Hydrosteel 7000 Manual V3.1
Contents
1. NOT NEL GL dn ae Na TUNES 4 38 GINOHS 310H V ESTE ES E EE E EE 6 hM DH ES oj ff S310H SW l E NIXIJ 1349VN8 3803d4 MINE SI 3NOVA NOILONAP QG31V1 SNI 7 HIV3HS TVLIW MO ONISN HARTING uugosSsxrg IdNOQOWYSHL G3LNNOW 380d S 1V SIVAYSLNI AVINDAY IV LINGNOO OL 1109 SW 093 SdHo3 d SINANSYNSVAW XNT3 10 AHL S3AOSdWI NOlILOJ3IOdd YSHLVAM IVILNASSSA SI NOILVIASNI ONIGGVIO Q3NOTIVL lt NMON SI HLONAT Q33I0n038 JONO SOIO3NNOO G4LVNINdAL LINGNOO NOILVIASNI Q Q3NOILISOd2. 37 Hydrosteel 7000 unit 37 Probe instalation 37 Fault finding and CAN SS EET EIE 38 TI 38 B eeie ce Q 39 Technical specifications UFANFFSXNNN UN FEES PE E XE SI MEVS REGUM RU RA 40 Instrument warranty and ba NUMEN 42 riga m R G 42 vicc Y O H 42 o 1 c E danas 42 Manual e n 43 Unrivalled Detection Page 4 of 43 WWW lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Statements Responsibility for Use Hydrosteel 7000 flux monitor for permanent installation provides flux readings that are subject to interpretation lon Science Ltd can accept no responsibility for the incorrect use that
3. 28 ji ee 30 IPETON ES 30 PANY p 31 FEY COS UCC SUN eet a easter rete erecta cient aw seinen see mms 32 S oe 32 Fux A ZO MIA c 32 QUO a mene eee ee non een eee eee ee Ce S ee ee eee eee 32 Hydrosteel 7000 PC SOmWaNe annen ae 33 Installation of Hydrosteel 33 Connecting to the Hydrosteel 7000 33 1 34 nee nee en eee eee ee ee eee 34 LADIES opa zio senes T E E Rm 35 CNA TENERLO o omm 35 EET mm 36 MSME SSNS een ener en Se eee ee ee eee eee 36 Maintenance ANG calibration
4. INAWHOVILVY JIdNOQOWSSHL JILINOVAR SNOILOANNOO YAMOd H04 531979 01 GALVNINASL SOM d 3344 ONIQQVIO X3ANN anis ONITI3AVML M31VM IN3A3Md OL SNOILO3S 3HOMd JHL OL W901 NOILVINSNI 5 OL 5 38 GINOHS 1V3S ANY dvd 1nd1no 43M0d uu vede cs me AVANVW JO SNOILOZS 3lViMdOMddV 31V21411432 3dAL 23 01 Y34394 SN313AVMVd AL3JVS OISNIMINI 304 acme AVANVW 40 NOIL23S TVOINHOAL NI ONIMVNG TWOINVHOAW 33S SINIOd ONILNNOW SNOISN3MIQ 304 NVYOVIG ONIMIM 33S ONIMIM AVANVW JO NOILO3S 1VOINHO3L 33S S39VI1OA AlddnS Q31 33MOd N3339 SILON 1SnvHX3 Q31 Wsuv1v G39 NOILO3NNOO ZZS SINIOd ONILNNOW AYVAWAS NOILLVIIVISNI QW e Page 8 of 43 WWW IOnscience com Unrivalled Detection C Hydrosteel 7000 MANUAL lon Science Ltd Introduction to Hydrosteel 7000 Operation Cycle Hydrosteel 7000 o
5. junction box Blue Connector Thermocouple 4 e A SCREEN FA ov BK 4 20mA 2 AE MI M EW NE cc Red Connector p SCREEN i RD ze Rb f 1 OV BK BK 4 20mA 1 ae WARNING Non Intrinsically Safe Non IS applications When the unit is installed with a non IS rated power supply the IS details on the front of the unit are not appropriate for the system The 15 label should be covered up or blocked out This will prevent safety discrepancies and or mis use in the future should the equipment be moved or the site be re defined as a hazardous area Intrinsically Safe IS applications Entry parameters Unrivalled Detection Power receivers we v m Nw qe m qm qm eee P f f 5 2 4 20mA 1 4 20mA 2 For information only see safety certificate before installation www lonscience com Page 12 of 43 Hydrosteel 7000 MANUAL lon Science Ltd Installation lon Science Ltd suggest using the following or similar safety barrier IS isolator for IS approved applications The system must be designed by a suitably trained engineer and approved by the local safety authority Power Supply Suggeste
6. Power up 4 20 mA circuit 4mA should register on each circuit f any discrepancy from the above is encountered see fault finding and diagnostics in the Maintenance section Operation test Basic test 1 Allow the Hydrosteel to complete one measurement cycle 10 minutes from switch on If the green LED is continuously lit the power is confirmed as correct If the Green LED starts to flash then the power dropped below 15 V browned out during the measurement cycle and it has restarted See fault finding and diagnostics in the Maintenance section 2 the red LED illuminates a fault has occurred during the measurement cycle See fault finding and diagnostics in Maintenance section 3 Perform a data download Check that no diagnostics have failed during the first measurement cycle If any diagnostics have failed again please refer fault finding and Diagnostics in the Maintenance section 4 The flux reading can be correlated by using a Hydrosteel 6000 close to the Hydrosteel 7000 probe point Record a Flux reading on the hand over document 5 The pipe temperature can be correlated by measuring the temperature at the probe steel surface or by connecting the Thermocouple to a hand held thermocouple thermometer Record the first thermocouple reading on the hand over document Test if Hydrosteel function test is available 1 Disconnect the flux AT S probe and connect hydrogen flood leak sample conduit 2 Allow the Hydrosteel to complet
7. Hydrosteel 7000 Instrument User Manual V3 1 za 3 9 IStrur nder nent Must ct Protection Mounteg in ditions suit Mable 18J 2008 on e ence is a 08 04 259 8 Ur Www ig Register your instrument online to receive your extended warranty Unrivalled Detection Register your instrument online for extended warranty Thank you for purchasing your lon Science instrument The standard warranty of your instrument can be extended to up to five years on PhoCheck Tiger and two years on other lon Science instruments To receive your extended warranty you must register your instrument online within one month of purchase terms and conditions apply Visit www ionscience com instrument registration Part number 910228 C Hydrosteel 7000 MANUAL lon Science Ltd Declaration of conformity Manufacturer lon Science Ltd The Way Fowlmere Cambridge SG8 7UJ UK Product Hydrosteel 7000 Product Description a fixed continuous monitor for the measurement of Hydrogen flux through steel equipment The flux is used as indication of internal corrosion Hydrosteel 7000 is for use in Oil and Gas operations where H2S HF acid or high temperature corrosion are present With a 4 20 mA analogue output Hydrosteel 7000 can be simply integrated into a DCS control system t
8. When installed in a hazardous area the Hydrosteel 7000 must be powered from galvanic isolator safety barrier or IS power supply The power supply must meet operational and safety requirements In addition the power supply must not create a spark risk in conjunction with the power cable The specific cable parameters allowed will depend on the safety barriers use 4 20mA outputs The 4 20 mA outputs are 2 wire loop powered That is for operation in addition of a 4 20 mA receiver there must be a loop power source This source must be intrinsically safe or supplied through an appropriate safety barrier or galvanic isolator RS232 Connection Non hazardous Conditions Under non hazardous area conditions the RS232 port may be connected to a self contained battery powered computer containing 30 V or less This allows connection to most laptop computers Hazardous Conditions If the laptop is to be used in the hazardous areas local safety rules must be followed Often all that is required is a suitable permit and the use of an explosive gas detector to prove that the local area is safe at the time of download Under hazardous conditions this circuit must only be connected to a galvanically isolated intrinsically safe RS232 connection To summarise e Hydrosteel 7000 can be installed in zones 1 amp 2 the presence of most common industrial gasses e Safety barrier or isolator is required for the main power supply e Safety ba
9. OV Red Connector SCREEN 53 p p RD ES 4 20 1 0 i d d MOV BK 1 NZ SAFE AREA Unrivalled Detection Page 13 of 43 www lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Installation Use of Galvanic isolator and alternative grounding Galvanic isolators may be used instead of safety barriers in the above circuit If an isolated supply is used the supply at the instrument should be checked for AC noise Measure the AC voltage between the 0 V and the local earth If there is AC noise this needs to be removed It might be due to a faulty power supply or induction of AC onto the cables To remove the noise it might be necessary to ground the 0 to an earth point either in the control equipment or at the HY7K instrument For electrically noisy environments the optimum grounding is shown in the wiring diagram below is essential to follow the following key rules 1 Screens may only be grounded at one end 2 Power supply 0 V is grounded at the Hydrosteel then a suitable rated Galvanic isolator must be used Electrical connections IS using galvanic isolator and alternative grounding Hydrosteel 7000 Control equipment Pap be SCREEN 7 mu Capacito
10. and national safety and environmental requirements This includes the European WEEE Waste Electrical and Electronic Equipment directive lon Science Ltd offers a take back service Please contact us for more information Calibration Facility lon Science Ltd offer a calibration service including the issue of certification using equipment which are themselves traceable to UK national standards Legal Notice Whilst every attempt is made to ensure the accuracy of the information contained in this manual lon Science accepts no liability for errors or omissions or any consequences deriving from the use of information contained herein It is provided as is and without any representation term condition or warranty of any kind either express or implied To the extent permitted by law lon Science shall not be liable to any person or entity for any loss or damage which may arise from the use of this manual We reserve the right at any time and without any notice to remove amend or vary any of the content which appears herein Unrivalled Detection Page 5 of 43 www lonscience com Hydrosteel 7000 MANUAL i Packing list lon Science Ltd Please take a little time to check the contents in the Hydrosteel shipment before installation Item 1 2 3 4 5 6 Description Hydrosteel 7000 monitor This Manual Applications Manual Software CD Modem cable USB to RS232 adapter HY7K conduit kit consisting of Sample tube as
