Hydrosteel 6000 User Manual V1.8
Contents
1. 4 Data logging and computer interface e Downloading or updating zone headers to instrument e Checking instrument detals eg serial number logged memory used e Displaying and recording flux measurements on PC in real time e Re programming analyser witha firmware upgrade Hardware requirements ISLPC data interface software runs on a PC under Window 95 or later or NT for the processing of saved data files Data downloading interfacing and upgrading of aninstrument requires the use of an IR link Box supplied by ISL connected to the RS232 communications port of a user supplied PC The IR Link Box works with serial communications to your PC running at 19200 baud 8 bit data no parity and1 stop bit About the IR Link Box The IR Link Box enables serial communications to take place between the communications port on your PC and the IR port on the Hydrosteel analyer Ensure that no other program on your PC is using the serial communications portwhen you want to transfer data from the Hydrosteel analyser Connect the serial ca IR Link Box ble between the IR Link Box and your PC Connect the output of the 6V supply to the back of the IR Link Box Connecting the IR Link Box 1 Connect the 6 V dc power supply provided to an ac supply 2 Connect the output of the 6 V dc power supply to the back of the IR Link Box A red LED will blink regularly when the IR Link Box has power applied to it 3 Connect the serial2. 5 ppm Rapid diffusion and hence rapid dispersion of hydrogen in air results in a very low and stable background prevailing in the ambient air of most environments even indoors This cond tion enables the Hydrosteel 6000 to be used in measuring a very small flux of hgrogen emanating from steel as a result of its interaction with hydrogen occluders and hydrogen occluding processes The integrity of the measured data is circumscribed by drift in the ambient air hydrogen content and this drift is usually very low The flow of the test gas stream F across the steel surface is carefully regulated by means of restrictions and a flow bypass between the pump and the detector to ensure that it remains smooth and constant An additional feature of the flow bypass is to ensure that in the event of a probe blockage the pump is not working against a negative pressure differential Flow regulation is particularly important as the flu of hydrogen emanating from the steel is given by J cxF A where Ais the effective area over which hydrogen is captured andc the enhanced hydrogen concentration resulting from hydrogen entrainment Page 4 of 40 i Hydrosteel 6000 Ion Science Ltd 1 About Hydrosteel 6000 Output from the amperometric sensor is an electric current which is proportional to the concentration of hydrogen presented to it This current is amplified and scaled for display and logging as a hydrogen flux To summarise the prowess of Hy
3. F 10 C to 50 C Test gas humidity tolerance continuous 15 to 100 non condensing lt 15 fora few hours Measurement surface Steel of gt 3 5 inch diameter cross section temperature range lt 230 F 110 C 265 F 130 C is possible for quick spot measurements only Test gas pressure tolerance ees ee Page 37 of 40 i Hydrosteel 6000 Ion Science Ltd Appendix A Analyser specification Notes Volumetric specifications are quoted at 20 C and one atmosphere ambi ent pressure Pre set input flow deploying 27 inch 70 cm gas sampling conduit and LER collector unless otherwise specified 1 pl 10 litres Full range 0 2500 pl cm s Resolution lt 2 pl cm s hydrogen emanating from Steel Linearity Linear over full range Reproducibility 5 or 1 pl cm s whichever is greater Rate of response FSD 1 90 27 inch 70 cm conduit a2 s 78 inch 200 cm conduit 55s Cross sensitivity versus hydrogen 100 CO lt 1 HS lt 20 NO lt 30 CHa 80 Relative response versus100 ppm 20 C 1 00 30 C 1 03 40 C 1 11 50 C 1 21 Pre set input flow rate 30 1 ml min Background signal drift lt 50 pl cm s equivalent per year lt 1 pl cm s per hr lt 0 5 pl cm s per C Operating lifetime sensor 1 year pump gt 1500 hr Page 38 of 40 i Hydrosteel 6000 Ion Science Ltd Appendix B Analyser Menu Options start up mode The following selections
4. When not required for immediate use switch off the analyserby pressing the on off key I O The analyser takes a few seconds to shut down during which time you can abort the switchoff by again pressing the I O key Connecting the low temperature LT R probe to the analyser 1 Attach one end of either the 70 cm or 200 cm gas sample tubes to the connector at the top of the analyser as shown below Tighten finger tightNote we recommend that you use the shorter of the two sample tubes However if you require the extension arms you may find it necessary to use the longer 200cm sample tube 2 Attach the other end of the sample tube to the LT R probe Tighten finger tight 3 If required for extended use attach one or both of the extension arms to collector assembly as on the next page Page 8 of 40 i Hydrosteel 6000 Ion Science Ltd 2 Using Hydrosteel 6000 Connecting the high temperature roaming HT R probe to the analyser using HT R flexible conduit 1 Remove HT R collector assembly from the box and remove the magnet sleepers 2 Manually unscrew the collector handle from the assembly The handle unscrews below the white heat shield 3 Insert the HT R 2ft flexible conduit assembly A 41019 through the handle as shown below Tighten the nut onto the collector plate until itis finger tight Screw into place the HT R handle Probe bracket Probe plate HT R gas sample Collector locking screw tube handle Page 9
5. cable provided between the back of the IR Link Box and the serial connection on your PC NB A USB to Serial RS232 adaptor may be used if your PC or laptop no longer has an RS232 port Page 20 of 40 Hydrosteel 6000 ote Ion Science Ltd 4 Data logging and computer interface Installing the ISL data interface software Copy the complete ISL directory Ion Science Ltd from the dislprovided onto your computers C drive When using the software for the first time you will be required to select the appropriate communications serial port that your IR Link box is connected to To select a port enter the ISLPC software program and clk on the Settings tab Downloading Data from your Hydrosteel 1 Remove the Hydrosteel analysers leather jacket Turn the analyser on To enter normal operation either allow mode 90 s countdown or press the on off key twice to zero the instrument Now press the Spanner then the Data key The instrument will displayPC connect 2 Locate the infrared port at the rear of the Hydrosteel and then position this port at about 5cm 2 away from the datatransfer window of the IR LINK Box ensuring that the IR port is oriented downwards ie adjacent to the desk surfaceas shown below 3 Ensure that no other program on your PC is using the serial communications IR port Position the data trans fer port at the rear of the analyser against the window of the IR Page 21 of 40 Hydrosteel 6000 Ion
