Ion Science 7000 User Manual
Unrivalled Detection. www.ionscience.com
Hydrosteel 7000
Instrument User Manual V3.1
Part number: 910228
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Part number: 910228
Hydrosteel 7000 MANUAL Ion Science Ltd
Unrivalled Detection. www.ionscience.com
Declaration of conformity
Manufacturer: Ion 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 to give warning or control of high corrosion
levels in the operating equipment.
Directive 94/9/EC ATEX
Identification: II 2G Ex ia IIC T4 (-40
o
C ≤ Ta ≤ +60
o
C)
Notified Body: Baseefa Ltd, 1180, Buxton, UK
EC Type Examination Certificate(s)
Baseefa04ATEX0205 latest supplement Baseefa04ATEX0205 issue 4 issued 13
th
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) 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 Ion Science Ltd, I declare that, on the date this product accompanied by this declaration 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: 20th November 2008
Page 3 of 43
Hydrosteel 7000 MANUAL Ion Science Ltd
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Contents
Declaration of conformity ............................................................................................................................... 3
Statements ....................................................................................................................................................... 5
Responsibility for Use .................................................................................................................................... 5
Warnings ........................................................................................................................................................ 5
Quality Assurance .......................................................................................................................................... 5
Calibration Facility .......................................................................................................................................... 5
Legal Notice ................................................................................................................................................... 5
Packing list ....................................................................................................................................................... 5
Introduction to Hydrosteel 7000 ..................................................................................................................... 7
Introduction to safety certification .............................................................................................................. 10
Installation ...................................................................................................................................................... 11
HY7K probe site identification ...................................................................................................................... 11
HY7K analyser site identification ................................................................................................................. 11
Power and signal requirements ................................................................................................................... 12
Cable Requirements .................................................................................................................................... 14
Removal of cladding and insulation ............................................................................................................. 14
Preparation of test site ................................................................................................................................. 14
HY7K probe installation................................................................................................................................ 15
Thermocouple installation ............................................................................................................................ 18
Re-insulation and cladding ........................................................................................................................... 18
Installation of sample conduit ....................................................................................................................... 20
Mounting of Hydrosteel 7000 analyser ........................................................................................................ 23
Commossioning ............................................................................................................................................. 24
Inspection of the equipment installation ....................................................................................................... 24
Probe connection to Hydrosteel 7000 .......................................................................................................... 25
Terminating power and 4-20mA cable to Hydrosteel 7000 .......................................................................... 28
Start up ......................................................................................................................................................... 30
Operation test ............................................................................................................................................... 30
Hand over ..................................................................................................................................................... 31
Hydrosteel setup ............................................................................................................................................ 32
Clock time .................................................................................................................................................... 32
Flux 4-20mA output range ........................................................................................................................... 32
Operation ..................................................................................................................................................... 32
Hydrosteel 7000 PC software ....................................................................................................................... 33
Installation of Hydrosteel Software .............................................................................................................. 33
Connecting to the Hydrosteel 7000 .............................................................................................................. 33
Downloading data ........................................................................................................................................ 34
Graph operation ........................................................................................................................................... 34
Data table operation ..................................................................................................................................... 35
Data handling ............................................................................................................................................... 35
Print options ................................................................................................................................................. 36
Instrument Settings ...................................................................................................................................... 36
Maintenance and calibration ........................................................................................................................ 37
Hydrosteel 7000 unit maintenance .............................................................................................................. 37
Probe installation .......................................................................................................................................... 37
Fault finding and diagnostics ................................................................................................................ 38
Fault findings ................................................................................................................................................ 38
Diagnostics ................................................................................................................................................... 39
Technical specifications ............................................................................................................................... 40
Instrument warranty and service ................................................................................................................. 42
Warranty ....................................................................................................................................................... 42
Service ......................................................................................................................................................... 42
Contact details ............................................................................................................................................. 42
Manual log ...................................................................................................................................................... 43
Page 4 of 43
Hydrosteel 7000 MANUAL Ion Science Ltd
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Statements
Responsibility for Use
Hydrosteel 7000 flux monitor for permanent installation provides flux readings that are subject to
interpretation. Ion Science Ltd can accept no responsibility for the incorrect use that 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 Ion Science Ltd or
your local Ion Science Ltd representative.