11. must be connected to the thermocouple cable in the conduit at the thermocouple junction box To maintain the continuity of the thermocouple screen EMC cables glands supplied must be used Clamp the thermocouple pot into the cable gland The internal conductive spring tabs will make electrical contact with the thermocouple sheath and the pot will be mechanically secured when the seal is compressed tight Please see photographs below that follow Unrivalled Detection Page 21 of 43 www ionscience com Hydrosteel 7000 MANUAL lon Science Ltd Installation If it has not already been terminated terminate the thermocouple conduit cable into the gland bend the screen wire back and jam it between the insert and the housing Please see the photographs below Connect the thermocouple wires using the terminals inside the junction box The thermocouple junction box is mounted onto the probe bracket so it is fixed in place when the bracket is fitted to the pipe cladding A ground connection should be made from the thermocouple bracket to the local earth for the purposes of screening This earth may be through the contact between probe bracket and cladding However if the cladding is electrically isolated or of a non conductive material an earth connection should be made directly to a stud on the probe bracket Fixing of sample conduit Use P clips 1 HF 02 and M5 screws or bolts not supplied to fix the conduit to appropriate refinery struct
12. vessel Note magnet orientation Thermocouple installation Care should now be taken to prevent the magnet from tugging the thermocouple lead The thermocouple is semi flexible and further care must be taken when handling to prevent damage by repeated flexing of the lead at a single point Max working temperature for magnets is 800 F 426 C The magnet thermocouple should be fitted so the magnet legs bridge across the pipe or vessel curve near the location of the mounted probe as illustrated below Once fitted the screw should be tightened using an Allen key until the thermocouple tip is pressed firmly against the steel as illustrated Care should be taken when doing this as excess tightening could crack the ceramic block Re insulation and cladding Weather shielding for the probe is essential to prevent water ingress blocking the sample flow and preventing operation This may be achieved by installing insulation and cladding with the use of sealing bungs or tape Alternatively a custom made cloche might be used for exposed pipes or where insulation is not needed lon science recommends that a short segment of insulation capped at each end is used to cover the probe See the diagram below Unrivalled Detection Page 18 of 43 www ionscience com Hydrosteel 7000 MANUAL lon Science Ltd Installation i The cladding joints and probe exit from the cladding should be sealed with a suitabl
13. 32 adaptor may be used 4 20 mA output for flux 4 20 mA output for pipe temperature Measurements Logged to memory Flux AT F probe to 2400 pl cm s 1 pl cm s 1090 at cal value Pipe temp 40 C to 615 C 2 C at cal value Internal temp 40 C to 125 C 1 C at cal value 0 to 60 ml min 0 1 ml min 5 at cal value 4 20mA output Detector Range Resoltio Accuacy 4mA 20m A 10mA Flux AT F probe 0 pl cm s 2400pl cm s 1 pl cm s 1090 at cal Value Pipe temp 500 C 2 C at cal value e Note Range output range is variables from 1 to 2400pl cm s and is selected using the Data Download Package Memory The memory will record approximately 18 months of data Once memory is full data is logged in a first in first out rolling cycle by memory sector Diagnostics e Operating temp 40 C to 60 C e 2 sensor Electrolytic conductivity e Flow 30 ml min 3 e Power alarm Insufficient supply voltage e Visual Alarm Via red LED on instrument e Transmitted alarm 3 5 MA on 4 20 mA outputs Log to memory Operating lifetime Pump 10 000 hr cumulative use Probe Dimensions Probe diameter Probe length 10 m 30 ft Probe head length 320 mm inc allowance for 90 bend Probe conduit diameter Probe conduit bend radius Probe fixing Banding for gt 4 up to 32 Magnets for large diameter pipes where banding not practical max working te
14. 51 23 OL 10 i EN BN E E o 2 ker S3LON 8E 2 I 38O ld 314n020W 3H L 1531 YAQNN LN3WdIno3 I EN OL Q3123NNO2 GE 21912313 SI 380 4 ILON V 38O ld OL 1201 H13V3 LNV1d ZNIN3332S 341123443 3Q1AO d OL 1201 OL 3123 2 38 LSNW 1504 H13V3 O OJ 939971 131205 3334 MOTA Q322v L i 3385 Na 4 7 39 FO O3 Naas T V q 939 1 MOTIAK 49399 1 eg Eo 9114 191205 13NYd ol e gt AO I AlddNS ania 932971 N3332 Q322v L M 13Nvd 131205 13Nvd y f 9 3n18 9399Y L E 133205 3334 991 4 uaeg 9 q31 lt wy poy n NOIL23NNO2 2 2Su 5 IO 0004 224S0upAH OJ y id t Ja A Y fuawdinba 0441002 upJboiq buiuoissiuuo2 9007 224S0UupAH Page 29 of 43 WWW lOnscience com Unrivalled Detection C Hydrosteel 7000 MANUAL lon Science Ltd Commissioning Start up Power up intrinsically safe circuit Green LED on Hydrosteel 7000 should light to show correct power is available to the unit the measurement cycle will start automatically
15. 7UJ UK Tel 44 0 1763 207206 Fax 44 0 1763 208814 Email info ionscience com Web www ionscience com Italian Office lon Science Italia Via Emilia 51 c 40011 Anzola Emilia Bologna ITALY Tel 39 051 0561850 Fax 39 051 0561851 Email info ionscience it Web www ionscience it Unrivalled Detection USA Office lon Science LLC 33 Commercial Drive Waterbury VT 05676 USA Tel 1 802 244 5153 Fax 1 802 244 8942 Email info ionscienceusa com Web www ionscience com Page 42 of 43 German Office lon Science Messtechnik GMBH Laubach 30 Metmann Neandertal 40822 GERMANY Tel 49 2104 14480 Fax 49 2104 144825 Email info ism d de Web www ism d de www lonscience com C Hydrosteel 7000 MANUAL lon Science Ltd Manual log Amendment PC Software Version updated Firmware Hydrosteel Update log added in back 01 7000 2 5 of manual Hydrosteel Page 12 Added Pipe 5 BE 7 01 7000 2 6 info Page 20 Letters overlapping sorted Certificates of conformity 7000 2 7 up dates after standards review on ARO8060 Hydrosteel Warranty added on cover 23 07 10 7000 V2 9 Declaration of conformity updated Contents updated Warranty and Service added page 42 Hydrosteel Pages 1 amp 4 updated to 03 03 11 7000 V3 0 correct Quality Management System Page 4 Responsibility of use updated and l
16. Diagnostic flag LL NL ML ML M K Data handling The software can create two file types HY7 and CSV The HY7 is specific to the HY7K PC package and cannot be opened by another software package The package is not designed to edit the data or provide any processing functionality The CSV file can be imported into spreadsheet packages such as Microsoft Excel for editing and performing detailed analysis In addition to the basic operations of open save and export the user can save file sections to a new file and merge files together Unrivalled Detection Page 35 of 43 WWW lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Hydrosteel 7000 PC software Save section A specific episode of flux in data can be saved on its own To save a section highlight the section on the graph with the mouse then select the Save Section As option from the file menu A save data as dialogue box will appear and ask for a file name and location to save the file Merging files This enables new data to be added to existing files so that a continuous data record is created Files may only be merged if they do not contain any overlapping data and are from the same instrument To merge two files open a file and then select merge from the drop down file menu This will prompt your to select the second file to merge Print options There are options to print and print preview the displayed gr
17. ameter Magnetic attachment to pipes or vessels of greater than 32 diameter Maximum temperature tolerance is 800 F 426 C Stand for large diameter very high temperature equipment HY7K analyser site identification The Hydrosteel 7000 probe must be installed within reach of the probe employing the 10m 32ft long sample conduit provided Allowance should be made for securing the conduit between the probe and analyser to cable trains or other suitable support means The Hydrosteel 7000 is housed in a tough glass reinforced polyester enclosure The lid RS232 connector cable glands and all fittings provide IP66 protection The unit may be installed in any location provided environmental limits defined in Technical Specifications are not exceeded The ideal location for the HY7K should be accessible without scaffolding So that it may be accessed for data downloads and servicing Unrivalled Detection Page 11 of 43 www lonscience com Hydrosteel 7000 MANUAL Installation lon Science Ltd Power and signal requirements Non Intrinsically Safe Non IS applications Input power 15 24 Volts 35mA 4 20 mA power 8 35 V dc 22mA The Hydrosteel is to be wired up as per the wiring diagram below Electrical connections Non IS Hydrosteel 7000 Yellow Connector p SCREEN Control equipment Sav RD 1 RD BK V Power Thermocouple