6. lowtemperature probe 7 inch diameter test surface sites should be identified on mild steel vessels or piping of 3 5 inches diameter or greater and of surface temperature of less than150 C 300 F Locate sites whichare smooth particularly avoiding rides or grooves Page 15 of 40 Hydrosteel 6000 Ion Science Ltd 3 Guide to field measurements Remove dust loose rust and liquids and disbonded paint work from the site Disbonded paint is usually evident from flaky or cracked paint in the locale of the target site and should be completelyremoved With the HT R 2 3 inch diameter high temperature probe 3 inch diameter test sites should be identified on carbon or low alloy steel vessels or piping of 8 inches diameter or greater and of surface temperature of less than 500 C 930 F For tests through inspection ports ensure that there is a clear pathway through the port to the steel surface so that when the probe is inserted i engages fully with a 3 inch diameter surface of steel without the intervention of insulation wool Ensure that the test surface is completely free of any layers of rust Step 4 Data handling If required access the test site zone menu and data logging menu by pressing the keypadData key see Section 3 1 Step 5 Deployment procedure With the LT R 6 inch diameter low temperature probe Ensure the probe plate underside is not damaged and is free from dust or magnetic detritus Manipulate the pr
7. number of accessories accompany the Hydrosteel 6000 Analysis Kit When you first receive your Analysis Kit we suggest that youcheck the items received against the Packing List If any item is damaged or missing notify your supplier stating the serial number stamped on the rear of the handheld analyser together with your order number and the supplier s invoice number Familiarise yourself with the components of the Hydrosteel 6000 Analysis Kit pages 34 2 2 System Assembly and Start up Normalising the analyser 1 Remove the analyser from the field case 2 Remove the leather outer case 3 Using the special key provided open the battery compartment at the rear of the analyser and insert the four batteries complete with their holder supplied see the diagram below Close and lock the battery compartment 4 Refit the leather outer case Press the on off key O whichis located on the analyser front panel WARNING The analyser batteries must be alkaline type AA size Using any other type of battery will invalidate the Intrinsic Safety approval Use the special key to open close the battery compartment 5 A countdown shows the time remaining anda red LED flashes The detector is then normalised and a hydrogen flux measurement of default units of pl cm s is displayed Page 7 of 40 Hydrosteel 6000 MEA Ion Science Ltd 2 Using Hydrosteel 6000 6 Your Hydrosteel 6000 analyser is now operati onal 7
8. of 40 tul Hydrosteel 6000 MEA Ion Science Ltd 2 Using Hydrosteel 6000 Connecting the High Temperature roaming HT R probe to the analyser using HT R very HT extension conduit 1 Remove HT R collector assembly from the box and remove the magnet sleepers 2 Manually unscrew the collector handle from the assembly The handle unscrews below the white heat shield 3 Insert the HT R very HT extension condui t assembly A 41017 through the handle as shown below Tighten the nut onto the collector plate until itis finger tight Screw into place the HT R handle Sie i T e i ee a a e 4 The HT R very HT extension conduit assembly is connected to the analyser using the HT R 2ft flexible conduit assembly A 41019 as shown below Page 10 of 40 Hydrosteel 6000 MEA Ion Science Ltd 2 Using Hydrosteel 6000 Before proceeding further ensure that you are familiar with the user recommendations and the analyser menu structure described below User recommendations Hydrosteel 6000 is a robust unit with electrical and pneumatic design features to ensure that accidental misuse does not represent a threat to the user or to the sensitive system components However we recommend that you 2 3 On the analyser front panel the three keys have dual functions according to whether the analyser isin start up mod for 90 s normalisation after the analyser is switched on or operating mode after normali
9. ona level surface Page 29 of 40 Hydrosteel 6000 ote Ion Science Ltd 5 Routine Maintenance 3 Connect short flexible sample tube from hydrosteel 6000 inlet to the top port on the flow meter 4 Determine the flow by reading the tube markings from the middle ofhe float The reading should be between 40 and 55 indicating that the instrument flow is correct i i i 4 f i i 5 If the reading is outside the limits stated above retest the flow after checking that all connections have been made securely and are leak free 6 If the unit is still reading outside the limits the unit will need to be returned to ISL for service and calibration Sticking floats There is limited clearance between the float and the inside of the tube In some cases flow tubes are found tostick after transport or long periods in storage due to condensation resulting from temperature changes It is advised to blow clean dry gas through the meter to free the float Page 30 of 40 Hydrosteel 6000 ote Ion Science Ltd 5 Routine Maintenance Hydrogen gas test e The location for carrying out ths test must have an ambient atmosphere that is distant from sources of hydrogen release to the atmosphere e Because the flood leak unit contains alow concentration of hydrogen gas it is important that the air in the environs of the calibration equi pments well venti lated e The temperature in the environs should be stable and