Quality Assurance
Hydrosteel 7000 has been manufactured in compliance with ISO9001:2008 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 and national safety and
environmental requirements. This includes the European WEEE (Waste Electrical and Electronic Equipment)
directive. Ion Science Ltd offers a take back service. Please contact us for more information.
Calibration Facility
Ion 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, 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.
Packing list
Page 5 of 43
Hydrosteel 7000 MANUAL Ion Science Ltd
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Please take a little time to check the contents in the Hydrosteel shipment before installation.
Item Description Qty.
1 Hydrosteel 7000 monitor 1
2 This Manual 1
3 Applications Manual 1
4 Software CD 1
5 Modem cable 1
6 USB to RS232 adapter 1
7 HY7K conduit kit consisting of:
7.1 Sample tube assembly 1
7.2 Han connector assembly 1
7.3 P clips for sample tube conduit 6
7.4 Thermocouple junction box 1
8 HY7K probe kit
8.1 AT-S collector plate 1
8.2 Background probe 1
8.3 Magnetically attachable TC cable 2
8.4 Wire brush 1
Accessories include:
1 Banding kit consisting of:
1.1 Banding tool 1
1.2 Banding (3/8”) stainless steel (box 30.5m) 1
1.3 Buckles box of 100 1
2 Magnetic probe fixing kit (4 high temp magnets) 1
Page 6 of 43
Hydrosteel 7000 MANUAL Ion Science Ltd
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Introduction to Hydrosteel 7000
The Hydrosteel 7000 is an 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 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 Installation
summary diagram. The reader should refer to Installation section, and to the Hydrosteel 7000 ATEX
certificate for further details.
Power to instrument should be supplied via zener safety barrier or galvanic isolator.
Two 4-20 mA receivers that supply loop power to hazardous area through appropriate safety barrier /
galvanic isolator are needed.
To ensure EMC compliance always use screened cables for bother power and 4-20 mA outputs.
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.
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. Baseefa04ATEX0205.
Page 7 of 43
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Introduction to Hydrosteel 7000
Page 8 of 43
Hydrosteel 7000 MANUAL Ion Science Ltd
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Time
Operation
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 & 4-20mA outputs updated
Introduction to Hydrosteel 7000
Operation Cycle
Hydrosteel 7000 operates 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.
Connectivity
1 mains power supply 15-24 V @ 34 mA in hazardous area
4-20 mA output #1: hydrogen flux requiring loop power of 8-30 V @20 mA
4-20 mA output #2: pipe temperature requiring loop power of 8-30 V @20 mA
RS232 connection for optional interrogation of unit: all data is logged to the unit’s internal memory
probe connection.
Page 9 of 43
Hydrosteel 7000 MANUAL Ion Science Ltd
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Hydrosteel 7000
S/No: “**-*****”
Manufactured: “Date”
Baseefa04ATEX0205
II 2 G EEx ia IIC T4,
-20 C <= T ambient <= +60 C
Ion Science Ltd, Cambs, England
1180
Introduction to safety certification
Apparatus certification (ATEX)
Hydrosteel 7000 has been issued with EC-type examination certificate Baseefa04ATEX0205 BASEEFA
2001. Confirming compliance with the European ATEX directive 94/9/EC for group II, Category 2 gas
atmospheres, EEx ia IIc T4 (T
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 Ion Science Ltd name, location, instrument serial number and year of manufacture.
Other non-European certification information may also appear on this label.
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
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;
The Hydrosteel 7000 can be installed in zones 1 & 2 in the presence of most common industrial
gasses.
A Safety barrier or isolator is required for the main power supply.
Safety barriers or isolators are required for the 4-20 mA outputs if they are used.
A 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.