18. an to the bottom of the list using the scroll bar to find the 7K PC listing This is because Microsoft has a large number of blanked out entries in the middle that look like the list has ended when in fact they are just hidden 1 Double click the file called 7K PC setup exe located on the lon Science software CD 2 Follow the on screen prompts saving the software in a drive of your choice typically your C drive 3 Click on the 7K PC icon in the ISL directory to start the software This is found in the Microsoft start all programs menu On start up of 7K PC software a quick start menu appears with the most likely initial commands Open file Connect to Instrument Settings and Close e Open file Allows a file previously saved to the PC memory to be viewed e Connect to Instrument connects to the Hydrosteel 7000 for data download e Settings enables the user to select the coms port for connection to the instrument or search for a Hydrosteel 7000 instrument connected to one of the coms ports Setup of USB to RS232 coms port If the Lap top or PC does not have a dedicated coms port then the USB to RS232 coms port adapter supplied with the Hydrosteel kit should be used Follow the instructions with this item to load the drivers and set up the operation Connecting to the Hydrosteel 7000 1 Connect modem cable from PC coms port to Hydrosteel 7000 coms port Make sure the instrument is switched on 2 Start the 7K PC software and
19. aph table or table section The graph area printed will be that on display at the time of printing Should a particular section be desired for printing then the zoom and pan functions should be used to select this as the displayed graph area As the Hydrosteel is capable of storing large numbers of data points caution should be exercised when deciding to pint table data as it could run to a very large number of pages It is possible to print a limited section of the table Simply use the curser to highlight a section of the graph in blue which will select the corresponding table data points Alternatively select the table data points using the curser arrows Print table section will print this section only Instrument Settings There are the following instrument settings that may be accessed using the 7K PC software Set Clock The clock is set to Greenwich Mean Time GMT at factory When unit is interrogated using data download package the time associated with data points will be automatically adjusted to the time zone set on the computer operating system Microsoft Windows Whenever a previously saved data file is opened the times are not adjusted The clock can be changed by selecting the Set Clock Erase Data option from the instrument pull down menu and choosing the appropriate option Note the time is set with reference to the clock on the computer so this must be correct before the clock in the instrument is set In changing the instrume
20. bered sided The crimps should be fitted as follows according to the numbering on the Han DD module Pin 1 white pin 2 screen pin 3 green Use insert tool Harting part number 0999 000 0171 or with care a small flat blade screw driver to push crimp sockets until they are securely located Note to remove the crimps from the sockets if they are incorrectly placed or require maintenance the Harting extraction tool is required 16 Check the adapter and M20 cable gland parts are tightly fitted to the Han connector housing 17 Feed nylon tubes through the pneumatic module 1 JNIB 01 Flux through position 1 and background through position 2 Since both tubes are natural in colour marking using black tape for background and red tape for flux has been fitted to the un terminated end This may have been lost when the conduit was cut to length If so trace through the liens by blowing or sucking Unrivalled Detection Page 26 of 43 www lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Commissioning 18 Fit the pneumatic connectors on to the nylon tubes 19 Snap the pneumatic connectors into the pneumatic module 20 The Han frame 1 JFIB 02 hinges to allow fitting of the insert modules from the rear Note orientation 21 Note frame and modules have keyways to allow only one orientation of fitting The Bt arrows point to the top of the pneumatic module With the pneumatic module on the s
21. blockages The most common form of blockage is water If water has penetrated that system then the tubes will need to be blown out with dry air and the weather protection afforded to the probed will need to be investigated H2 Flow Fault Flux Sample Flow incorrect Check the background probe and sample tube In some extreme cases the blockage may be at the filters inside the HY7K The most Yes Yes common form of blockage is water If water has penetrated that system then the weather protection afforded to the probed will need to be investigated Hydrogen Hydrogen sensor faulty sensor faulty Yes Yes Return HY7K for servicing The Sensor is not working reliably Thermocouple Thermocouple open circuit fault Check the thermocouple connections and continuity Note the pipe temperature recorded in the data log will be 615 as an indication of this fault HY7K monitor internal temperature is less Temperature out side operating range than 40 C or greater than 50 C Investigate the local temperature If the instrument is too close to hot equipment then it should be relocated to a cooler place If the ambient temperature is excessively cold then the HY7K will be situated in a heated location Unrivalled Detection Page 39 of 43 WWW lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Technical specifications Environmental Operating Temperature 10 to 50 C 14 to 122 F Storage Tempera
22. claration is placed on the market the product conforms to all technical and regulatory requirements of the above listed directives Name Mark Stockdale Position Technical Director Signature Date 20 November 2008 Unrivalled Detection Page 3 of 43 www lonscience com Hydrosteel 7000 MANUAL lon Science Ltd C Contents Declarauon of conformity 2 3 SOU INS NS NEP um m m 5 Responsibility for Use NEU u 5 EEEN EE A A ET 5 Qualy ASSANGE 5 Calibration FACHU RU 5 LO JALNOUCO 5 wieder H 6 Introduction to Hydrosteel 7000 oiii aa araa 7 Introduction to safety 10 c 11 HY7K probe 11 HY7K analyser site 11 Power and signal re
23. confirm fault and follow fault fault with given diagnostics matrix over leaf measurement 4 20mA 1 flux measurement 4 20mA 2 pipe temperature measurement RS232 connection fails Communication parameters Check com port settings incorrectly set Incorrect modem cable Check the null modem cable used Check red or green LED is lit If the fuse has blown then the coms will not as fuse may have Blown operate The unit needs to be returned to lon Science Ltd for servicing Unrivalled Detection Page 38 of 43 www lonscience com C Hydrosteel 7000 MANUAL lon Science Ltd Diagnostics and fault finding Diagnostics The diagnostics are saved to the memory with each measurement cycle results These can be examined by downloading the logged data In addition the unit will alarm using the Red LED and 4 20mA outputs The table below shows the diagnostic faults and the actions that should be taken Recommended action Diagnostic 4 20 mA 1 4 20 mA 1 LED Flux output Temp output On 3 5 mA 3 5 mA Clock fault Clock lost from memory Yes The data points will be saved sequentially in the memory log Reprogram the clock time and date using the DDP program Background flow Back Ground Flow incorrect fault Check the background probe and sample tube In some extreme cases the blockage may be at the filters inside the HY7K A pressure decay test may be instrumental in proving the Yes Yes tubes are free from
24. ctions No status bar will be displayed during the up grade process so patience is required The firmware upgrade will take some time 3 6minutes Unrivalled Detection Page 36 of 43 www lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Maintenance and calibration Hydrosteel 7000 unit maintenance The unit should be checked routinely for operation and re calibrated yearly Re calibration requires that the unit be returned to lon Science Ltd for service Quarterly maintenance Inspection of LED 4 20 mA outputs and diagnostic data should be stored to memory to ensure that it 15 running correctly If the 4 20 mA are used the diagnostic alarms will be raised as 3 5 mA alarm signals It is still advisable to check the LED and then if necessary the diagnostic data as this provides additional information Yearly maintenance e Inspect the LED 4 20 mA outputs and diagnostic data stored to memory e Factory calibration and service This includes testing and possible replacement of sensor filters pump restriction back up battery tubing valve fuses Note lon Science does not recommend maintenance in the field that requires the lid to be removed With the lid removed the Hydrosteel 7000 analyser is vulnerable to water and dirt ingress Probe installation Hydrosteel probes are made of high temperature tolerant materials and are corrosion resistant The main concerns are blockage of the probes and conduit by water or ru
25. d barriers for INLET power supply Manufactures pt no Cable length estimate m amp Fuchs KFD2 VD Ex1 1835 Galvanic Isolator e All cable lengths are estimated for Zone 1 IIC installation of the equipment e Using 1 C S A conductors S T P cables with capacitance of 250 pF m L R ratio of 25 uH Q conductor resistance at 20 C of 18 4 Q Km e Calculation assumes that cables are at 80 C maximum operating temperature Signal Output Suggested barriers for 4 20mA OUTLET MTL5044 dual channel Galvanic isolator Stahl 9001 51 280 110 141 Stahl 9160 13 11 11S Galvanic isolator WARNING Intrinsically safe IS applications HY7K fuses may not be replaced in the field If a fuse is blown the Hydrosteel 7000 will require inspection by lon Science Ltd or and lon Science Approved Service Centre before it is used in an IS application Electrical connections IS with safety barriers Hydrosteel 7000 Control equipment Yellow Connector g SCREEN k en DZ RD __ RD RE r Jav Bek y BK Power Thermocouple Thermocouple junction box F Blue Connector neci den SCREEN X ac Zz 4 EY E Lm V mor ge 7 lt d d og 2 4 ov BK i o px 4 20mA 2 1 N