10. the Hydrosteel equilibrated to the ambient temperature This is performed using a flood leak of 100 ppm of hydrogen gas inair mixture This gas has a tolerance of 10 ppm The Hydrasteel provided readings in flux units of pl cm s or nl cm s With the LT probe selected readings should be between 280 pl ct s and 380 pl cm s With the HT probe selected readings should be between 2200 pL ctis and 3000 pL cm s 1 Switch unit on ard let it complete the stabilisation count down and zero Note the probe type indicated by the analyser display CT or HT 2 Ensure that the temperature reading in the bottom right hand corner is not flashing This ind cates that the sensor in the Hydrogeel is currently undergoing a temperature change whi ch may create a temporary shi ft in the background flux 3 Ensure that the flux reading is stable and approximate zero lt 5pl at s for LT probe or 30 pL cnt s for HT probe selection In exceptional circmstances base line drift occurs due to the continuous presence of hydrogen background Page 31 of 40 Hydrosteel 6000 Ion Science Ltd 5 Routine Maintenance 4 Manually fit the regulator to the gas bottle to finger tightness 6 Press the barb of the flood leak adapter into the other end of the tube ieee iT ee hit z j HA Luha kop y iT Utes Sal P 4 Pat lek Mune ole ba 1 Aj Wi y i PeT re s Ey b i ay Page 32 of 40 i Hydrosteel 6000 Ion Scien
11. D PC Connect analyser inde D communicates with PC via IRDA finite link return to operating mode s Page 40 of 40 Hydrosteel 6000 ote Ion Science Ltd Update Log Date updated Instrument Firmware PC Software Hydrosteel Update log 23 12 08 V2 38 V3 25 6000 added in back of manual Hydrosteel Page 5 13 01 09 V2 38 V3 25 6000 Specification updates for AT S and HT S Probes Page 41 of 40
12. Extended monitoring is terminated automatically on loss of sufficient battery power or by operator intervention RECORD key Demarcate the site as required during the test measurement Step 7 Completing the task To download data to computer remove the analyser from the jacket activate PC connect TOOL RECORD keys align with the IRDA link box and execute the file ISPLC EXE SeeSection 3 2 Make sure test equi pment is cleanand dry return to the field case and store field ase ina cool dry location WARNING The HT R probe and associated equipment includes a heat shield which partially reduces the temperature of the collector handle It does NOT enable handling of the collector without gloves ALWAYS wear suitable heat reistant gloves when handling the high temperature collector Page 17 of 40 Hydrosteel 6000 Ion Science Ltd 4 Data logging and computer interface 4 1 Using the Data logging Facility Two data logging modes are available short and long Short data logging stores measurements over a one minute interval and is used dr obtaining a spot flux measurement at a specific site In this mode a record is obtained not only of the analyser response but also of recent measurement stability When the data is downloaded to computer the response of the analyser due to attachment of the device is computed and displayed as a measurement together wi th the measurement uncertainty due to any background hydrogen dri f
13. Jon SBECiENCE Hydrosteel 6000 User Manual V18 Part No 40010 www ionscience com lon Science Ltd The Way Fowlmere Cambs SG8 7UJ U K Tel 44 0 1763 208 503 Fax 44 0 1763 208 614 Advanced Gas Sensing Technologies Email info ionscience com Web www ionscience com Declaration of conformity Manufacturer Ion Science Ltd The Way Fowlmere Cambridge England S68 7UJ Product Hydrosteel 6000 Product description the ultimate portable monitoring tool for sour HF and high temperature corrosion and diffusible hydrogen damage in steel The intrinsically safe instrument is totally non intrusive and with minimal test surface preparation and no consumables such as grease required reliable measurements can be made within a minute Marking II 2 G Baseefa02ATEX0093 EExiaIICT4 20 C lt Ta lt 60 C Notified body ATEX Baseefa 2001 Ltd Rockhead Business Park Staden Lane Buxton Derbyshire SK17 9RZ Notified body No EC 1180 Directives 94 9 EC ATEX 100A 89 336 EC EMC Standards BS EN 13908 2002 ATEX Application of quality systems BS EN 50014 1998 ATEX general requirements BS EN 50020 2002 ATEX Intrinsic safety i BS EN 61010 1 2001 Safety requirements for measurement control amp lab equipment use BS EN ISO 9001 2000 Quality management systems BS EN 61326 1 1997 EMC Equipment for measurement control and laboratory I the undersigned herby declare that the equipment specified above conforms
14. Page 22 of 40 Hydrosteel 6000 Ion Science Ltd 4 Data logging and computer interface Data download display Data files downloaded from an instrument are presented in three windows 1 Data file index summary data is ordered sequentially according to zone and then log file number Spot 60 s measurement log files include a computed flux with an associated uncertainty based on the response transient of the instrument and prevailing instrument dri ft if any 2 Data file graphical analysis flux transients corresponding to each data file are displayed See also Section4 3 Data file numerical data detailed data for each recorded data log The hori zontal menu bar at the top of the ISL Data Interface window provides access to the main features of the ISLPC Software Depending on the displyed feature abbreviated versions of these menus are available by rightlicking the mouse Caution Before closing the programme from theData sub menu ensure you ei ther Save data downloaded from the analyser orexport the data for usein spreadsheets such as Microsoft Excel More details on specific menu options are given below Page 23 of 40 Hydrosteel 6000 MEA Ion Science Ltd 4 Data logging and computer interface Graphical analysis of data Setting the time and response scales Choose Elapsed Real time as required for time scale Choose Spread Zero reference and Log Linear scale required for the recorded response ISL Ins
15. Science Ltd 4 Data logging and computer interface 4 Within the ISL Directory on your PC doubleclick on theislpc exe i con 5 If the message window Connected to Hydrosteel is displayed Proceed to step 7 6 If the Link Failed window is TEETE displayed check the Hardware prese creck re tonne as instructed using Retry as A EL required Ty a diferent computer serial port Eraur Mare Adapter is conmacted bo the mans aupph Emure that the DIC oullet i pushed iimb inte the IR Link Box A red Hashing light should be visible bebend the IA Bor window To change the prescribed serial port click on OK select Hydrosteel and from the ISL Instrument Interface window menu bar select Settings Port Click on an alternative serial port usually Com 1 or Com 2 click ok and close the ISL instrument interface menu panel Return to step 4 If problems persist please contact the supplier or Ion Science Technical staff 7 The ISL Instrument Inter fac window is now displayed From the menu bar click on Data download During data transfers an additional LED in the IR_Link box will flash occasionally The progress in data downloading is di splayed Talking to Instrument Reading logged dala EDOTEANKEN Cancel Petite ttt The Inter face program will display other messages if there are problems If the communication with the analyser fails the message window shown in step 6 will be displayed
