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Hydrosteel 6000
Instrument User Manual V2.2
Part number: 40010
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Part number: 40010
Hydrosteel 6000 MANUAL Ion Science Ltd
Unrivalled Detection. www.ionscience.com
Declaration of conformity
Manufacturer: Ion Science Ltd, The Way, Fowlmere, Cambridge, England. SG8 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: ll 2 G Baseefa 02ATEX0093 Ex ia IIC T4 -20C Ta +60C
Ref Baseefa Cert Report 05©0007, 07©0772
Baseefa Certificate number Baseefa02ATEX0093 Issued 28 of August 2008
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 61010-1:2010 Safety requirements for measurement, control & lab equipment use
BS EN ISO 9001:2008 Quality management systems
BS EN 61326-1:1997 EMC – Equipment for measurement, control and laboratory
I the undersigned hereby declare that the equipment specified above conforms to the stated Directives and
Standards.
Signed By:
Name: Mark Stockdale,
Position: Technical Director
Date: 23rd April 2007
Safety: This intrinsic safety rating permits its deployment in all 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 -20C and +60C.
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 3 of 39
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Contents
Declaration of Conformity............................................................................................................................... 3
Statements ....................................................................................................................................................... 5
Responsibility for Use .................................................................................................................................... 5
Legal Notice ................................................................................................................................................... 5
Contents of the Hydrosteel 6000 Complete Kit ............................................................................................ 6
About Hydrosteel 6000 .................................................................................................................................... 7
Principle of Operation ..................................................................................................................................... 7
Application specific measurements ................................................................................................................ 7
About Hydrosteel 6000 .................................................................................................................................... 8
Deployment Methods ..................................................................................................................................... 8
Calibration Check Facility............................................................................................................................... 8
Initial Appraisal ............................................................................................................................................... 9
System Assembly and Start-up ...................................................................................................................... 9
Using Hydrosteel 6000 .................................................................................................................................. 10
Analyser Operation Menu ............................................................................................................................ 13
Analyser display ........................................................................................................................................... 14
Guide to Field Measurements ...................................................................................................................... 16
Data Logging and Computer Interface ........................................................................................................ 19
Using the Data logging Facility .................................................................................................................... 19
Data Logging and Computer Interface ........................................................................................................ 23
Routine Maintenance ..................................................................................................................................... 26
Checking system performance .................................................................................................................... 26
Hydrosteel function test instructions .......................................................................................................... 27
Flow test ....................................................................................................................................................... 27
Hydrogen gas test ........................................................................................................................................ 28
Battery Replacement .................................................................................................................................... 32
Probe plate Replacement............................................................................................................................. 32
Cleaning ....................................................................................................................................................... 33
Instrument Warranty and Service ................................................................................................................ 34
Warranty ....................................................................................................................................................... 34
Service ......................................................................................................................................................... 34
Contact details ............................................................................................................................................. 34
Appendix A ..................................................................................................................................................... 35
Appendix B ..................................................................................................................................................... 37
Update Log ..................................................................................................................................................... 39
Page 4 of 39
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Statements
Responsibility for Use
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.
Legal Notice
Whilst every attempt is made to ensure the accuracy of the information contained in this manual, Ion 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, Ion 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.
Page 5 of 39
Hydrosteel 6000 MANUAL Ion Science Ltd
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Hydrosteel 6000
Peli field case
Extension poles and
swivel joint
2 replacement LT-R
plates
LT-R 6 ft
LT-R Probe
LT-R 2 ft sample conduit
Very HT-R
extension
6 replacement
HT-R plates
Manual and
software CD
HT-R
probe
HT-R sample
conduit
Mains
adaptor
IR Link
Battery Key
Battery
Pack
HT-R
HT-R conduit spanner
small (2)
HT-R
Contents of the Hydrosteel 6000 complete kit
sample
conduit
Introduction to TVOC
For installation requirements please refer to Installation and Technical Specification of this manual. Before
attempting an installation, please fully read and understand this user manual, and for hazardous area (IS)
installations please also refer to the TVOC Intrinsically safe certificate for further details.