26. e from the centre of the site for flux monitoring Additionally if the probe is to be fixed with banding to pipes and vessels of less than 32 diameter insulation and cladding must be removed from the entire circumference of the vessel or pipe under test Preparation of test site The surface should be free from ridges such as weld filets which could prevent the collector plate from making intimate contact with the steel surface The identified test site surface should be at least 4 in diameter to accommodate both the probe and magnetic thermocouple assembly This surface should be free from rust and flaking paint which might otherwise prevent hydrogen flux from exiting the steel surface Unrivalled Detection Page 14 of 43 www lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Installation HY7K probe installation The probe consists of the AT S probe the background probe and the Thermocouple probe The AT S probe may be fixed in place using magnets or banding depending on the test site geometry The background probe is attached to the AT S probe using clips The thermocouple probe is magnetic and may be placed directly on to the surface of magnetic steels AT S and background probe installation with banding Components To affix the probe you will need two equal lengths of banding appropriate for the target pipe diameter That is the pipe circumference plus 30 cm for tool operation and fitting of buckles lon Science rec
27. e caps should not be removed during this procedure in order to prevent insulation debris and fibres from entering them The probe capillaries will withstand flexing to about 2 radius however flexing of the thermocouple lead should be minimised It is essential that the AT S probe plate remains firmly in place and is not distorted by tugging of the capillary conduit Make sure the probe cap is in place The free ends of the probes and sample conduit should either be pushed through a hole in the insulation as it is laid over them or a slit can be made in the insulation to accommodate them Unrivalled Detection Page 19 of 43 WWW lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Installation A hole in the cladding should be formed to enable the AT S probe ambient gas probe and thermocouple to emerge approximately radially from the pipe or vessel A 60 mm cavity such as one for UT inspection ports is often suitable together with a rubber bung with a radial slit through which the probe capillaries and thermocouple lead emerge Installation of sample conduit Fixing of probe conduit bracket It is unlikely that the sample conduit routed from the probe to the analyser is of exactly the correct length Generally it is preferable to loop spare conduit at or near the analyser terminus and to work from the secured probe towards it The probe bracket is affixed to the 10 m sample conduit and must be secured to enable t
28. e one measurement cycle 10 minutes from switch on 3 Perform a data download 4 The flux reading should be between 280 pl cm s and 380 pl cm l s Record the flux reading on the hand over document 5 The pipe temperature can be correlated by measuring the temperature at the probe steel surface or by connecting the thermocouple to a hand held thermocouple thermometer Record the first thermocouple reading on the hand over document 4 20 mA test 1 Both 4 20 mA outputs should be 4mA from unit switch on of the 4 20 mA power supplies for each output After the first measurement cycle is complete the 4 20 mA output will be up dated to reflect the current reading 2 The 4 20 mA output after the first measurement cycle can be ascertained by performing data download and using the flux and pipe temperature readings to calculate the 4 20 mA outputs See the table below Detector Range Resolution Accuracy y j20m V 10mA OS Flux AT F probe 0 pl cm s 2400 pl cm s 1 pl cm s 10 at cal Value Pipe temp 500 C 2 C 2 cal value 3 Note Flux 4 20 mA output range may be changed see Hydrsoteel setup section 4 Check the initial 4 mA reading and any subsequent readings have been correctly measured by the 4 20 mA receivers 5 Program the correct units and range for each output into the data collection system See the table above Unrivalled Detection Page 30 of 43 www lonscience com Hydr
29. e sealant to prevent the ingress of water This arrangement has a number of advantages e The insulation around the probe is isolated from the general equipment insulation by the cap This will prevent reduce water that gains access through damaged cladding from penetrating to the area of the probe e When inspecting the integrity of weather protection only the short section of insulation needs to be inspected e When repairing the cladding checking for water ingress or inspecting the probe only the short section needs to be opened Equipment with insulation and cladding This is often extensive and of complex geometry making it difficult to ensure the cladding is weather proof Isoalted section of insualtion and cladding capped and sealed at both ends Idealy the clading section should be greater than 12 long Probe bracket banded or riveted onto the cladding poo 9 Xe MO mm cladding be nsulation End cap p d The test site should be insulated and clad with the probe thermocouple and AT S probe now in place Note that the AT S probe and ambient gas prob
30. e that each connector is individual to the appropriated panel socket The connectors will fit cable diameter s 6 12 mm Terminate the cables following to the connectors as show by the commissioning diagram overleaf If any connection is not made to the Hydrosteel the mating face of the connector must be protected from water ingress by the fitting protective caps or covering with a plastic bag Unrivalled Detection Page 28 of 43 WWW lonscience com lon Science Ltd Hydrosteel 7000 MANUAL issioning Comm 1 3 2 2NIXIJ AIdWVS 2 N 2114 31aWvs NNO Nova ZH SLNAYND INV 39V LT1OA AlddNS NI NOILV21JI234S 1V21NH23 OL 343 2 mum o Se31L3WV lVd AL3dvs DISNIALNI 31V21JIL332 NOILVNIWVX3 34
31. eel Applications Manual available from lon Science Ltd Frequently the value of flux measurement at a particular site is confirmed by routine spot flux measurement with the Hydrosteel 6000 spot flux analyser Probe compatibility with surface steel geometry and temperature is defined in the Technical Specifications The user is also invited to consider the ease of installation at prospective test sites and their proximity to sites appropriate for Hydrosteel 7000 analyser location see addressed points below Caution The weather resistance of the Hydrosteel system is dependant on the probe installation The probe must be sheltered from water and dust ingress as this will block sample flow and prevent operation This may be done by applying insulation and cladding and or a suitable shelter as appropriate Water running down the outside of the pipes must be considered especially if the probe is situated on the underside of equipment It is important to shield from water access even on hot pipes as in heavy weather conditions the water will evaporate to form steam which will condense in the sample tube and instrument The probe is fixed to the test site by one of the following methods The appropriate fixing method should be identified in advance of installation to ensure correct planning of provisions for installation e Jubilee clips to pipes or vessels of minimum 2 using the AT S probe Banding to pipes or vessels of 4 to 32 di
32. egal notice added Hydrosteel Manual layout and format 10 12 12 7000 V3 1 updated DEV090621 01 DEV090621 01 Hydrosteel Page 32 print options 23 06 09 DEV090621 01 7000 V2 8 added to PC SW Note on use of RS232 adapter Software installation instructions P35 firmware upgrade instructions DEV090621 01 Unrivalled Detection Page 43 of 43 www lonscience com
33. et using the data download software Note that the time is set with reference to the clock on the computer this must be correct before the clock in the instrument is set See Data download software for further instructions Flux 4 20mA output range The Flux 4 20mA range default is 4mA 0 pl cm s and 20 mA 2400 pl cm s This may be change to 20 mA being from 1 pl cm s to 2400 pl cm s using the Flux 4 20 mA range calibration option in the instrument menu of the DDP The Flux range is variable so that it may be optimised for the corrosion application Please refer to the applications manual or contact lon Science for assistance Operation One switched on the Hydrsoteel will operate continuously Every 10 minutes the HY7K will data log and output over 4 20 mA loops new readings As users you may decide for a full integrated system where the 4 20 mA data is collected by a data collection system DCS and is available immediately for daily use in optimising a process Alternatively the data log may be relied upon to collect the data The data would then be analysed periodically in conjunction other corrosion and process data The analysis and use of data is outside the scope of this manual Please refer to the Hydrosteel applications manual or contact lon Science Ltd for technical support To download data the Data Download Program is needed This is software that should be installed on a portable PC so that it may be connected to the HY7K usin