16. Science Ltd Contents of the Hydrosteel 6000 Complete Kit Battery Key Mains adaptor LT R 6 ft sample conduit 2 replacement LT R Battery plates Pack IR Link 6 replacement Extension poles and HT R plates Hydrosteel 6000 ewivel isint analyser in leather jacket HT R sample conduit conduit HT R conduit spanner conduit Spanner small 2 extension Peli field case large Page 3 of 40 i Hydrosteel 6000 Ion Science Ltd 1 About Hydrosteel 6000 1 1 Principle of Operation Collecting a hydrogen sample Hydrosteel 6000 enables measurements to be made of gaseous hydrogen flux emanating from a steel surface The steel surface can be of variable curvature and surface condition To make the measurement a stream of ambient air is drawn across the steel surface by a high performance low power demand pump This test gas stream is confined within a specially designed collector plate contained in the probe assembly which is attached to the steel surface The probe assembly and collector plates vary according to application The probe types are listed with there features inSection 1 2 The collected hydrogen is conveyed through narrow bore tubing into the measurement analyser and across the face of a very sensitive amperometric detector Determining the level of the collected hydrogen The zero hydrogen datum point for Hydrosteel 6000 measurement is the background hydrogen concentration in air at sea level namely 0
17. ated power supply capable of delivering 200 mA minimum Note Itis important to ensure that the centre pin of the connector is positive with respect to the shroud Failure to provide this connection may cause damageto the analyser circuitry WARNING If the Hydrosteel analyser is to be used in an intrinsially safe zone any external power supply must have appropriate safety certification Page 14 of 40 Hydrosteel 6000 ote Ion Science Ltd 3 Guide to field measurements Step 1 Preparing the equipment for flux measurements Open the field case Connect the hand held analyser to either the 6 diameter LT probe in the field case or the HT probe in the HT probe kit box using the appropriate gas sampling tube This comprises essential test equipment it weighs 1 kg and can be conveniently carried in a shoulder bag or small rucksack Before commencing a prolonged series of spot measurements or exended monitoring at one particular site ensure sufficient battery power is indicated by a full battery indicator on the analyser display If necessary replace batteries using the battery tray key Step 2 Confirming suitability of ambient conditions Turn on the analyser I O key in the open air at least 10 m from any source of hydrogen If you are using a different probe than previously reconfigure the analyser during the normalisation countdown see Appendix B for menu to indicate the correct probe LT low temperature or HT high te
18. can only be made instart up mode up to 90 seconds from turning the instrumenton Key press Main Function Countdown Key options O Power up displays system 8s none status time and power status After 8 s while the promptstart up mode is displayed press D Display data log summary DD Data download instructions DDD Data download DDDD Cancel download and return to Start up mode DS Clear memory O Turn analyser of f OO Zero analyser and enter operating mode SD Select time date clock 60s O S D parameters sequentially SSD Selectunits of measurement 10 s O S D SSSD Select probe 60s O S D SSSSD_ Select choice of temperature 60 s S D scale SSSSS exit and return to start up mode Page 39 of 40 Hydrosteel 6000 Ion Science Ltd Appendix B Analyser Display Options operating mode Key press Main Function Countdown Key options After 80 s of start up mode the analyser enters operating mode Display data log summary 5s D 60 s log mode 5 s data intervals 60s D Indefinite data log to 10 min inde D low data intervals Select D toend finite battery logging log full Access log statistics file length 5 s none maximum flux slope of present flux end log mode and return to berating mode only selectable af ter 1 minute of data logging From operating mode you can identify a zone for data logging Select zone Return to operating mode From operating mode you can download data to your PC S
19. ce Ltd 5 Routine Maintenance 7 Check the pressure on the regulator is not zero If the gas bottle becomes empty then please contact ION science toarrange a replacement The 150ml flood leak will drop once the pressure in the gas bottle drops below 4 bar 6Opsi 8 Open the regulator By turning the valve knob as indi cated 9 Connect the Hydrosteel 6000 analyser to the 2 ft LFR sample tube then connect the end of the sample tube to the flood leak as shown Page 33 of 40 Hydrosteel 6000 ote Ion Science Ltd 5 Routine Maintenance 10 Leave the instrument connected for 1 to 2 minutes for the reading to stabilise 11 For the LT probe the readings should be between 28Q cm s and 380 pL cm s For the HT probe the between 2200 pL crfi s and 3000 pL cnt s 12 If the reading is out side the limits stated above the Hydrosteel analyser will need to be returned to ISL for service and calibration In this casetiis a good idea to retest the hydrogen calibration after checking that all connections have been made securely there is sufficient gas pressure in the gas bottle and that the instrument was zeroed in clean air free from any hydrogen background 13 On completion of test disconnect all tubing and fittings and return to storage IMPORTANT ensure the regulator is closed see step 8 5 2 Battery Replacement When the battery symbol flashes low battery power exists and the batteries must be replaced If the instrumen
20. collector plate sample tube to the bulkhead fitting on the back of the probe assembly With the collector plate face facing towards you twist the collector plate clock wise 45 relative to the probe assembly Slide the collector plate central spindle out of the central hole in the probe assembly Thread the gas sample tube from the collector through the leather hole in the probe assembly To secure the new collector plate carry out the steps 4 3 2 and 1 in reverse High temperature collector plate replacement Manually unscrew the collector handle from the assembly Unscrew the HT sampling tube from the HT probe The handle unscrews below the white heat shield please also see illustration onpage 10 Using the 2 5 mm hexagonal screwdriver from the HT kit box unscrew the hexagonal collector plate locking screw to release the collector plate from the bracket Remove the plate Page 35 of 40 Hydrosteel 6000 ote Ion Science Ltd 3 Remove a new HT R collector plate from the kit box Handle the collector plates carefully Being designed for maximum flexibility they are liable to permanently deform if dropped w mishandled 4 Insert the collector plate capillary into the collector assembly until the back of the plate contacts the magnets If the capillary is obstructed the collector plate locking screw may require further loosening with the 2 5 mm hexagonal screw driver 5 Lock the collector plate into position using the hexa