–40 C to +60 C). This instruction manual describes the installations that
amp
Page 10 of 43
Hydrosteel 7000 MANUAL Ion Science Ltd
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Installation
The following sequence of installation steps are recommended.
HY7K probe site identification
HY7K analyser site identification
Power and signal requirements.
Cable requirements
Remove cladding and insulation
Preparation of test site
HY7K probe installation
Thermocouple installation
Re-insulation and cladding
Installation of sample conduit
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:
Attachment of the sample conduit to the analyser
Connection of electrical connection to HY7K
Inspection of the installed equipment
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 Hydrosteel Applications Manual,
available from Ion 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:
Jubilee® clips - to pipes or vessels of minimum 2” (using the AT-S probe)
Banding - to pipes or vessels of 4 to 32” diameter
Magnetic attachment - to pipes or vessels of greater than 32” diameter. Maximum
temperature tolerance is 800F 426C
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.
Page 11 of 43
Hydrosteel 7000 MANUAL Ion Science Ltd
Unrivalled Detection. www.ionscience.com
Power receivers
Ui
Ii
Pi
Ci
Li
Uo
Io
Po
Units
V
mA W uF
mH V mA
mW
PS 1
30
200
1.2 0 0
PS 2
30
200
1.2 0 0 4-20mA 1
30
200
1.2 0 0
4-20mA 2
30
200
1.2 0 0
RS232
30 0 0
13 3 50
Thermocouple
Thermocouple
junction box
1
3
E
2
SCREEN
E
3
2
+V RD
1
0V BK
Red Connector
Hydrosteel 7000
Yellow Connector
1
2
Electrical connections (Non IS)
+V RD
0V BK
SCREEN
RD
BK
BK
RD
0V BK
+V RD
SCREEN
+V
+V
0V
0V
3
E
Blue Connector
RD
BK
4-20mA 2
4-20mA 1
Control equipment
Power
+V
0V
Installation
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.
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 IS 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
For information only see safety certificate before installation
Page 12 of 43
Hydrosteel 7000 MANUAL Ion Science Ltd
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Electrical connections (IS) with safety barriers
Yellow Connector
Thermocouple
junction box
Thermocouple
2
3
E
SCREEN
+V RD
0V BK
Red Connector
SAFE AREA
1
SCREEN
+V RD
0V BK
1
E
3
2
SCREEN
0V BK
+V RD
2
E
3
1
Blue Connector
Hydrosteel 7000
0V
+V
BK
RD
4-20mA 1
0V
+V
0V
RD
BK
Power
+V
BK
RD
4-20mA 2
Control equipment
Manufacture
Manufactures pt. no.
Type
Cable length estimate
m
Pepperl & Fuchs
KFD2-VD-Ex1.1835
Galvanic Isolator
560
Stahl
9175-10-16-11
Galvanic Isolator
335
MTL Ltd
MTL4023
Galvanic Isolator
365
MTL Ltd
MTL7728P
Zener barrier
288
Turck
MK72S06-EX
Galvanic Isolator
686
Manufacture
Manufactures pt. no.
Type
Pepperl+Fuchs
Z728
Zener barrier
Pepperl+Fuchs
KFD2STC4-Ex1
Galvanic isolator
MTL
MTL7787 (dual channel)
Zener barrier
MTL
MTL5044 (dual channel)
Galvanic isolator
Stahl
9001/51-280-110-141
Zener barrier
Stahl
9160/13-11-11S
Galvanic isolator
Installation
Ion Science Ltd suggest using the following or similar safety barrier or 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:
Suggested barriers for INLET power supply
* Note
All cable lengths are estimated for Zone 1 IIC installation of the equipment
Using 1 mm2 C.S.A. conductors S.T.P. cables with capacitance of 250 pF/m, L/R ratio of 25 uH/
conductor resistance at 20 C of 18.4 /Km
Calculation assumes that cables are at 80 C (maximum operating temperature).
Signal Output
Suggested barriers for 4-20mA OUTLET
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 Ion Science Ltd or and Ion Science Approved
Service Centre before it is used in an IS application.
Page 13 of 43
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