the Enter (F1) key to accept the selection. The CheckMate™
will automatically proceed to the next display based on the selection.

If a standard ER probe (element) is selected, the CheckMate™ will

automatically go to the measure mode and the Taking Probe Reading – Please Wait
display will appear:
 READING ER PROBES 21

A series of > symbols will accumulate from left to right across the screen to indicate the
progression of the measurement function. At the conclusion of the measurement function
(approximately 30 seconds) the CheckMate™ will display the probe Metal Loss (MLoss:)
in the engineering units originally selected, the in divisions (Div:) and the current check
reading (Chk:) in divisions. A typical display is shown below:

If a TF5 or TF50 high sensitivity atmospheric ER probe has been selected, the Check-
Mate™ will go to a special Enter Probe Span display:

Using the numeric portion of the keypad, enter the probe span in Angstroms (Ǻ). The
packaging for the TF5 and TF50 ER provides the specific span for the probe. Alterna-
tively, the nominal span can be used without appreciable error. Pressing Enter (F1) will
cause the CheckMate™ to automatically go to the measure mode and the Taking Probe
Reading – Please Wait display will appear:
22 CHECKMATE™

A series of > symbols will accumulate from left to right across the screen to indicate the
progression of the measurement function At the conclusion of the measurement function
(approximately 30 seconds) the CheckMate™ will display the probe Metal Loss (MLoss:)
in angstroms, the reading in divisions (Div:) and the simulated check reading (Chk:) of
800 divisions (TF5 and TF50 high-sensitivity probes do not provide a check reading). A
typical display is shown below:

If OTHER is selected from the probe type selections on the Select Probe Type display
the CheckMate™ will go to a second Select Probe Type display that allows the select
the specific probe element conversion equation required and enter specific probe spans
(in mils) that may be special. The display is shown below:

Select and press A (F1) for Wire Loop type probes or press B/C (F2) for Tube Loop/Strip
Loop type probes or D (F3) for Cylindrical type probes. If you are unsure of the element
type, this information can be found on the probe packaging, etched on the probe body
adjacent to the connector or in Table 5.1 Probe Type Identification.
 READING ER PROBES 23

ER or TEMPERATURE Type Span

Probe Element (mils)
Strip Looop S4 C 1
Flush Element S4 B 2
Atmospheric Element S4 D
Strip Loop S8 C
Tube Loop T4 B
Flush Element S8 B 4
Atmospheric Element S8 D
Tube Loop T8 B
Flush Element S10 B 5
Cylindrical Element T10 D
Flush Element S20 B 10
Cylindrical Element T20 D
Wire Loop Element W40 A
Wire Loop Element W45 A 11.25
Flush Element S40 B 20
Wire Loop Element W80 A
Cylindrical Element T50 D 25
Table 5.1 ER and Temperature Probe Types and Spans

CAUTION: ER Model 2500, 3500, or 4500 probes are designated as a

“cylindrical” element, not a “tube” element which refers only to “tube
loop” elements.
24 CHECKMATE™
 READING ER PROBES 25

Custom Probe Setup CHAPTER 6

Probes may also be configured manually by following the procedure below:

From the Standby display, press SetUp (F4) to go to the Mate Configuration display:

Press Man Conf (F1) to go to the Enter Probe ID display:

Enter a number between 51 and 255 and press Enter (F1) to go to the Enter Probe
Tag display.

Note: If an invalid ID is entered, it is automatically cleared upon pressing Enter (F1).

Note: If the ID selected has already been configured, the This ID Already Configured
display appears:
26 CHECKMATE™

Configured

Try _
Cont Again Exit

Press Try Again (F2) to return to the Enter Probe ID display or Cont (F1) to continue to
the Enter Probe Tag display and reconfigure the ID. Pressing Exit (F4) returns to the
Mate Configuration display.

In the Enter Probe Tag display, enter up to twelve (12) alpha or numeric characters to
uniquely identify the monitoring location. This can be a Tag No., location or process
name. Pressing Clr (F2) clears a previously entered ID. Pressing BkSp (F3) backs up
one space for each time it is pressed so that a change can be made. Pressing Exit (F4)
returns to the Mate Configuration display.

Press Enter (F1) to go to the Select Probe Type display:

The probe type selections are W80 WIRE, W65 WIRE, W45 WIRE, W40 WIRE, TF50,
TF5, T50 CYLINDRICAL, T20 CYLINDRICAL, T10 CYLINDRICAL, T8 TUBE LOOP, T4
TUBE LOOP, S50 FLUSH, S40 FLUSH, S20 FLUSH, S10 FLUSH, S8 STRIP LOOP, S8
FLUSH, S4 STRIP LOOP, S4 FLUSH, S4 ATMOSPHERIC, OTHER and TEST PROBE
CO. You may scroll up through the list by repeatedly pressing the Up (F2) key or down
through the list by repeatedly pressing the Down (F3) key. When the probe element
selection is displayed, press the Enter (F1) key to accept the selection

If a ER probe (element) is selected, the CheckMate™ will automatically proceed to the

Enter Probe Alloy display:
 READING ER PROBES 27

The Enter Probe Alloy display allows the user to enter up to eight (8) alpha or numeric
characters to identify the alloy of the probe element for reference purposes only. It does
not affect the calculation of corrosion rates.