21. drosteel 6000 technology stems from capturing the hydrogen flux from a well defined area of steel surface in aknown flow of air and measuring the very small enhancement in hydrogen concentration entrained in the air stream By this means the very small hydrogen flux commonly emanating from steel can be quantitatively measured easily rapidly and reliably 1 2 Application specific measurements Hydrosteel can be used to locate map and monitor hydrogen flux as detailed in Section 1 3 below Hydrosteel engages interchangeable probes to enable attachment to steel of diameter greater than2 in 5 cm and surface temperatures from 40 to 500 C 40 to 930 F The interchangeable probes are classified as follows LT R Low Temperature Roaming Probe This probe utilises a collector plate 6 in 15 cm across to deliver the maximum sensitivity and is magneticdly attached to steel of 3 5 in 9 cm diameter or greater of surface temperatures up to 130 C 265 F for short periods quick spot measurements only and 110 C 230 F for general use for extended periods please consider use of AT S probe To ensure efficient hydrogen capture in wet or windy conditions the LT R probe incorporates a flexible seal around its perimeter HT R High Temperature Roaming Probe This utilises a small collector plate to give the instrument the maximum dynamic range commorly required with hot steel for which hydrogen permeation is enhanced The roaming probe
22. ess to an existing set of zone headings which can be upgraded and or downloaded to the analyser View Toolbar Normal Windows feature Status Bar Normal Windows feature Window Window provides the normal Windows features but is only available when data is displayed Settings Port Enables the correct PC port to be seleded for the RS232 connection to the ISL instrument Only usedif the port used has been altered or for first time installation of the IR_Link amp ISLPC Help Help Topics Refer to this manual until the ISL Help software file is available About ISLPC Version reference details for the ISL Data Interface Software Page 27 of 40 i Hydrosteel 6000 Ion Science Ltd 5 Routine Maintenance Only authorised and qualified persons must handle the Hydrosteel analyser using all normal safety practices Except for procedures described in this manual the Hydrosteel analyser must be serviced by Ion Science according to a prevailing contractual agreement Please feel free to ring our customer services department or e mail us at servi ce ionscience comif difficulties are encountered which have been inadequately covered by this manual 5 1 Checking system performance Normally the HT R and LT R probe plates are only liable to damage and degradation after extensive use when attached to a steel surface having ridgesor high spots Damage will be evident from worn or crushed grooves on the plate undersurface and poor challen
23. ge test results Replacement collector plates are supplied and should be fitted as ind cated inSection 5 3 All Hydrosteel equipment is factary calibrated ION Science Ltd recommends the instrument and challenge kit be calibrated yearly To be assured of analyser flow pneumatic performance and hydrogen measurement are within specifications a function test using the Function Test Kit Part No A 40107 unit is recommended The function test doesnot re cali brate the instrument The function test procedure is detailed over the following pages Page 28 of 40 Hydrosteel 6000 Ion Science Ltd 5 Routine Maintenance Hydrosteel function test instructions e To carry out the function test you must have the function test kit displayed above The Hydrosteel function test is divided into two parts The first is to check the sample flow The secondis to check the hydrogen sensor calibration Flow test The Hydrosteel flav is important to the accuracy of flux measurements The function test uses a variable area flow meter to check the correct flow is being drawn into the instrument The flow is determined by reading the tube markings from the middle of the float point Thereadings should be between 40 and 55 for a unit that has a correct flow The flow meter has to be ona level surface for correct operation 1 Switch the Hydrosteel 6000 analyser on and let it complete the stabilisation count down and zero 2 Ensure that the flow meter is
24. gonal screwdriver Re connect the HT sample tube nut onto the new collector plate until finger tight Screw into place the probe handle 5 Routine Maintenance 5 4 Cleaning Warning Organic solvents such as IPA should not be used to clean the analyser or collector plates The solvent vapour in strong concentrations may affect the sensor readings Attention must be made to keep the following areas clean 1 All pneumatic joints 2 Analyser inlet 3 Surface of collector plate 4 Bottom of probe assembly collector plate free from grit and metal filings that may be collected by magnetic attraction Cleaning general Clean the analyser and equi pment using a damp cloth and mild detergent Care musbe taken around the analyser inlet and all pneumatic openings sample tube etc to ensure that water does not enter Dry immediately with suitable towel Cleaning magnets The magnets may with time attract magnetic and ferromagnetic particles These can easily removed using an air jet from a typical air supply 100 psi 7 bar Simply play the jet across the surface wiping where necessary to blow the particles away Page 36 of 40 i Hydrosteel 6000 Ion Science Ltd Appendix A Hydrosteel 6000 LT R Technical Specifications Analyser Probe extension Collector Pe Batteries Time operable with 30 hr occasional 40 hr continuous batteries Monitoring Environmental operating conditions Ambient temperature range 15 F to 120