The TVOC safety rating permits its deployment in all hazardous areas of the quoted (or less demanding)
rating. For detail please refer to the marking on your instrument (found on the front main label). As of 1st of
October units will be manufactured with two protection concepts applied by separate certifications. Intrinsic
safety (ia) and Non sparking (nA). All units manufactured up to that date will only have intrinsic safety.
a) Intrinsic Safety (ia) permits the deployment in areas where explosive gases (of group IIA, IIB and IIC) are
intermittently present (zone 1) with an ambient temp range of -20°C to 50°C. Intrinsically safe installations will
require the use of safety barriers and appropriate wiring.
b) Non sparking (nA) permits deployment in areas where explosive gases (of group IIA, IIB, IIC) are unlikely
but possible (Zone 2) with ambient temp range of -20°C to 50°C. Non sparking installations do not require
safety barriers however the maximum working voltage should be strictly adhered to as a matter of safety. As
no safety barriers are required there is complete flexibility on the implementation of 3 wire system.
TVOC does require regular calibration onsite please see the Calibration section for more information. TVOC
calibration mode is accessed via a magnetic read switch system.
plate
Key
analyser in leather
jacket
conduit
spanner
large
conduit
Page 6 of 39
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About Hydrosteel 6000
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 their features in Section – Application
specific measurements.
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 0.5 ppm1. 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 condition enables the Hydrosteel 6000 to be used in measuring a very small flux of hydrogen
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 flux J of
hydrogen emanating from the steel is given by:
J = c x F / A
where A is the effective area over which hydrogen is captured, and c the enhanced hydrogen concentration
resulting from hydrogen entrainment.
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 Hydrosteel 6000 technology stems from capturing the hydrogen flux from a
well-defined area of steel surface in a known 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.
Application specific measurements
Hydrosteel can be used to locate, map, and monitor hydrogen flux as detailed in Section – Deployment
Methods on the next page. Hydrosteel engages interchangeable probes to enable attachment to steel of
diameter greater than 2 in., 5 cm, and surface temperatures from -40 to +500 ºC, -40 to 930 ºF. 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
magnetically attached to steel of 3.5 in., 9 cm diameter or greater, of surface temperatures up to 130 oC, 265
o
F for short periods (quick spot measurements only), and 110 oC, 230 oF 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.
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About Hydrosteel 6000
HT-R: High Temperature – Roaming Probe
This utilises a small collector plate to give the instrument the maximum dynamic range commonly required
with hot steel for which hydrogen permeation is enhanced. The roaming probe is magnetically attachable to
steel of at least 8 in., 20 cm diameter, and has an operating temperature range extending to 500 oC, 930 oF.
The probe is sufficiently small to access steel through standard inspection ports.
AT-S: All Temperature – Stationary Probe
This probe is 6 inches in diameter and designed to be semi-permanently attached to a steel surface, down to
2 inches in diameter, for frequent monitoring at the same site. The probe can be attached to steel at
temperatures up to 500 C, 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., 4 cm, at temperatures up to
500 oC, 930 oF.
Notes: When changing probe you should re-programme the instrument during start-up, as described in
Section – System Assembly and Start-up. Maintenance and replacement of the probes is described in
Section – Probe Plate Replacement.
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 of flux 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 permeation at a given site can 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 – Using the Data Logging Facility). Logging can be extended indefinitely using external power (see
Section – Using an External Power Supply).
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 with a 64character header.
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 within specification. Please refer to Section – Checking System
Performance for the check procedure.
Page 8 of 39
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WARNING
The analyser batteries must be alkaline-type AAsize. Using any other type of battery will
invalidate the Intrinsic Safety approval.
Use the special key to
open/close the battery
compartment
Using Hydrosteel 6000
Initial Appraisal
A number of accessories accompany the Hydrosteel 6000 Analysis Kit. When you first receive your Analysis
Kit, we suggest that you check 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 by going to the ‘Contents of the Hydrosteel 6000 Complete Kit’.
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 (I/O), which is located on the analyser front panel.
5 A countdown shows the time remaining, and a red LED flashes. The detector is then normalised,
and a hydrogen flux measurement of (default units of pl/cm2/s) is displayed.
6 Your Hydrosteel 6000 analyser is now operational.
7 When not required for immediate use, switch off the analyser by pressing the on/off key (I/O). The
analyser takes a few seconds to shut down, during which time you can abort the switch-off by again
pressing the I/O key.
Page 9 of 39
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Using Hydrosteel 6000
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 tight. Note: 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 10 of 39
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Probe plate
locking screw
Collector
handle
HT-R gas sample
tube
Probe plate
locking screw
HT-R gas sample
tube
Collector
handle
Collector
handle
Probe bracket
HT-R gas
sample tube
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 it is finger tight. Screw into place the HT-R handle.
Page 11 of 39
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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 conduit assembly (A-41017) through the handle as shown below.
Tighten the nut onto the collector plate until it is finger tight. Screw into place the HT-R handle.
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 12 of 39
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