34. g an RS232 cable and if necessary USB adapter supplied The section below details the operation of the Software The Hydrosteel has a number of internal diagnostics If one of these detects a fault then it will be displayed as a red LED on the outside of the instrument output on the 4 20 mA and saved in the data log See maintenance section for full details Unrivalled Detection Page 32 of 43 WWW lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Hydrosteel 7000 PC software The PC software is designed solely to allow the download and viewing of data recorded using Hydrosteel 7000 unit Once downloaded data files may then be stored on any computer system and opened for review as needed The data is displayed in two formats graphically and as a table of data entries with each row being the data recorded for a given measurement cycle The software follows a standard windows format for main functions and is therefore self explanatory for common operations such as open file save file etc Installation of Hydrosteel Software PC Requirements Hydrosteel Software must be used in conjunction with a PC laptop using Microsoft Windows 98 or later First remove any older version of 7K PC software if they are installed This is done using Add remove programs option in the Microsoft windows control panel Select 7K PC from the list and click on the remove button Note in Add remove programs it may be necessary to p
35. he AT S ambient gas probes and thermocouple lead to be attached to it Generally it will be necessary to fix the bracket to outside of the pipe cladding The probe bracket may be banded riveted or bolted into position It is important to ensure e Secure support for the probe bracket as it prevents forces being loaded onto the probes if the conduit is tugged Unrivalled Detection Page 20 of 43 WWW lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Installation e Conduit and tails do not rest against hot piping or equipment As they contain thermoplastic components that may be damaged WARNING Sample Conduit and tails must not be exposed to elevated temperatures above 100 C These temperatures can easily be experienced if the conduit or tails are in surface contact with high temperature process pipes Connection of probes to sample conduit Remove the probe caps Simply attach the AT S and ambient gas probes manually using the threaded unions provided Ensure that the correct capillaries are attached to the correct conduit cable e Tube with nut marked F red tube or red cable tie to AT S probe e Tube with nut marked B white tube or white cable tie to background probe e Tighten the conduit nuts securely 1 8 turn using 11mm spanners e Use cable ties through the slots in the probe bracket to hold the probe connections in place Connection of thermocouple cables The thermocouple lead terminates in two wires these
36. ide marked with capital B 22 Fit the frame into the Han connector housing Unrivalled Detection Page 27 of 43 www lonscience com lon Science Ltd Hydrosteel 7000 MANUAL Commissioning 23 Join the gland housing together 24 Check the full assembly has been assembled correctly If cable gland supplied requires the use of a sealing epoxy open the cable gland and follow the fitting instructions supplied with the cable gland Apply the sealing compound The cable gland must be closed before the sealing compound has cured 25 Once complete probe connection will be capable of disconnection and reconnection with Hydrosteel 7000 Tighten Han connector screws with flat blade screwdriver to secure the connector Additional fixing of conduit if necessary Use P clips 1 HF 02 and M5 screws or bolts not supplied to fix the sample tube conduit to appropriate refinery structures or cable trunking Alternatively use cable ties Connect conduit to Hydrosteel 7000 Connect the Han connector from the sample tube to the Hydrosteel 7000 Tighten Han connector screws with flat blade screwdriver to secure the connector Terminating power and 4 20mA cable to Hydrosteel 7000 IP6 rated cable connectors are supplied with Hydrosteel 7000 so that the instrument may be quickly disconnected and then reinstalled after servicing These are colour coded using cable ties Note the connector pins have been changed to provide key ways and ensur
37. instrument is powered by simple detachment of analyser connections under intrinsically safe conditions The requirements for installation in Zone 1 hazardous area are summarised below and in the nstallation summary diagram The reader should refer to nstallation section and to the Hydrosteel 7000 ATEX certificate for further details Power to instrument should be supplied via zener safety barrier or galvanic isolator e Two 4 20 mA receivers that supply loop power to hazardous area through appropriate safety barrier galvanic isolator are needed e To ensure EMC compliance always use screened cables for bother power and 4 20 mA outputs e Mounting to wall or frame with appropriate hole centres Probe to be installed on equipment with sample tube connection made to Hydrosteel 7000 Unit must be within 10 m 32 ft of probe test point e Weather protection for probe It is recommended that the probe is insulated and clad professionally The Hydrosteel 7000 has been certified intrinsically safe by European notified body BASEEFA 2001 to the ATEX directive 94 9 EC Baseefa04ATEXO0205 Unrivalled Detection Page 7 of 43 WWW lonscience com lon Science Ltd Hydrosteel 7000 MANUAL Introduction to Hydrosteel 7000 Qqd4inod8 SV GO3IVNIWe3L HION31 OL 100 48gO0sdd HOVE LH IL SI ONIGGVIO NOILVINSNI JHL
38. may causes harm or damage to persons or property Inadequate performance of the gas detection equipment described in this manual may not necessarily be self evident and consequently equipment must be regularly inspected and maintained Ion Science recommends that personnel responsible for equipment use institute a regime of regular checks to ensure it performs within calibration limits and that a record be maintained which logs calibration check data The equipment should be used in accordance with this manual and in compliance with local safety standards Warnings 1 Please read and understand this User Manual fully before installing operating or servicing the Hydrosteel 2 Ensure you are in a SAFE area before carrying out any type of maintenance on the Hydrosteel 7000 Instrument 3 Substitution of components may impair intrinsic safety and result in unsafe conditions 4 For safety reasons the Hydrosteel must only be operated and serviced by qualified personnel 5 Refer to the certificate for clarification of any aspects of intrinsic safety or contact lon Science Ltd or your local lon Science Ltd representative Quality Assurance Hydrosteel 7000 has been manufactured in compliance with 1509001 2008 and BSEN 13980 2002 which ensures that the equipment supplied to our customers has been designed and assembled reproducibly and from traceable components Disposal Dispose of Hydrosteel 7000 its components in accordance with all local
39. ment Instrument serial number Instrument firmware version Clock This is the current date time stamp from the instrument Clock Data of first stored record Last calibration date Download options Download data from this accept a date time to short the download Download data Download calibration This is for ISL servicing of instruments Memory dump This is a last resort option if the memory has become corrupted Downloading data Each Hydrosteel 7000 has its own unique serial number This number is printed on the front of the unit and contained in the unit software All data downloaded from an instrument is stamped with this serial number This allows data from multiple units to be distinguished The serial number is displayed at the top of the graph and data table and also saved to the top of a CSV export file Data download 1 To download the data press download button There is an option to download data only from a specific date This might be the date of the last data download A status bar will appear while the data downloads if the memory is full 1year this will take some time 2 One the data has downloaded it will be displayed as graph and table 3 Save the data as required Erasing logged data Once the data has been downloaded and saved we recommend that the logged data is erased This will minimise the data download time and prevent multiple files having the same data Graph operation The graph aut
40. mperature 800 F 426 C Note insulation and cladding are highly recommended and are essential if weather protection is required EMC To achieve the immunity detailed above all wiring should be screened twisted pairs Unrivalled Detection Page 41 of 43 www lonscience com C Hydrosteel 7000 MANUAL lon Science Ltd Instrument warranty and service Warranty Standard Warranty can be extended to up to 2 years on the Hydrosteel 7000 when registering your instrument via our website www ionscience com instrument registration To receive your Extended Warranty you need to register within one month of purchase Terms and Conditions apply You will then receive a confirmation email that your Extended Warranty Period has been activated and processed Full details along with a copy of our Warranty Statement can be found by visiting www ionscience com instrument registration Service lon Science is pleased to offer a number of service options on our Hydrosteel 7000 product range that allow you to choose the instrument cover that best suits your needs At lon Science we recommend that all of our gas detection instruments be returned for service and factory calibration once every 12 months Contact lon Science or your local distributor for service options in your area Find your local distributor by visiting www ionscience com Contact details UK Head Office lon Science Ltd The Way Fowlmere Cambridge SG8