25. is complete Note If the analyser has been used recently the normalisation countdown can be reduced by pressing the O key twice After normalisation three measurements are displayed as descibed below Hydrogen flux In normal operating mode the analyser display indicates measured hydrogen flux or flow per unit area collected from a surface in units ofpl cm s or nm s Flux measurement Temperature indicator Probe indicator Battery life indicator The flux units are corrected for standard temperature and pressure That is 1 pl cm s 10 litres of hydrogen at a pressure of one atmosphere 760 mm Hg 1014 mbar and 20 C emanating from each square centimetre of surface per second Flux measurements exceeding 1000 pl cri s are displayedin unitsof nl cm s to two decimal places 1000 pl cnf s 1 nl cm s Page 12 of 40 Hydrosteel 6000 MEA Ion Science Ltd 2 Using Hydrosteel 6000 When the collector is not attached to a steel surface a flux continues to be displayed inorder to give aclear indication of any background drift which ay affect the integrity of subsequent measurements Battery level indication At the base of the display a battery iconis ind cated together with the temperature in degrees Centigrade As the battery becomes exhausted the battery icon progressively empties until the icon is shown in outline only and subsequently it flashes When the battery symbol is flashing data logging may not be p
26. is magnetically attachable to steel of at least 8 in 20 cm diameter and has an operating temperature range extending to 500 C 930 F The probe is sufficiently smdl to access steel through standard inspection ports AT S All Temperature Stationary Probe This probe is 6 inches in diameter and designed to be semipermanently attached to a steel surface down to 2inches in diameter for frequent monitoring at theame site The probe can be attached to steel at temperatures up to 500C 930 F HT S High Temperature Stationary Probe This small collector is designed for semi permanent attachment to pipe bends and other curved areas where corrosion can be significant and steel pipes with a diameter as small as 1 5 in 4cm at temperatures up to 500 C 930 F Notes When changing probe you should reprogramme the instrument during start up as described in Section 2 2 Maintenance and replacement of the probes is described in Section 5 3 Page 5 of 40 i Hydrosteel 6000 Ion Science Ltd 1 About Hydrosteel 6000 1 3 Deployment Methods Hydrosteel 6000 can be deployed to meet several different objectives as described below Hydrogen flux search The Hydrosteel analyser has a real time display offlux which can be used to search for sites of hydrogen permeation Since the analyser commences measurement at the time of attachment to a surface and a 50 response is achieved in approximately 20 seconds prospective hydrogen permeatio
27. mperature The analysers internal temperature will be indicated on the display panel A flashing reading indicates that the analyser is experiencing an abrupt change in temperature in which case allow several mi ns for the flashing to subside It is highly recommended to use the thermally insulating leather jacket to reduce the effect of abrupt temperature changes Abrupt temperature changes may occur for many reasons Most common are moving from a heated or air conditioned environment to the cold or hot local conditions Alternatively the radiant heat from hot pipes or equipment may create a significant temperature change When approaching hot pipes use the 2 meter high temperature sample tube in addition to the thermal jacket this will allow the analyser to be shielded and kept at a greater distance from the hot test area Connect the appropriate probe After the countdown the analyser will display a reading of less than 5 pl afs with the LT probe and 003 nl cm s with the HT probe Approach the test site location of interest The only gas liable to compromise dependable measurement of hydrogen flux is hydrogen itself for examplawithin a few metres of hydrogen leaking from a flange This will be ragtered on the analyser display and in the analysers memory enabling confidence in the logged measurements to be calculated when data is downloaded to a PC Step 3 Steel test surface site selection and preparation With the LT R 6 inch diameter
28. n at a given sitecan be established within this time An extension arm can be used to deploy the collector to a surface some 6 ft 2 m beyond normal reach Spot measurements Once a site of interest has been located the hydrogen flux can be measured within a period of one minute It may be convenient to log the measurement using the handheld Hydrosteel short log facility Whilst waiting for the measurements to be logged the handheld analyser can be attached to the steel pipe under test using its magnetic leather case This procedure allows you to make notes or demarcate the site for re testing in the future Continuous monitoring A site can be monitored for up to the lifetime of the batteries using the Hydrosteel long log facility see Section 4 1 Logging can be extended indefinitely using external power seeSection 2 5 Zone Programming When performing the above measurements data can be logged with respect zone or area of test Available to the user are 199 zones that act as memory tags for saved logs Each zone can be named witha 64character header seeSection 4 3 1 4 Calibration Check Facility Hydrosteel is calibrated in house but the equipment is offered with a function test facility to enable you to check that your equipment is performing wi thi ispeci fication Please refer to Section 5 1 for the check procedure Page 6 of 40 Hydrosteel 6000 Ion Science Ltd 2 Using Hydrosteel 6000 2 1 Initial Appraisal A
29. obe by using the probe handle or extension arms Introduce it directly to the test site ensuring that the probe ALIGNMENT indicator runs in the same direction as the pipe or axis of the vessel as illustrated Confirm the prob s flexible plate conforms snugly to the steel surface On piping of less than 8 inches diameter use the strap provided Tk strap should be drawn tight as shown below so as to ensure the probe plate is tight against the steel when the hands are released Page 16 of 40 Hydrosteel 6000 MEA Ion Science Ltd re ai lt a a 3 Guide to field measurements With the HT R 2 3 inch diameter high temperature probe Introduce the probe directly to the steel surface Any orientation of the probe is acceptable but take particular care with piping of less than 12 inches diameter to ensure the probes flexible plate is attached snugly to the metal surface Note the high temperature magnets are attracted to steel less strongly than conventional magnets be particularly careful during measurements not to pull away the probe from the steel Step 6 During measurement and monitoring The analyser inits jacket can also be secured magneticdly to any steel nearby at ambient temperature A significant response should be evident within 20 25 s of probe engagement and flux measurement obtained within one minute For spot measurements allow remove probe to appear on the display before removing the probe