If a TF5 or TF50 high sensitivity atmospheric ER probe has been selected, the CheckMate™
will go to a special Enter Probe Span display:

Using the numeric portion of the keypad, enter the probe span in Angstroms (Ǻ). The
packaging for the TF5 and TF50 ER provides the specific span for the probe. Alterna-
tively, the nominal span can be used without appreciable error.

If OTHER is selected from the probe type selections on the Select Probe Type display
the CheckMate™ will go to a second Select Probe Type display that allows the select
the specific probe element conversion equation required and enter specific probe spans
(in mils) that may be special. The display is shown below:

Enter A for Wire Loop type probes or enter B or C for Tube Loop/Strip Loop type probes or
enter D for Cylindrical type probes. If you are unsure of the element type, this information
can be found on the probe packaging, etched on the probe body adjacent to the connector
or in Table 5.1 Probe Type Identification.
28 CHECKMATE™

Pressing Enter (F1) will go to the ID Configured display:

 DISPLAYING DATA ON THE CHECKMATE™ 29

Displaying Data on the CheckMate™ CHAPTER 7

Probe reading data can be displayed on the CheckMate™ either by the probe currently
attached or by ID. The data includes the Tag ID, Metal Loss, Corrosion Rate, Divisions
and Check Readings.

From the Standby screen, press Disp (F2) to go to the Display Data By display:

Press Curr Probe (F1) to go directly to the current probe display or press ID (F2) to
select the probe by ID.

Press More (F1) to go to the second screen of information:

30 CHECKMATE™

Press More (F1) one more time to go to the third screen of information:
 TRANSFERRING DATA TO THE PC 31

Transferring Data to the PC CHAPTER 8

Probe reading data is downloaded to the PC using the CheckMate™ to PC program,

Corrdata® CSV. It is a simple, Windows compatible program that allows fast download of
data stored in the CheckMate™ to a Comma Separated Value (CSV) file. This file can
then be opened with Excel or another comparable spreadsheet program.

Installation

The Corrdata CSV program can be found on the CD-ROM included with the instrument.
Insert the auto run CD-ROM and follow the on screen instructions to install. The default
installation directory is C:\Program Files\RCS\Corrdata CSV.

Configuring Corrdata CSV

When installation is complete, click on the Start Menu to launch the program. Click on the
Select menu, then Data Directory to choose the location for where to save the CSV files.
Next, from the Select Menu, place a check next to the COM port to be used.

Connect the CheckMate™ to the PC

Connect the CheckMate™ instrument to the 9 pin COM port on the back of the PC using
the provided cable. Make sure this is the same COM port as selected previously (in most
cases this will be COM 1, however verify this in device manager).

Now click on the large button: “Get CHECKMATE Data and Make Excel (CSV) Files.
Click OK on the window that appears next.
32 CHECKMATE™

CheckMate™ Procedure

From the Standby screen of the CheckMate™, press Dump (F2) to go to the Start
Dump display:

Press Start (F1) to begin downloading data to the PC.

The CSV files are saved by tag number and ID in a folder called DataFiles under the
directory created previously. They may be opened using Excel or a similar spreadsheet
program.

If the CheckMate™ is not connected to the PC properly, or the PC is not running Corrdata
CSV, the following screen may be displayed.

Make sure that Corrdata CSV software is running, that the correct COM port is checked
in the Select menu, and that the CheckMate™ is connected to that COM port using the
supplied cable.

If data is still not transferred after checking the connection between the PC and
CheckMate™, please see the Troubleshooting section (Chapter 9) for further help.
 TROUBLESHOOTING GUIDE 33

Troubleshooting Guide CHAPTER 9

Symptom Problem Solution

CheckMate™ will not turn on. Batteries not installed. Install batteries (see Chapter 3)

Battery voltage low. Install new batteries.

Batteries installed incorrectly. Check the polarities as indicated

on the unit.

CheckMate™ turns off before 2 Battery voltage low. Install new batteries.
minutes auto shutdown.

CheckMate™ will not transfer Corrdata CSV is not running. Launch Corrdata CSV from the
data to the computer. Start Menu. Click the Get Data
button and then OK.

Cable is not connected properly. Check that the cable is fully

plugged into CheckMate™ and
that the other end is fully plugged
into the 9 pin serial port on the
back of the PC.

Check that the COM port

selected in Corrdata CSV is the
actual COM port to which the
CheckMate™ is connected.

CheckMate™ not reading probe. No probe connected to Connect probe to CheckMate™

CheckMate™
34 CHECKMATE™