41. n on under Operation Data table operation The table shows the data in chronological order with the first data point at the top of the table Use the scroll bar quickest or up down arrows to navigate up or down the table A data point may also be selected with the mouse The selected data point will be high lighted on the graph as a fine vertical dashed line A region of data points may be selected using the arrow keys and holding down the shift key the data selected will be highlighted blue on the graph and the table As a default the table shows the following columns of data Date time Flux Pipe temperature Diagnostic flag The diagnostic flag will indicate the status of the instrument at the time of the measurement It there was a fault it will be stated see diagnostics section for details The table may be expanded to show the complete set of readings logged during a measurement cycle by using the expand shrink table in the windows drop down menu or the expand shrink icon on the tool bar These are listed below Date time Flux Valid Logged data point check sum valid Supply Supply voltage at the instrument Internal temperature Pipe temperature Pump voltage Pump current Flow Background Hydrogen background reading Variance Zero Hydrogen sensor zero reading SR Hydrogen sensor impedance diagnostic SR pins RC Hydrogen sensor impedance diagnostic RC pins SC Hydrogen sensor impedance diagnostic SC pins
42. nt clock time all the data in the memory will be erased to maintain data integrity Erase logged Data If the instrument memory is full data is stored on a scrolling basis Use the Erase data option only in order to delete all data from the instrument memory Flux 4 20mA Range menu This menu enables the Flux 4 20 mA output range to be changed It is necessary for the instrument to be connected for this operation Simply connect the RS232 cable activate the flux 4 20 mA range window and follow the on screen prompts Firmware Upgrade This enables the instrument firmware to be upgraded for improved operation Simply connect the RS232 cable to the instrument with it powered up Open the 7k PC software select firmware upgrade from the instrument dropdown menu and follow the on screen instructions You will be asked to find the upgrade file upg this will be provided by ion science by e mail or CDROM simply select it from it s saved location Once the upgrade is complete switch the instrument on and off to ensure the new program is active Warning The firmware upgrade must not be interrupted or the operation of the instrument is likely to be corrupted If this occurs the instrument will have to be returned to lon science for reprogramming Ensure that the modem cable is securely connected and if a laptop is used check the batteries have sufficient power Select the firmware up grade from the instrument drop down menu and follow the dire
43. o give warning or control of high corrosion levels in the operating equipment Directive 94 9 EC ATEX Identification 11 2G Ex ia IIC T4 40 C lt Ta lt 60 C Notified Body Baseefa Ltd 1180 Buxton UK EC Type Examination Certificate s 04 205 latest supplement 04 205 issue 4 issued 13 February 2009 Standards BS EN 60079 0 2006 Electrical Apparatus for Potentially Explosive Atmospheres General Requirement BS EN 60079 11 2007 Explosive Atmospheres Equipment Protection by Intrinsic Safety i BS EN 61010 1 2010 Safety requirements for electrical equipment for measurement control and laboratory use General requirements Directive 2004 108EC Electrical Equipment Electromagnetic Compatibility EMC BS EN 61326 1997 A1 A2 X Electromagnetic Compatibility EMC Equipment for measurement control and laboratory use CFR 47 2004 Class B EMC US standard Clarifications of EMC performance to standards With respect to BS EN 61326 1997 A1 A2 the Hydrosteel 7000 achieves performance criteria B that is the apparatus continues to perform after the test but during the test a degradation of performance is seen Other Standards BS EN ISO 9001 2008 Quality Management Systems Requirements BS EN 13980 2002 Potentially Explosive Atmospheres Application of Quality Systems On behalf of lon Science Ltd declare that on the date this product accompanied by this de
44. ock and 6 O clock top and bottom then a second AT S probe may be fitted to the same banding Fit the seconds AT S probe at length of three quarters of the target pipe circumstances along the banding Relocation to target site e hot work permit is not required for installation of the probe as the requirements are purely mechanical and non destructive e Ensure you are equipped with the collector assembly banding assemblies band tensioning tool suitable PPE personal protective equipment and a stiff wire brush to remove loose rust from the test site if necessary Step 1 Check again that you can access the entire circumference of the target pipe section and that it is free from loose rust Use the wire brush to remove residual rust if necessary Step 2 Fit the collector plate to the appropriate place and pass the banding round the pipe circumference secure this into the buckle and tension following the manufacturer s instructions For hot pipes it is very important to let the banding heat up to the temperature of the pipe as the banding will expand and lengthen In these circumstances tension the banding using the tightening tool and leave the tool in place for sufficient time for the banding to reach temperature re tension the banding as necessary before locking the banding off Step 3 Check that the probe is held correctly position and that they are fully pressed against the piping surface particularly at the probe
45. omatically plots the flux data For graph options use the graph drop down menu on the tool bar or right click with the mouse on the graph Option include different data plots horizontal and vertical gridlines or liner stair step interpolation A data point can be selected by clicking on graph with the mouse The corresponding data point in the table will be highlighted blue A region of data points can be selected by clicking and dragging on the graph again the data points will be highlighted blue on the graph and table Zoom in To zoom in select zoom in icon Magnifying glass with a doted box point the mouse pointer at a corner of the area to zoom in on click the left mouse button and drag a zoom box over the required area then left mouse click again The graph will zoom in on the boxed region You may zoom in repeatedly as needed Unrivalled Detection Page 34 of 43 www lonscience com C Hydrosteel 7000 MANUAL lon Science Ltd Hydrosteel 7000 PC software Zoom out Use the magnifying glass icon with the minus sign in the middle to zoom out to view complete data set Use the magnifying glass icon with the undo arrow to return to the last zoom section Status bar The status bar at the bottom of the graph above the table will indicate Green for correct operation yellow for off and red if there was a diagnostic fault detected with the instrument reading Data displayed in red indicates a diagnostic flag see diagnostics sectio
46. ommends that standard 3 8 9 31 mm width 0 015 0 38 mm gauge Stainless steel banding and buckles be used This uses a specialist band tightening tool Banding kit may be purchased as an accessory Items required are e 5 probe collector plate Back ground probe Probe clips A 910227 tensioning tool e Band cuters 2 Banding buckles x2 Banding lengths to suit pipe 3 8 0 015 guage e Wire bush for preparing the metal surface PPE personal protective equipment Pre assembly Best done in a clean environment off site e Assemble the background probe on to the AT S probe using the probe clips e Prepare the banding by cutting it to length Equal to the Pipe circumference plus approximately 30 cm For difficult installations longer lengths may be required with the banding being cut afterwards to remove the excess e Fit the buckles to the banding following the manufactures instructions e Fit the banding into the support bracket on AT S e Manually adjust the collector so that it is located at a distance equal to of the target pipe circumference from the buckle end of the strap Loosen or tighten the butterfly nuts as required Ensure the collector cap is secured to finger tightness Unrivalled Detection Page 15 of 43 www lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Installation e If it is desired to measure the flux on opposite sides of a pipe e g the 12 O cl
47. onfirming correct operation The commissioning consists of the following sub sections e Inspection of the equipment installation Terminate probe connection to Hydrosteel 7000 e Terminating power and 4 20 mA cables to Hydrosteel 7000 e Start up e Operation test e Hand over Inspection of the equipment installation The installation should be inspected prior to commissioning The following is a check list of features for inspection Probe if accessible Clean test surface without ridges such as welds Secure fitting with the collector plate firmly pressed against the test surface Protect the probe from ingress of water Probe bracket to sample conduit Secure Free of features that might present a danger to personnel Sample tube fixed securely so that is safe from foreseeable damage Hydrosteel 7000 mounting Secure and accessible Sample conduit and electrical connections accessible for connections Electrical cables Continuity of cable cores has been tested Insulation resistance between cores and between cores and screen has been tested Connection of cables to correct services has been tested n a hazardous area the Power and 4 20 mA cables are labelled so that correct connections can be made to the Hydrosteel Unrivalled Detection Page 24 of 43 www lonscience com lon Science Ltd Hydrosteel 7000 MANUAL Commissioning Probe connection to Hydrosteel 7000 Termination of sam