30. onsequence all stored data is also erased caution ensure that any relevant data has been downloaded before using this option Instrument Details Reads details of the ISL Serial number 20000620 001 instrument currently Log memoyused 2099 interrogated using the IR_Link Log mameykes 63425 Serial Number Log Memory Used Log ace oe Memory Free and the Instrument Or time are speci fied Show Reading Enables a real time display of the instrument measurement to be shown on your PC Close this window to access any other Diagnostics Allows instrument data to be downloaded prior to hardware fault finding Click on Read Flash following instructions as they appear Firmware Upgrade Downloads an ION SCIENCE upgrade file upg to the analyser A complete upgrade consisting 4 files usually lasts abod 4 minutes ISL Inetument Inter arce Upgrade of inctrument firrevare wil ease al logged dats and zone inbormation Do you want to proceed ES ow Caution Ensure that all relevant data has been downloaded and saved to PC before using this option Page 26 of 40 Hydrosteel 6000 Ion Science Ltd 4 Data logging and computer interface Zones New Allows you to create aset of zone headings Enter up to 60 characters into each of the 199 zone addresses These can then be downloaded to Hydrosteel Having created the headings you can also save them as type zon files on your PC for future use Open Provides acc
31. ossible and although the system is still functional quantitative measurements of hydrogen flux are not recommended Temperature indication Located at the bottom right of the display the indicated temperature measurement is one taken from inside the analyser near the hydrogen sensor During temperature changes the displayed measurement flashes indicating that youcan expect some temporary background signal drift as the detector re adjusts to the change in temperature If you are experiencing temperature changes to the unit during operation it is highly recommended that you use the thermally insulating leather jacket Probe indication To the left of the battery icon the display one of the following denoting the probe in use Ensure at all times that the probe in use and probe indicator correspond If not reconfigure the analyser to indicate the correct probe fren the analyser start up menu as indicated inAppendix B The probe indicator should correspond to the probe inuse as follows LT R low temperature roaming HT R high temperature roaming blank ambient hydrogen measurement probe independent Page 13 of 40 Hydrosteel 6000 MEA Ion Science Ltd 2 Using Hydrosteel 6000 2 5 Using an External Power Supply To extend the continuous operation time of the analyser particularly for long term moni toring appli cations an external power supply can be used For satisfactory operation the analyser requires a 6 V dc regul
32. ownload the same data again later or to avoid losing data later on There are 2 levels of protection used to stop changesto records the first level is data encryption and the second level is the watermark inserted by the islpc program into the encrypted data Open Allows access to stored measurement data files Refer to Section 4 The islpc program searches for the file vdidity before opening data and VALID will then be insertedinto the header data of an open file Close Closed highlighted Numerical or Graphi cal window Caution Before closing the programme from theData sub menu ensure you ei ther Save data downloaded from the analyser orexport the data for use in spreadsheets such as Microsoft Excel Export Saves highlighted data as a comma separated variable file csv file for external analysis using standard spreadsheets e g Excel Please note csv files cannot be read by islpc exe The csv file contains a summary of all data files followed by data presented in chronological order Page 25 of 40 Hydrosteel 6000 MEA Ion Science Ltd 4 Data logging and computer interface Instrument Download Data Downloads measurement data from the ISL ingrument Provides the same facility as the Data menu Erase All Data Erases all data storedin the ISL instrument Caution Ensure that any relevant data has been downloaded before using this option Clear Zone Headers Clears the zone headers stored inthe ISL instrument As a c
33. sation consult this manual or the service team at Ion Sience when you are unsure of how to proceed avoid exposing any part of the system to corrosive media or liquids avoid exposing the system components to ambient temperatures that exceed 50 C for more than a few hours hen not in use store all the system components and equipment in a cool dry place Analyser Operation Menu Three front panel keys S Spanner D Data and O On Off TN em E BY Ex98E2316 Eex ia IIC W Start up mode adjust time flux units select zone check orobe temperature scale calibration o tarde data lo Co turn off 7 zro Page 11 of 40 Hydrosteel 6000 MEA Ion Science Ltd 2 Using Hydrosteel 6000 The key options available are shown on the analyser display After completing a function the analyser returns to startup mode or operating mode as appropriate For example in start up mode you can divert to reset the clock because of a change to Summer Time and on completion of this function the analyser automatically completes the normalising procedure For reference a complete list of the key sequences togetherwith countdowns and available interrupt keys is provided inAppendix B 2 4 Analyser display As part of the startup procedure the analyser sequentially displays the instrument name manufacturer data log details and calibration details Thereafter countdown is displayed until normalisation of the analyser