48. osteel 7000 MANUAL lon Science Ltd Commissioning Hand over 1 With the permission of the owner photograph the unit as installed The photographs will provide a documentary record of sound installation Photographs should show the following e Correct probe installation e Probe is securely mounted and safe from foreseeable damage e Sample conduit has been mounted securely and is safe from foreseeable damage e is mounted securely and is safe from foreseeable damage e connections have been made securely to the HY7K and are safe from foreseeable damage 2 Produce hand over document with the following details e Customer details e Customers PO no e Hand over date e Site or location reference e Equipment tag number or other reference e Add the photographs e Operation test results e First flux and pipe temperature measurements 3 Have the installation inspected and the hand over the signed document Unrivalled Detection Page 31 of 43 www lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Hydrosteel setup Clock time The clock is set to GMT at factory When unit is interrogated using data download package The time associated with data points will be automatically adjusted to the time zone set on the computer operating system Microsoft windows Whenever a previously saved data file is opened the times are not adjusted If the instrument clock time is incorrect for any reason it can be res
49. perates a 10 minute measurement cycle At the end of each cycle 4 20 mA outputs step change to provide the most recent cycle data measurement and store all data and diagnostic measurements to the internal memory The unit draws a controlled flow of sample gas from the probe into the unit where the concentration of hydrogen gas in the sample is measured The instrument sequentially measures hydrogen in sample gas drawn from the background probe 3 minutes and flux probe 3 minutes From the differential response the flux is calculated and data outputs are updated The rest of the cycle 4 minutes is dedicated to clear down for a zero measurement and diagnostic measurements as Summarised below Time 0 to 3 minutes Hydrogen zero measurement 3 to 6 minutes Hydrogen background reading 6 to 9 minutes Hydrogen flux reading 9 to 9 5 minutes Hydrogen sensor diagnostics 9 5 to 10 minutes Data stored in memory amp 4 20mA outputs updated Connectivity e 1 mains power supply 15 24 V 34 mA in hazardous area e 4 20 mA output 1 hydrogen flux requiring loop power of 8 30 V 020 mA e 4 20 mA output 2 pipe temperature requiring loop power of 8 30 V 20 mA e RS232 connection for optional interrogation of unit all data is logged to the unit s internal memory probe connection Unrivalled Detection Page 9 of 43 www lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Introduction to safety certification Apparatus ce
50. perimeter points identified in the accompanying diagrams Unrivalled Detection Page 16 of 43 www lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Installation Also check that the bands are fully parallel NB The probe can slide along the banding by loosening the thumbscrews on the probe brackets provided the banding is not too tight onto the pipe Check the banding buckles are a reasonable distance from the plate so that the banding runs flat against the steel surface and then onto the collector plate If the band buckles are very close to the collector edge the banding may not pull the collector plate flat on to the surface with no or only a very small gap Step 4 Lock off the banding as normal following the banding manufactures instructions Wait 3 5 minutes Due to expansion of the banding attached to pipe at elevated temperatures it may require tightening after some time Re check probe tightness and positioning as per step 3 and retighten or refit banding as necessary Unrivalled Detection Page 17 of 43 www lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Installation AT S Probe Installation with Magnets Step 1 Press the collector plate against the target steel surface so that it conforms to pipe or vessel curvature Step 2 With the probe held in place attach the magnets as shown in the diagram below Note The max working temperature for magnets are 800 F 426 C Axis of pipe or
51. ple conduit with Han connector 1 Fit Harting connector assembly to the Hydrosteel 7000 This assembly is complete with a special Cable gland 2 Offer the sample conduit from the probe up to the Hydrosteel 7000 and mark the required length of the spiral sheath where it will enter the cable gland on the Harting connector 3 maintain traceability of the pneumatic lines after cutting Mark the tubes above the point at which they are to be cut so that they may be differentiated using a wrap of insulating tape is an ideal marking 4 Pull the spiral conduit so that it extends by at least 30 cm Cut through the conduit using a hacksaw By extending the conduit this ensures that the sub components pneumatic tubes and thermocouple have a 30 cm excess protruding from the conduit when it relaxes 5 If it has not been possible to mark the tube or the marking has been lost the lines must be traced through by blowing or sucking on the tube 6 Fit the M20 conduit adapter 1 HG 03 to the sample tube conduit 7 The cable gland supplied may be one of two types Type one uses a sealing epoxy compound type two uses a machined rubber gland If cable gland that use s a sealing compound is supplied then the sealing compound should not be applied until the sample conduit has been completed to ensure correct fit The cable assembly should be fitted dry following the fitting instructions supplied with the cable gland Split the cable gland and thread
52. quiremellls x sta vein Rar asters maso eV tonat ire stus Es Pe 12 Cable SCM AES RARI hern NP EOS Ep PI IV Sua MED mE pf oa NUR ell HD 14 Removal of Cladding and insulation 14 Preparation Oftest Sile siosio ena E EE TTE 14 ah d orobe instalation nE EE EE A EE r EEA 15 Thermocouple instalation e a a tomas Gu sas aS 18 Re insulation and cladding 18 installation of sample a NE Mn ts 20 Mounting of Hydrosteel 7000 nnne nnns 23 SONATAS BENNETT OE m 24 Inspection of the equipment installation 24 Probe connection to 7000 ccc ceccc cece eee eeee seca eeeeeeeeeeaeeseeeseeeeeeseeeseeeaeeeaeeseeeseeeaeeseeeseeeaeeeas 25 Terminating power and 4 20mA cable to Hydrosteel 7000
53. rriers or isolators are required for the 4 20 mA outputs if they are used e portable computer may be used to download data provided local rules such as permits and safety precautions are followed The use of a standard laptop does not invalidate the HY7K safety certificate See Power and signal requirements in the installation section for full details Unrivalled Detection Page 10 of 43 www lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Installation The following sequence of installation steps are recommended e HYTK probe site identification 7 analyser site identification e Power and signal requirements e Cable requirements e Remove cladding and insulation e Preparation of test site HYT7K probe installation e Thermocouple installation e Re insulation and cladding e Installation of sample conduit e Mounting of Hydrosteel 7000 analyser See installation summary drawing for an overview of requirements The Commissioning section addresses the following items required to complete the installation e Attachment of the sample conduit to the analyser e Connection of electrical connection to HY7K e Inspection of the installed equipment e Start up Set up and operation test HY7K probe site identification Suitable sites for Hydrosteel 7000 flux monitoring are primarily identified by the benefits conferred by measuring flux at the specific location of interest as further identified in the Hydrost
54. rs and Power OV shorted Suas 7 T m V to ground stud inside HY7K 1 5 E OV BK y y IS Galvanic ELA Thermocouple Thermocouple H Blue Connector i o 2 i mu I RD i RD se AUR m i1 42042 S 1 D c OV Red Connector JBearth uM 0 NE Note JB earth and HY7K earth must be N 3 V RD RD V equi potential and have no more than 1 Ohms J _ e a resistance between them T 1 OV BK BK 4 20 1 J OV yt lt _ Screens no longer grounded TS rs the control equipment ear Cable Requirements To meet the EMC compliance for immunity it is required that power and 4 20 mA current loops are supplied with screened twisted pairs Pairs should be individually screened with the screens terminated in the safe area and to the terminals on the Hydrosteel 7000 Note the Hydrosteel does not allow DC earth loops to ground down the screens Removal of cladding and insulation Hydrosteel flux measurement requires intimate contact between the probe plate and test surface so it is necessary to remove any insulation from the target sites For ease of access during probe installation cladding and insulation should be removed from a 1 ft distanc
55. rtification ATEX Hydrosteel 7000 has been issued with EC type examination certificate 04 205 BASEEFA 2001 Confirming compliance with the European ATEX directive 94 9 EC for group Category 2 gas atmospheres EEx ia llc T4 40 C to 60 C This instruction manual describes the installations that conform with PD60079 12 2000 electrical installation in hazardous areas When designing systems for installation outside the UK the local Code of practice should be consulted Certification label information The certification label is fitted on the top outer surface of the enclosure This shows the certification information plus the lon Science Ltd name location instrument serial number and year of manufacture Other non European certification information may also appear on this label Hydrosteel 7000 S No dekekedekn Manufactured Date Baseefa04ATEX0205 Il 2 G EEx ia TA C 1180 20 C lt lt T ambient lt 60 C lon Science Ltd Cambs England Note The specified operating temperature range for the Hydrosteel 7000 is 20 C and 50 C due to constraints on the internal components System certificates Currently no system certificates have been issued for this equipment The Hydrosteel 7000 can be operated safely in the hazardous area utilising a range of safety barriers See Power and signal requirements in the Installation section for full details Main power supply
56. select settings Note if the USB adaptor is used and is attached before PC switch on then the Software will not be able to open the PC coms port Simply disconnect and reconnect the USB adaptor to make things operational and continue with the instructions below 3 Select Search for instrument The PC software will pole the existing com ports in ascending order to find which port the Hydrosteel is attached to Once the instrument has been found select OK to continue If the instrument is not found check the power and connections to the HY7K and if necessary use another coms port 4 Select connect to instrument A window will appear as the software attempts to communicate to the Hydrosteel 7000 The top box will confirm the instrument status if the connection has been correctly made If the communication fails an error message will be displayed error failed to get data See Fault Finding under Operation Unrivalled Detection Page 33 of 43 www lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Hydrosteel 7000 PC software The Connect to instrument window Instrument status reflects the diagnostic situation of the instrument Current status and Historic status confirm the current operation and flag if a diagnostic fail has occurred in past operation since switch on or last data download respectively See Diagnostics under Operation Instrument Details gives the following information on the instru
57. sembly Han connector assembly P clips for sample tube conduit Thermocouple junction box probe kit AT S collector plate Background probe Magnetically attachable TC cable Wire brush Accessories include Nanana Co N Unrivalled Detection Banding kit consisting of Banding tool Banding 3 8 stainless steel box 30 5m Buckles box of 100 Magnetic probe fixing kit 4 high temp magnets Page 6 of 43 Qty 1 1 1 1 1 1 2 Nan ol c www lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Introduction to Hydrosteel 7000 The Hydrosteel 7000 is intrinsically safe instrument for the measurement of hydrogen flux from pipes and vessels The unit is designed for operator free maintenance for up to one year subject to correct installation and appropriate power supply During this time the unit will take unlimited measurements and log them internally The unit has two 4 20 mA outputs that provide constant output of flux and surface temperature data An RS232 port enables the download of internally stored data The unit has been robustly designed with IP66 weather proofing for external installation in most environments Hydrosteel 7000 has been designed with a view to presenting trouble free installation commissioning and maintenance For maintenance we recommend the service exchange of the product Disconnection of the unit for service can be carried out while the
58. st from corrosion of the target surface or mechanical damage The following should be inspected yearly and after every shut down sample tube is secure and free from damage e Han connection to the Hydrosteel 7000 is free from damage e If the probe is accessible check the following e The conformance to the test surface is correct and the banding is secure e Evidence of corrosion e The probe is free from blockages or dirt debris that may potentially cause a blockage appropriate do a quick pressure decay test No pressure should be supported if the system is free from blockages e If the probe is covered by insulation check the following Inspect at the entry point that no damage has occurred to the probe e Check that insulation is secure sealed and free from external damage that might allow water ingress Water that penetrates the insulation may block the probe directly or cause corrosion of the test surface under the probe This corrosion is likely to block the air flow during sampling e Check that the thermocouple is functioning See the diagnostics table for more information Unrivalled Detection Page 37 of 43 www lonscience com C Hydrosteel 7000 MANUAL lon Science Ltd Fault finding and diagnostics Fault findings WARNING Ensure plant safety before starting maintenance Certified test equipment should always be used unless a gas clearance certificate has been issued The following table lists
59. the fault outputs and their consequences Please contact lon Science or your local Hydrosteel representative if you need any assistance Symptom Cause Check No LED lights No power Ensure that there is 15 V d c across the power Incorrect wiring terminals at the unit Check the polarity that the positive wire goes to the terminal If the voltage and polarity have been incorrectly Fuse has blown applied then the fuse may have blown Note if the fuse has blown the instrument will need to be returned to lon Science Ltd Green LED flashes Insufficient power unit keeps Ensure that there are 15 V across power continuously on resetting terminals at the unit Note the green LED will go off for 2 3 seconds when the pump starts Green with alternate Fault has occurred since last Perform a data download and look at the log of quick Flashes of the download last diagnostics to identify the fault See diagnostics operation Fault is gt matrix below for resolve the issue currently present and unit is operating correctly RED LED lights Unit has self diagnosed a Download data to find out specific diagnostic fault failure See diagnostics matrix below for resolve the issue 4 20 mA No loop power or incorrect Ensure that there is gt 8 V across power wiring terminals at the unit Check that positive wire goes to the terminal 4 20 mA 3 5mA Unit has self diagnosed a Download data to
60. the pneumatic tubes and thermocouple through 8 Close the cable gland and tighten following cable gland fitting instructions 9 Trim the nylon tubes and the thermocouple cable so that 10 cm extends out of the end of the conduit gland If any extra length is required the conduit can be compressed to reveal a greater length of cable and tubes 10 On the end of the thermocouple cable strip 30 mm of PVC outside sheath to expose screen and sub cores Cut back 30 mm of outer sheath Remove aluminum foil 11 Remove aluminium foil screen to the point of exit from the PVC sheath Unrivalled Detection Page 25 of 43 www lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Commissioning 12 Strip 8mm length off white and green wires Strip 8mm of insulation 13 Crimp all three wires using crimp contact pins Pt No 1 JCPB 01 Push the exposed conductor ends into contact pins Please Note the screen is tight into crimp socket so don t twist the conductors together and tease gently into avoid bending the conductors If necessary cut 1 or 2 conductor strands out of the bundle to enable it to fit Use the end location of Harting service tool Harting part number 09 99 000 0021 to crimp 14 Feed the nylon tubes and the thermocouple cable through the male reducer and Han connector housing 15 Fit crimps into Han DD module 1 JSIB 01 from the rear The rear of the module is the flat fully num
61. ture 25 to 50 C 13 to 140 F Zone 1 2 Safe Operating Temperature 40 to 60 C 40 to 140 F IP rating monitor IP66 note unit should not be mounted upside down IP66 note unit should not be mounted upside down IP rating probe IP40 The weather resistance of the probe and hence the Hydrosteel system is dependant on the probe installation Caution the probe must be sheltered from water and dust ingress as this will block sample flow and prevent operation Mechanical Monitor Dimensions amp Mounting points monitor 180 7 087 96 5 8 _ 160 6 29 8 2 0 55 suit bolts a Pr 95 59 AN 120 4 72 260 10 23 240 9 45 M 9 U J C J cm T T 07 B uy V T po WT 1 1 Sa Q S J NO LLLI B L C LL No Lt IIb ot x mm 5 C Unrivalled Detection Page 40 of 43 www lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Technical specifications Communications e RS232 via a standard modem cable terminated with male and female 9 pin Sub D connector at each end Cable length 3 metre A USB RS2
62. ures or cable trunking from the probe bracket towards the analyser location Avoid structures which are liable to exceed 100 C Unrivalled Detection Page 22 of 43 WWW lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Installation Mounting of Hydrosteel 7000 analyser Dimensions for mounting are shown below The Hydrosteel 7000 can be mounted in any orientation except upside down which does not cause entry of water into the exhaust port for example during drench testing 180 7 08 96 5 3 8 _ 160 6 29 _ 8 2 0 33 suit M8 bolts 6 Ww Bo00000009 3 H Du 5 i AND LO 33 4 B S 33 120 4 72 oO e rT 1 FH E I H 1 4 i Kem 2 MUS 2 C V A 2 7 S gt 7 O maA V _ N e wy L e tr 11 2 5 3 5 O a 3 1 Unrivalled Detection Page 23 of 43 WWW lonscience com Hydrosteel 7000 MANUAL lon Science Ltd Commossioning Commissioning is a matter of terminating the probe and electrical connections to the Hydrosteel 7000 unit checking the installation and c
Download Pdf Manuals
Related Search