34. t During long data logging measurements are first recorded every five seconds then at a reducing rate until stopped manually or by an analyser feature memory overflow or battery empty During both forms of data logging the data memory used is indicated by a memory bar extending across the display from left to right This memory bar blinks on each occasion that data is recorded Appropriate log prompts are indicated at the bottom of the display Memory bar data log mode and prompts Short data logging 1 From normal operating mode access short data logging by pressing the D data key twice While attach probe is displayed attach the probe to the target steel surface The memory bar flashes at onesecond intervals 2 Twelve 5 second time averaged measurements are recorded together with the date time stamp analyser temperature selected probe and zone number and description 3 When short data logging is complete remove probe will be displayed Remove the probe from the steel surface The analyser reverts to normal operating mode automatically Page 18 of 40 Hydrosteel 6000 Ion Science Ltd 4 Data logging and computer interface Making a single measurement In order to make a single measurement short data logging can be abbreviated as follows 1 As above from normal operating mode press the D key twice to enter short data logging 2 As soon as the memory bar appears which signifies that one flux meas
35. t is left running until the batters fall bellow the operating voltage the instrument will restart then sense the battery voltage is too low where will flash the start up screen before displaying the messafe battery voltage too low and switching off If the instrument is switched on with extremely low but not dead batteries one of a number of things may occur firstthe red LED will illuminate permanently the LCD will show a slight contrast as though the instrument is trying to witch on However inthis state the instrument will not respond to key presses Second the instrument may display and hang at the start up screen Again the instrument will not respond to key presses Third the instrument will start recognisethat the battery voltage is too low and switch of in the same way thatit does when the batteries die 1 Using the battery screwdriver provided remove the battery cover at the Page 34 of 40 Hydrosteel 6000 5 3 1 Ton Science Ltd underside of the analyser Remove the exhausted batteries from the battery tray and replace with four new AA alkaline batteries Note For the correct battery orientation follow the symbols marked on the tray Ensure that the flying power lead is securely fastened to the battery tray Refit the tray into the analyser body To save power always turn offthe analyser when not in use Routine Maintenance Probe plate Replacement Low temperature collector plate replacement Unscrew the 1 8 nut on the
36. to the stated Directives and Standards Signed By i Name Mark Stockdale Position Technical Director Date 23 April 2007 Safety This intrinsic safety rating permits its deployment in dl potentially explosive atmospheres of the quoted or less demanding rating That is in areas where explosive gases of Group IIA IIB and IIC are intermittently present Zone 1 within an ambient temperature range of 20 C and 60 C Hydrosteel complies with the requirements of 73 23 EEC low voltage directive and apart from a low voltage pump there are no moving parts within the instrument so that the machinery directives are not applicable Page 1 of 42 Hydrosteel 6000 Ion Science Ltd CONTENTS Hydrosteel 6000 field case and contents 3 1 About Hydrosteel 6000 4 Principle of Operation 4 Application Specific Measurements 5 Deployment Methods 5 Calibration Check Facility 6 2 Using Hydrosteel 6000 7 Initial Appraisal 7 System Assembly and Start up 7 Analyser Operation Menu 11 Analyser Display 12 Using an External Power Supply 15 3 Guide to Field Measurements 14 4 Data Logging and Computer Interface 17 Using the Data Logging Facility 17 Communication between analyser and PC 18 5 Routine Maintenance 27 Checking Instrument Performance 27 Battery Replacement 33 Probe Plate Replacement 33 Cleaning 35 Appendices A Hydrosteel 6000 Technical Specifications 36 B Analyser Menu Options 38 Page 2 of 40 Hydrosteel 6000 ote Ion
37. trument Interface march 23rd 2001 phd Analysis G Miel Fa File Edit Data Lamp Calibration Gas Table Instrument ones Text View Window Settings Help e x OSH eeg 06 Jun 2029 15 26 27 0 257 15 06 00 15 16 00 15 26 00 15 36 00 06 Jun 2029 Real time File 1 For help Press F1 NUM a Using the cursor Right Click on the graphical analysis window to reveal the dropdown menu wi th the following options e Elapsed Real time e No Markers e Cursor on off e Log Linear scale e Spread Zero reference e Alarms on off Choose No Markers to remove all the crosses from the display Choose Cursor on and use mouse and a Left Click to position the cursor on the Graph The data x y will be shown top right Page 24 of 40 Hydrosteel 6000 ote Ion Science Ltd 4 Data logging and computer interface Main ISLPC Menu Functions File Print Print highlighted Numerical or Graphical data file via your PC Print Preview Allows you to view the currently chosen data file for next print Print Set up Allows the characteristics of tle printer that is connected to your PC to be selected Recent File Allows access to recently used files Exit Exit the ISL Data Interface Software application Data Download Data Reads measurement data from the ISL instrument Save Save As Saves highlighted Numerical and Graphical data to PC file in an encrypted format phd This is highly recommended to avoid having to d
38. urement has been recorded press theD key while the prompt to end logis displayed press the D key again twice Long data logging 1 As above from normal operating mode access short data logging by twoD key presses 2 Wait for the memory bar to be displayed 3 Press the D key again once The prompt to end logis displayed and long data logging has started 4 Measurements are automatically recorded at five secondintervals for the first 10 minutes at one minute intervals for the next 120 minutes then every 10 minutes During each 10 minute period of long data logging the analyser enters a sleep cycle during which analyser functions such as the measurement circuitry including the pump are only active for about 90 s During the sleep cycle the prompt sleepingis displayed for the remainder of the 10 minute period 5 To exit data logging from sleep mode press theD key slowly twice 4 2 Communication between analyser and PC Communication between the analyser and computer requires the useof the IR Link Box Hydrosteel software and Windows PC connect software ISLPC EXE The IR Link Box is provided with your Hydrosteel 6000 Analysis Kit as is the ISLPC software on floppy disk Communication between the instrument and a PC allows the followng functions to be performed e Downloadng of logged data from the instrument to the PC for storage and analysis e Erasing logged data Page 19 of 40 Hydrosteel 6000 Ion Science Ltd
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